SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

SY215C9C5KL/SY225C9C5KL
Crawler Hydraulic Excavator

Shop Manual

WARNING

● Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep
this manual with the machine for reading and future reference.

Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413

http://www.sanygroup.com

Tel: 0086-21-57008518 Fax: 0086-21-58596210

Service hotline: 0086-21-58592902
Complaint hotline: 0086-21-58590631
E-mail: [email protected]

© 2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, Contact Sany Group.
Shop Manual - April 2017
SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Table of Contents

Table of Contents

1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
1.1.2 Revision and distribution ................................................................................ 1-4
1.1.3 Symbols ......................................................................................................... 1-5
1.1.4 Units ............................................................................................................... 1-5
1.2 Technical Terms ....................................................................................................... 1-6
1.2.1 Standard size and tolerance .......................................................................... 1-6
1.2.2 Standard clearance and value ....................................................................... 1-7
1.2.3 Standard interference .................................................................................... 1-7
1.2.4 Repair limit and allowable value .................................................................... 1-8
1.2.5 Clearance limit ............................................................................................... 1-8
1.2.6 Interference limit ............................................................................................ 1-8
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12
1.3.1.4 Handling the integrated control monitor .............................................. 1-16
1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.3.2.1 Be careful of the operating environment ............................................. 1-18
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18
1.3.2.3 Sealing openings ................................................................................ 1-18
1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19
1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19
1.3.2.6 Flushing operations............................................................................. 1-19
1.3.2.7 Cleaning operations ............................................................................ 1-20
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23

Shop Manual - April 2017 I

Table of Contents SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.6 Type of Bolts .......................................................................................................... 1-24

1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.8.2 Temperature ................................................................................................. 1-31

2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-5
2.2.1 Rules and shop behavior ............................................................................... 2-6
2.2.2 Housekeeping ................................................................................................ 2-6
2.2.3 Shop Liquids Storage..................................................................................... 2-7
2.2.4 Cleaning the Parts ......................................................................................... 2-7
2.2.5 Cleaning the Machine .................................................................................... 2-8
2.2.6 Appropriate Working Apparel ......................................................................... 2-8
2.2.7 Personal Protective Equipment...................................................................... 2-8
2.2.8 Using the Correct Tools.................................................................................. 2-9
2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9
2.2.10 Electrical Dangers ...................................................................................... 2-10
2.2.11 Hoisting a Load .......................................................................................... 2-10
2.3 Before Repair..........................................................................................................2-11
2.3.1 Safe Work Preparations ................................................................................2-11
2.3.2 Preparing yourself ........................................................................................ 2-12
2.3.3 Lockout/Tagout............................................................................................. 2-13
2.3.4 Two people when engine running ................................................................ 2-15
2.3.5 Safety Partners ............................................................................................ 2-15
2.4 Repair Precautions ................................................................................................ 2-16
2.4.1 Running the Machine ................................................................................... 2-16
2.4.2 Mounting and Dismounting .......................................................................... 2-17
2.4.3 Removing Attachments ................................................................................ 2-18
2.4.4 Jacking Up the Machine............................................................................... 2-18
2.4.5 Adding Fluids to a System ........................................................................... 2-18
2.4.6 Aligning Parts or Components ..................................................................... 2-19
2.4.7 Driving Pins .................................................................................................. 2-19
2.4.8 When compressed air is used...................................................................... 2-19
2.4.9 Welding operation ........................................................................................ 2-20

II Shop Manual - April 2017

SY215C9C5K/SY225C9C5K rawler Hydraulic Excavator Table of Contents

2.4.10 Track Recoil Springs .................................................................................. 2-20

2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21
2.4.12 Air-conditioning system maintenance ........................................................ 2-22
2.4.13 High voltage precautions ........................................................................... 2-22
2.4.14 Disconnecting the System Power .............................................................. 2-23
2.4.15 Accumulator ............................................................................................... 2-23
2.4.17 Battery Hazards ......................................................................................... 2-24
2.4.18 Jump-Start Safety ...................................................................................... 2-25
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
2.4.20 Chemical hazard ........................................................................................ 2-27
2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27
2.4.22 Proper disposal of wastes .......................................................................... 2-28
2.5 Other Precautions .................................................................................................. 2-29
2.5.1 Sling work and giving signals ....................................................................... 2-29
2.5.2 Using mobile crane ...................................................................................... 2-31
2.5.3 Using overhead hoist crane ......................................................................... 2-31
2.5.4 Selecting wire ropes..................................................................................... 2-33

3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working ranges........................................................................................................ 3-4
3.3 Technical Specifications........................................................................................... 3-5
3.4 Table of Weights ...................................................................................................... 3-7
3.5 Engine Oil, Fuel and Coolant ................................................................................... 3-8
3.6 Engine Performance Curve ................................................................................... 3-10

4 Structure and Functions

4.1 Engine and Cooling System .................................................................................... 4-5
4.1.1 Engine-relate parts......................................................................................... 4-5
4.1.2 Radiator and intercooler................................................................................. 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Power train ..................................................................................................... 4-7
4.2.2 Travel reducer AS .......................................................................................... 4-8
4.2.3 Swing reduction mechanism ........................................................................ 4-10
4.2.4 Swing bearing .............................................................................................. 4-12
4.3 Undercarriage ........................................................................................................ 4-14

Shop Manual - April 2017 III

Table of Contents SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.3.1 Track frame and tensioning mechanism ...................................................... 4-14

4.3.2 Idler .............................................................................................................. 4-16
4.3.3 Carrier roller ................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Tracks .......................................................................................................... 4-21
4.4 Hydraulic System, Part 1 ....................................................................................... 4-25
4.4.1 Deployment of hydraulic parts ..................................................................... 4-25
4.4.2 Hydraulic Pump........................................................................... 4-26
4.4.3 Pilot pump .................................................................................................... 4-28
4.4.4 Regulator ............................................................................ 4-29
4.4.4.1 Oil delivery control .............................................................................. 4-44
4.4.5 Pilot pump .................................................................................................... 4-45
4.4.6 Regulator ........................................................................... 4-46
4.5 Hydraulic System, Part 2 ....................................................................................... 4-58
4.5.1 Control valve ................................................................................................ 4-58
4.5.1.1 Main valve structure ............................................................................ 4-60
4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-65
4.6 Hydraulic System, Part 3 ....................................................................................... 4-88
4.6.1 Swing motor ................................................................................................. 4-88
4.6.2 Relief valve section ...................................................................................... 4-91
4.6.3 Anti-jerk valve............................................................................................... 4-93
4.6.4 Central swivel joint ....................................................................................... 4-95
4.6.5 Travel motor ................................................................................................. 4-96
4.6.5.1 Operation of parking brake ............................................................... 4-103
4.6.5.2 Operation of braking valve ................................................................ 4-104
4.6.6 Control system ............................................................................................4-112
4.6.7 Pilot valve....................................................................................................4-113
4.6.8 Travel pilot valve .........................................................................................4-117
4.6.9 Solenoid valves .......................................................................................... 4-121
4.6.10 Pilot accumulator ..................................................................................... 4-122
4.6.11 Pilot oil filter .............................................................................................. 4-123
4.7 Work Equipment .................................................................................................. 4-124
4.7.1 Component dimensions ............................................................................. 4-124
4.7.2 Arm dimensions ......................................................................................... 4-126
4.7.3 Bucket dimensions ..................................................................................... 4-128
4.8 Air Conditioning System....................................................................................... 4-130

IV Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Table of Contents

4.8.1 Layout of A/C components ......................................................................... 4-131

4.8.2 A/C control panel........................................................................................ 4-132
4.8.3 Diagram of electrical circuit ........................................................................ 4-133
4.8.4 Refrigeration principle ................................................................................ 4-135
4.8.5 Compressor ............................................................................................... 4-136
4.8.6 Clutch ......................................................................................................... 4-138
4.8.7 Condenser ................................................................................................. 4-139
4.8.8 Expansion valve ......................................................................................... 4-140
4.8.9 Evaporator ................................................................................................ 4-140
4.8.10 Dehydrator .............................................................................................. 4-141
4.8.11 Pressure switch ........................................................................................ 4-142
4.8.12 Refrigerant ............................................................................................... 4-143
4.8.12.1 Evacuation ...................................................................................... 4-146
4.8.12.2 Refrigerant filling operation ............................................................. 4-148
4.8.12.3 Troubleshooting with manifold pressure gauge .............................. 4-153
4.8.13 Compressor oil ......................................................................................... 4-162
4.9 Engine Control ..................................................................................................... 4-163
4.9.1 System operation ....................................................................................... 4-164
4.9.2 System components .................................................................................. 4-165
4.9.2.1 Fuel control dial................................................................................. 4-165
4.9.2.2 Engine control unit (ECU) ................................................................. 4-166
4.10 Electrical Control System................................................................................... 4-170
4.10.1 Control function ........................................................................................ 4-170
4.10.2 Diagram of machine control system......................................................... 4-171
4.10.3 Engine-pump combination control ........................................................... 4-173
4.10.4 Valve control function ............................................................................... 4-176
4.10.5 Travel control function .............................................................................. 4-177
4.10.6 Low engine oil pressure alarm and protection ......................................... 4-178
4.10.7 High engine coolant temperature alarm and protection ........................... 4-179
4.10.8 Engine preheating control ........................................................................ 4-180
4.10.9 Engine starting and energizing delay control ........................................... 4-181
4.10.10 System parts and components .............................................................. 4-182
4.10.10.1 Pump pressure sensor .................................................................. 4-182
4.10.10.2 Pilot pressure sensor .................................................................... 4-183
4.10.10.3 Engine speed sensor .................................................................... 4-184
4.10.10.4 Coolant temperature sensor ......................................................... 4-185

Shop Manual - April 2017 V

Table of Contents SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.10.5 Fuel level sensor ........................................................................... 4-186

4.10.10.6 Oil pressure switch........................................................................ 4-187
4.11 Monitor System .................................................................................................. 4-188
4.11.1 Monitor ..................................................................................................... 4-189
4.11.2 Monitor panel ........................................................................................... 4-190

5 Standard Values
5.1 Standard Values for Engine-Related Parts .............................................................. 5-3
5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4

6 Testing and Adjusting

6.1 Exhaust Gas Color - Test ......................................................................................... 6-3
6.2 Valve Clearance - Adjust.......................................................................................... 6-5
6.3 Compression Force - Test........................................................................................ 6-8
6.4 Fuel Injection Timing - Test and Adjust .................................................................. 6-10
6.5 Engine Oil Pressure - Test ......................................................................................6-11
6.6 Engine Speed Sensor - Adjust ............................................................................... 6-12
6.7 A/C Compressor Belt Tension - Check and Adjust................................................. 6-13
6.8 Swing Bearing Clearance - Check ......................................................................... 6-14
6.9 Track Tensioning device - Check and Adjust ......................................................... 6-16
6.10 Oil in hydraulic circuits - Test and Adjust ............................................................. 6-18
6.11 Control Oil Circuit Pressure - Check and Adjust .................................................. 6-22
6.12 Solenoid Valve Output Pressure - Test ................................................................ 6-23
6.13 Pilot Valve Output Pressure - Test ....................................................................... 6-25
6.14 Work Equipment and Swing PPC Valves - Adjust ............................................... 6-26
6.15 Hydraulic Drift of Work Equipment - Test ............................................................. 6-27
6.16 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-29
6.17 Oil Leakage Amount - Test................................................................................... 6-30
6.18 Air in Each Component - Purge ........................................................................... 6-34
6.19 Sensors - Test ...................................................................................................... 6-36
6.19.1 Coolant temperature sensor ...................................................................... 6-36
6.19.2 Engine speed sensor ................................................................................. 6-36
6.19.3 Pressure sensor ......................................................................................... 6-37
6.19.4 Fuel level sensor ....................................................................................... 6-37

7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5
VI Shop Manual - April 2017
SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Table of Contents

7.2 Troubleshooting Types and Steps ........................................................................... 7-6

7.2.1 Troubleshooting types .................................................................................... 7-6
7.2.2 Troubleshooting steps .................................................................................... 7-6
7.3 Connectors .............................................................................................................. 7-8
7.3.1 List of connectors ........................................................................................... 7-8
7.3.2 Connector locations ..................................................................................... 7-12
7.3.3 SWP connectors .......................................................................................... 7-14
7.3.4 A/AMP connectors ....................................................................................... 7-15
7.3.5 DT connectors.............................................................................................. 7-15
7.4 Troubleshooting with an Event Code ..................................................................... 7-17
7.5 Troubleshooting the Electrical System (E-Mode)................................................... 7-31
7.6 Troubleshooting the Hydraulic and Mechanical System (H-Mode) ........................ 7-51

8 Disassembly and Assembly

8.1 Operating Precautions ............................................................................................. 8-5
8.2 Start Motor AS ........................................................................................................ 8-8
8.2.1 Removing sequence ...................................................................................... 8-8
8.2.2 Installing sequence ........................................................................................ 8-8
8.3 Fuel Injection Pump AS .......................................................................................... 8-9
8.3.1 Removal ......................................................................................................... 8-9
8.4 Engine Rear Oil Seal ............................................................................................ 8-14
8.4.1 Removal ....................................................................................................... 8-14
8.4.2 Installation .................................................................................................... 8-15
8.5 Cylinder Head AS ................................................................................................. 8-16
8.5.1 Removal ....................................................................................................... 8-16
8.5.2 Installation .................................................................................................... 8-19
8.6 Engine Rear Oil Seal ............................................................................................ 8-21
8.6.2 Removal ....................................................................................................... 8-22
8.6.1 Installation .................................................................................................... 8-22
1.Install the flywheel housing. ................................................................................ 8-22
2.Install the flywheel housing support. ................................................................... 8-22
8.7 Cylinder Head AS ................................................................................................. 8-25
8.7.1 Removal ....................................................................................................... 8-26
8.7.2 Insallation ..................................................................................................... 8-27
• Assembling operation is to be performed in the reverse order of disassembling
operation. ............................................................................................................... 8-27

Shop Manual - April 2017 VII

Table of Contents SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

• Install the cylinder head cover according to the tag sequence shown in FIG. .... 8-27
8.8 Radiator AS ........................................................................................................... 8-39
8.9 Engine and Hydraulic Pump AS ............................................................................ 8-44
8.9.1 Removal ....................................................................................................... 8-44
8.9.2 Installation .................................................................................................... 8-49
8.10 Radiator AS ......................................................................................................... 8-50
8.11 Engine and Hydraulic Pump AS .......................................................................... 8-56
8.11.1 Removal ..................................................................................................... 8-56
8.11.2 Installation .................................................................................................. 8-61
8.12 Final Drive AS ...................................................................................................... 8-62
8.12.1 Removal ..................................................................................................... 8-62
8.12.2 Installation .................................................................................................. 8-63
8.13 Final Drive AS ..................................................................................................... 8-64
8.13.1 Disassembly............................................................................................... 8-64
8.13.2 Assembly.................................................................................................... 8-67
8.14 Swing Motor and Swing Drive AS ........................................................................ 8-73
8.14.1 Removal ..................................................................................................... 8-73
8.14.2 Installation .................................................................................................. 8-74
8.14.3 Disassembly............................................................................................... 8-75
8.14.4 Assembly.................................................................................................... 8-79
8.15 Idler AS ............................................................................................................... 8-85
8.15.1 Disassembly............................................................................................... 8-85
8.15.2 Assembly.................................................................................................... 8-86
8.16 Sprocket .............................................................................................................. 8-89
8.16.1 Removal ..................................................................................................... 8-89
8.16.2 Installation .................................................................................................. 8-89
8.17 Track AS ............................................................................................................. 8-90
8.17.1 Removal ..................................................................................................... 8-90
8.17.2 Installation .................................................................................................. 8-91
8.18 Swing Bearing AS ............................................................................................... 8-93
8.18.1 Removal ..................................................................................................... 8-93
8.18.2 Installation .................................................................................................. 8-94
8.19 Swing frame AS ................................................................................................... 8-95
8.19.1 Removal ..................................................................................................... 8-95
8.19.2 Installation .................................................................................................. 8-97
8.20 Swivel Joint AS ................................................................................................... 8-98

VIII Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Table of Contents

8.20.1 Removal ..................................................................................................... 8-98

8.20.2 Installation .................................................................................................. 8-99
8.21 Central Swivel Joint AS ..................................................................................... 8-100
8.21.1 Disassembly............................................................................................. 8-100
8.21.2 Assembly.................................................................................................. 8-101
8.22 Hydraulic Tank AS ............................................................................................. 8-102
8.22.1 Removal ................................................................................................... 8-102
8.22.2 Installation ................................................................................................ 8-104
8.23 Control Valve AS ................................................................................................ 8-105
8.23.1 Removal ................................................................................................... 8-105
8.23.2 Installation ................................................................................................ 8-109
8.24 Hydraulic Pump AS ............................................................................................8-110
8.24.1 Removal ....................................................................................................8-110
8.24.2 Installation .................................................................................................8-113
8.25 Middle Oil Seal (Hydraulic Pump Input Shaft) ....................................................8-114
8.25.1 Removal ....................................................................................................8-114
8.25.2 Installation .................................................................................................8-114
8.26 Independent Radiator AS....................................................................................8-115
8.26.1 Removal ....................................................................................................8-115
8.26.1 Installation .................................................................................................8-116
8.27 Work Equipment Pilot Valve AS .........................................................................8-117
8.27.1 Assembly...................................................................................................8-117
8.28 Travel Pilot Valve AS ..........................................................................................8-118
8.28.1 Assembly...................................................................................................8-118
8.29 Hydraulic Cylinder AS ........................................................................................8-119
8.29.1 Disassembly............................................................................................. 8-120
8.29.2 Assembly.................................................................................................. 8-125
8.30 Work Equipment AS .......................................................................................... 8-131
8.30.1 Removal ................................................................................................... 8-131
8.30.2 Installation ................................................................................................ 8-133
8.31 Air Conditioner AS.............................................................................................. 8-134
8.31.1 Removal ................................................................................................... 8-134
8.31.2 Installation ................................................................................................ 8-137
8.32 Counterweight AS ............................................................................................. 8-138
8.32.1 Removal ................................................................................................... 8-138
8.32.2 Installation ................................................................................................ 8-139

Shop Manual - April 2017 IX

Table of Contents SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.33 Cab AS .............................................................................................................. 8-140

8.33.1 Removal ................................................................................................... 8-140
8.33.2 Installation ................................................................................................ 8-143
8.34 Monitor .............................................................................................................. 8-144
8.34.1 Removal ................................................................................................... 8-144
8.34.2 Installation ................................................................................................ 8-144
8.35 Controller AS ..................................................................................................... 8-145
8.35.1 Removal ................................................................................................... 8-145
8.35.2 Installation ................................................................................................ 8-145
8.36 Radio ................................................................................................................. 8-146
8.36.1 Structure .................................................................................................. 8-146
8.36.2 Removal ................................................................................................... 8-147
8.36.3 Installation ................................................................................................ 8-147
8.36.4 Connector model and wiring .................................................................... 8-148
8.37 Battery ............................................................................................................... 8-149
8.37.1 Structure .................................................................................................. 8-149
8.38 Battery ............................................................................................................... 8-150
8.38.1 Installation and Removal.......................................................................... 8-150
8.38.2 Installation ................................................................................................ 8-150
8.38.3 Replacement ............................................................................................ 8-151
8.39 Start Switch........................................................................................................ 8-152
8.39.1 Structure .................................................................................................. 8-152
8.39.2 Removal ................................................................................................... 8-153
8.39.3 Installation ................................................................................................ 8-153
8.39.4 Working principle and wiring ................................................................... 8-154
8.40 Electrical Power Center ..................................................................................... 8-155
8.40.1 Installation and Removal ......................................................................... 8-155
8.40.2 Installation ................................................................................................ 8-155
8.41 Wiper ................................................................................................................. 8-156
8.41.1 Structure ................................................................................................. 8-156
8.41.2 Working principle ..................................................................................... 8-156
8.41.3 Removal ................................................................................................... 8-157
8.41.4 Installation ................................................................................................ 8-157
8.41.5 Wiper arm angle adjustment .................................................................. 8-158
8.42 Relays ................................................................................................................ 8-159
8.41.1 Engine relays ........................................................................................... 8-159

X Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Table of Contents

8.42.1 Other load relays...................................................................................... 8-160

8.43 Connector Terminals .......................................................................................... 8-162
8.43.1 Insertion ................................................................................................... 8-162
8.43.2 Removal ................................................................................................... 8-163

9 System Schematics
9.1 Hydraulic Circuit Diagram ........................................................................................ 9-3
9.2 Electrical Diagram ................................................................................................... 9-4
9.3 Cab harness .......................................................................................................... 9-16
9.4 Control Switch Harness ......................................................................................... 9-17
9.5 Tool box Harness ................................................................................................... 9-18
9.6 Pump room Harness .............................................................................................. 9-19
9.7 Vehicle Body Harness............................................................................................ 9-20
9.8 Boom Harness ....................................................................................................... 9-21

Shop Manual - April 2017 XI

Table of Contents SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

XII Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

Introduction
1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
1.1.2 Revision and distribution ................................................................................ 1-4
1.1.3 Symbols ......................................................................................................... 1-5
1.1.4 Units ............................................................................................................... 1-5
1.2 Technical Terms ....................................................................................................... 1-6
1.2.1 Standard size and tolerance .......................................................................... 1-6
1.2.2 Standard clearance and value ....................................................................... 1-7
1.2.3 Standard interference .................................................................................... 1-7
1.2.4 Repair limit and allowable value .................................................................... 1-8
1.2.5 Clearance limit ............................................................................................... 1-8
1.2.6 Interference limit ............................................................................................ 1-8
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12
1.3.1.4 Handling the integrated control monitor .............................................. 1-16
1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.3.2.1 Be careful of the operating environment ............................................. 1-18
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18
1.3.2.3 Sealing openings ................................................................................ 1-18
1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19
1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19
Shop Manual - April 2017 1-1
Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.3.2.6 Flushing operations............................................................................. 1-19

1.3.2.7 Cleaning operations ............................................................................ 1-20
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23
1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.8.2 Temperature ................................................................................................. 1-31

1-2 Shop Manual - June 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1 INTRODUCTION
1.1 How to Read the Manual
● Some attachments and optional parts in
this shop manual may not be delivered to
certain areas. If one of them is required,
consult Sany distributors.
● Materials and specifications are subject to
change without notice.

1.1.1 Shop manual organization

This shop manual contains the necessary
technical information for services performed
in a workshop. For ease of understanding, the
manual is divided into the following sections.

Introduction
This section provides an overview of what is
covered in the rest of this manual and how to
use this manual,.

Shop Safety
This section covers basic shop safety infor-
mation relating to this equipment. It also de-
scribes what the hazard alerts mean that are
used throughout the manual.

Specifications
Technical specification of work equipment and
optional parts are given in this section.

Structure and functions

This section explains the structure and func-
tion of each component. It helps the reader
to get a better understanding of the machine
structure, and also serves as a reference for
troubleshooting.

Shop Manual - April 2017 1-3

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Standard Values
This section explains the standard values for
a new machine and judgement criteria for test-
ing, adjusting, and troubleshooting. This stan-
dard value table is used to check the standard
values in testing and adjusting and to judge
parts in troubleshooting.

Testing and adjusting

This section details the inspection before and
after repair work as well as the adjustment
during inspection and repair work. Trouble-
shooting table that involves “Fault”and
“Cause”are also included in this section.

Troubleshooting
This section explains the way to detect faulty
parts and the method to repair them. This sec-
tion is divided into the following parts: Electri-
cal system, Engine, Hydraulic and mechanical
system and Monitoring system.

Disassembly and assembly

This section explains the procedures as well
as precautions for removing, installing, disas-
sembling and assembling of each component.

System Schematics
This section provides hydraulic circuit dia-
grams and electrical circuit diagrams.

1.1.2 Revision and distribution

Any complements, revisions, or other change
of notices will be sent to Sany distributors. Get
the most up-to-date information before you
start any work.

1-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.1.3 Symbols
Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.

Symbol Item Remarks

Special safety precautions are necessary when performing

Safety
work.

Special technical precautions or other precautions for pre-

★ Caution
serving standards are necessary when performing work.
Weight of parts of component or parts. Caution necessary
Weight when selecting hoisting wire, or when working posture is
important, etc.
Tightening Places that require special attention for tightening torque
torque during assembly.

Coat Places to be coated with adhesives, etc. during assembly.

Oil, Coolant Places where oil, etc. must be added, and capacity.

Places where oil, etc. must be drained, and quantity to be

Drain
drained.

1.1.4 Units
In this shop manual, the units are indicated with International System of units (SI). For reference,
conventionally used Gravitational System of units is indicated in parentheses { }.

Shop Manual - April 2017 1-5

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.2 Technical Terms

The maintenance standard values necessary
for judgment of products and parts are de-
scribed by the following terms.

1.2.1 Standard size and tolerance

● To be accurate, the finishing size of parts
is a little different from one to another.
● To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
● The above size set temporarily is called
the "standard size" and the range of differ-
ence from the standard size is called the
"tolerance".
● The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

Example

Standard size Tolerance

–0.022
120
–0.126

★ The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)]. Ex-
ample) 120 (–0.022/–0.126)
● Usually, the size of a hole and the size
of the shaft to be fitted to that hole are
indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of fit is decided by
the tolerance.
● Indication of size of rotating shaft and
hole and relationship drawing of them.
Fig. 1-1

1-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

Example

Tolerance
Standard size
Shaft Hole
-0.030 +0.046
φ60
-0.076 0

1.2.2 Standard clearance and value

● The clearance made when new parts are

assembled is called the "standard clear-
ance", which is indicated by the range from
the minimum clearance to the maximum
clearance.

● When some parts are repaired, the clear-

ance is generally adjusted to the standard
clearance.

● A value of performance and function of

new products or equivalent is called the
"standard value", which is indicated by a
range or a target value.

● When some parts are repaired, the value

of performance/function is set to the stan-
dard value.

1.2.3 Standard interference

● When the size of a hole is smaller than the

size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the "interference".

● The range (A – B) from the difference (A)

between the minimum size of the shaft and
the maximum size of the shaft to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the "standard interference".

● After repairing or replacing some parts,

measure the size of their hole and shaft
and check that the interference is in the
standard range.

Shop Manual - April 2017 1-7

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.2.4 Repair limit and allowable value

● The size of a part changes due to wear

and deformation while it is used. The limit
of changed size is called the "repair limit".

● If a part is worn to the repair limit must be

replaced or repaired.

● The performance and function of a product

lowers while it is used. A value below which
the product can be used without causing a
problem is called the "allowable value".

● If a product is worn to the allowable value,

it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.

1.2.5 Clearance limit

● Parts can be used until the clearance be-

tween them is increased to a certain limit.
The limit at which those parts cannot be
used is called the "clearance limit".

● If the clearance between the parts exceeds

the clearance limit, they must be replaced
or repaired.

1.2.6 Interference limit

● The allowable maximum interference be-

tween the hole of a part and the shaft of
another part to be assembled is called the
"interference limit".

● The interference limit shows the repair limit

of the part of smaller tolerance.

● If the interference between the parts ex-

ceeds the interference limit, they must be
replaced or repaired.

1-8 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.3 Handling Electrical and Hy-

draulic Components
To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair procedures for mechatronics and is aimed
at improving the quality of repairs. For this
purpose, it gives sections on "Handling electric
components" and "Handling hydraulic equip-
ment" (particularly gear oil and hydraulic oil).

1.3.1 Points to remember when han-

dling electric components

1.3.1.1 Handling wiring harnesses and

connectors
Wiring harnesses consist of wiring con-
necting one component to another compo-
nent, connectors used for connecting and
disconnecting one wire from another wire,
and protectors or tubes used for protecting
the wiring.
Compared with other electrical compo-
nents fitted in boxes or cases, wiring har-
nesses are more likely to be affected by
the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection
and repair operations, they are frequently Fig. 1-2
removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

Shop Manual - April 2017 1-9

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.3.1.2 Main failures occurring in wiring

harness
1. Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.

Fig. 1-3

2. Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

Fig. 1-4

3. Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

Fig. 1-5

1-10 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

4. High-pressure water entering connector

The connector is designed to make it dif-
ficult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector is designed to prevent water from
entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the con-
nector, the pins will be short-circuited by
Fig. 1-6
the water, so if any water gets in, immedi-
ately dry the connector or take other ap-
propriate action before passing electricity
through it.
5. Oil or dirt stuck to connector
If oil or grease are stuck to the connec-
tor and an oil film is formed on the mating
surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe
it off with a dry cloth or blow it dry with
compressed air and spray it with a contact
restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins. Fig. 1-7
★ If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and wa-
ter from the compressed air completely
before cleaning with compressed air.

Shop Manual - April 2017 1-11

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.3.1.3 Removing, installing, and drying

connectors and wiring harnesses
1. Disconnecting connectors
A. Hold the connectors when disconnect-
ing.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw fully,
then hold the male and female connec-
tors in each hand and pull apart. For
connectors which have a lock stop-
per, press down the stopper with your
thumb and pull the connectors apart.
Fig. 1-8
★ Never pull with one hand.
B. When removing from clips
● Both of the connector and clip have
stoppers, which are engaged with each
other when the connector is installed.

Fig. 1-9

● When removing a connector from a clip,

pull the connector in a parallel direction
to the clip for removing stoppers.
★ If the connector is twisted up and
down or to the left or right, the hous-
ing may break.

Fig. 1-10

1-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

C. Action to take after removing connec-

tors
After removing any connector, cover
it with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
★ If the machine is left disassembled
for a long time, it is particularly easy
for improper contact to occur, so al-
ways cover the connector.
Fig. 1-11

2. Connecting connectors
A. Check the connector visually
Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
Check that there is no damage or
breakage to the outside of the connec-
tor. Fig. 1-12

★ If there is any oil, water, or dirt stuck

to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
★ If there is any damage or breakage,
replace the connector.
B. Fix the connector securely.
Align the position of the connector cor-

Shop Manual - April 2017 1-13

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

rectly, and then insert it securely. For

connectors with lock stopper, push in
the connector until the stopper clicks
into position.
C. Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
Fig. 1-13
★ If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
● If the connector clamp has been
removed, be sure to return it to its
original position. Check also that
there are no loose clamps.
3. Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respective-
ly, push them in until they click 2 times.
● Male connector: 1 Fig. 1-14
● Female connector: 2
● Normal locking state (Horizontal): a, b,
d
● Incomplete locking state (Diagonal): c

Fig. 1-15

1-14 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

4. Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
A. Disconnect the connector and wipe off
the water with a dry cloth.
★ If the connector is blown dry with Fig. 1-16
compressed air, there is the risk that
oil in the air may cause defective
contact, so remove all oil and wa-
ter from the compressed air before
blowing with air.
B. Dry the connector with a dryer.
If water gets inside the connector, use
a dryer to dry the connector.
★ Hot air from the dryer can be used,
but regulate the time that the hot air
is used in order not to make the con-
nector or related parts too hot, as
this will cause deformation or dam- Fig. 1-17
age to the connector.
C. Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
★ After completely drying the connec-
tor, blow it with contact restorer and
reassemble.

Fig. 1-18

Shop Manual - April 2017 1-15

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.3.1.4 Handling the integrated control

monitor
1. The integrated control monitor contains
a microcomputer, an electronic control
circuits, an LCD monitor and GPS position-
ing circuit. They control all of the electronic
circuits on the machine, so be extremely
careful when handling the integrated
control monitor.
2. Do not place objects on the integrated
control monitor.
3. Cover the control connectors with tape or Fig. 1-19
a vinyl bag. Never touch the connector
contacts with your hand.
4. Do not leave it where it may be exposed to
rain.
5. Do not place the integrated control monitor
on oil, water, or soil, or in any hot place,
even for a short time.
6. Precautions for arc welding
When welding on the controller, disconnect
all wiring harness connectors connected
to the controller. Fit an arc welding ground
close to the welding point.
Fig. 1-20

Fig. 1-21

1-16 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.3.1.5 Electric circuits troubleshooting

precautions
1. Always turn the power OFF before discon-
necting or connecting connectors.
2. Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
★ Disconnect and connect the related
connectors several times to check.
3. Always connect any disconnected connec-
tors before going on to the next step.
★ If the power is turned ON with the con-
nectors still disconnected, unnecessary
abnormality displays will be generated.
4. When carrying out troubleshooting of
circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
★ If there is any change, there is probably
defective contact in that circuit.

Shop Manual - April 2017 1-17

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.3.2 Points to remember when handling hydraulic equipment

With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.

1.3.2.1 Be careful of the operating environ-

ment
Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of
dust.

1.3.2.2 Disassembly and maintenance work

in the field
If disassembly or maintenance work is
carried out on hydraulic equipment in the Fig. 1-22
field, there is danger of dust entering the
equipment. It is also difficult to check the
performance after repairs, so it is desir-
able to use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be carried out in a specially pre-
pared dust-proof workshop, and the perfor-
mance should be checked with special test
equipment.

1.3.2.3 Sealing openings

After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surround-
ing area being made dirty by leaking oil so
never do this. Do not simply drain oil out
onto the ground, but collect it and ask the
customer to dispose of it, or take it back
with you for disposal.
Fig. 1-23

1-18 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.3.2.4 Do not let any dirt or dust get in

during refilling operations
Be careful not to let any dirt or dust get
in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has collected during storage, so this is an
even more effective method.

Fig. 1-24

1.3.2.5 Change hydraulic oil when the

temperature is high
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can
also be drained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old hy-
draulic oil must be drained out. (Drain the
oil from the hydraulic tank; also drain the
oil from the filter and from the drain plug in
the circuit.) If any old oil is left, the contam-
inants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic
oil.

1.3.2.6 Flushing operations

After disassembling and assembling the
equipment, or changing the oil, use flush-
ing oil to remove the contaminants, sludge,
and old oil from the hydraulic circuit. Nor-
mally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the
specified hydraulic oil.

Fig. 1-25

Shop Manual - April 2017 1-19

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.3.2.7 Cleaning operations

After repairing the hydraulic equipment
(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit. The oil cleaning equip-
ment is used to remove the ultra fine (about
3 μ) particles that the filter built in the hy-
draulic equipment cannot remove, so it is
an extremely effective device.

Fig. 1-26

1.4 Hose Connector

Hose connector is used to connect hoses with
a small diameter. The metal sealing surface (4)
of the joint (1) must be in close contact with
the metal sealing surface (5) of the hose (2) to
seal pressurized oil.

NOTICE

● Do not over-tighten the nut (3). Exces-

sive force applied on the metal sealing
surface (4) and (5) may cause the joint
(1) to break. Be sure to tighten nut (3) Fig. 1-27
according to technical specifications.
● Scratches or other damages on seal-
ing surface (4) and (5) may cause leaks
at the joint. Be extremely careful not
to damage the sealing surfaces during
connecting and disconnecting work.

1-20 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.4.1 Type of hose connector

Fig. 1-28

1.4.2 Hose connector tightening torque table

Wrench size mm Wrench size mm Tightening torque

Type
Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
19 19 59(6,44)
22 22 98(10,72)
27 27 118(12,87)
36 36 235(24,173)
24° Male
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
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)

NOTICE

● The torque values listed in the table are

intended for general application.
● Do not use torque values listed in this
table when different torque values are
specified for a special purpose.

Shop Manual - April 2017 1-21

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.4.3 Connection of O-rings

Place O-ring (6) in contact with the contact

surface of the joint (7) to seal the pressurized
oil.

NOTICE

● Replace o-rings (6) with new ones when

re-connecting hoses.
● Before tightening nut (9), make sure the
o-ring (6) has been placed into the o-ring
seat (8).Displacement of the o-ring may Fig. 1-29
have it damaged and cause leaks.
● Be careful not to damage the o-ring seat
(8) or the sealing surface (10). Damaged
o-ring (6) may cause oil leakage.
● If oil leakage due to loosened nut (9) is
detected, do not try to stop the leakage
by tightening nut (9). Instead, replace o-
ring (6) with a new one and make sure it
is well positioned, and tighten nut (9).

Wrench size mm Wrench size mm Tightening torque

Connecting nut Hose joint 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)

1-22 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.5 Table of Standard Tightening Torques

Table of tightening torques for bolts and nuts

★ Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using
torque wrench)

Bolt di- Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
ameter grade size size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 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

NOTICE

The following items apply to fine thread and coarse thread.

● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce
the friction coefficient. Thrust bolts do not require greasing.
● Torque tolerance is ±10%.
● Always use bolts of correct length. The tip of bolts with excessive length may contact
the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length
may result in insufficient fastening.
● The torque values listed in the table are intended for general application. If different
torque values are specified for a special purpose, the torque values in this table are not
applicable any more.
● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

Shop Manual - April 2017 1-23

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

1.6 Type of Bolts

Tighten nuts and bolts properly to specified

torque values. The type and grade of bolts are
illustrated on the right.
Use correct bolts and tighten them properly
when assembling machines or components.

Fig. 1-30

1.7 Tightening Sequence

When two or more bolts are being tightened,

follow the tightening sequence shown on the
right to ensure even tightening.

CAUTION

● Always use suitable tools for specific

work. Use of improper tools and meth-
ods may cause a hazardous situation.
● Use tools of correct sizes when loosen-
ing or tightening the nuts or bolts. Oth-
erwise, the tools may slide and cause
personal injury. Fig. 1-31

Fig. 1-32

1-24 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.8 Maintenance of Half Flanges

1. Clean the sealing surface of the flange and

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface may squeeze the seal out.
If these faults are not corrected properly,
parts may have to be replaced.

2. Always use specified O-rings. Check that

the O-rings are not damaged. Do not file
Fig. 1-33
the surface of the O-ring. Apply grease
onto the O-ring to locate it.

3. Tighten the half flanges carefully. Locate

the opening at the center so that it is
perpendicular to the oil opening. Tighten
the bolt manually to maintain the location
of the components.

Fig. 1-34

1.8.1 Table of tightening torques for half flange bolts

★ Unless specified otherwise, tighten the half flange bolts to the torques below.

Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
10 14 59~74 6.0~7.5
12 17 98~123 10.0~12.5
16 22 235~285 23.5~29.5

Shop Manual - April 2017 1-25

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Conversion Table
Method of using conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details
of the method of using the conversion table, see the example given below.
Example:
Method of using the conversion table to convert from millimeters to inches
Convert 55 mm into inches
Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a
horizontal line from (A).
Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).
Take the point where the two lines cross as (C). This point (C) gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
Convert 550 mm into inches
The number 550 does not appear in the table, so divide it by 10 (move the decimal point one
place to the left) to convert it to 55 mm.
Carry out the same procedure as above to convert 55 mm to 2.165 inches.
The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

1-26 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

Millimeters to Inches

(B) 1mm=0.03937in

0 1 2 3 4 5 6 7 8 9
0 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A) 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

Millimeters to Inches
1mm=0.03937in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
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

Shop Manual - April 2017 1-27

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Kilogram to Pound
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

Liters to U.S. Gallons

1 L=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

1-28 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

Liters to U.K. Gallons

1 L=0.21997 U.K.Gal

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

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

Shop Manual - April 2017 1-29

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

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

1-30 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Introduction

1.8.2 Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading
into a Centigrade temperature reading or vice versa is to enter the accompanying table in the
center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or
Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to
be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to
be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -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 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

Shop Manual - April 2017 1-31

Introduction SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
A N
BL

1-32 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

Shop Safety
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-5
2.2.1 Rules and shop behavior ............................................................................... 2-6
2.2.2 Housekeeping ................................................................................................ 2-6
2.2.3 Shop Liquids Storage..................................................................................... 2-7
2.2.4 Cleaning the Parts ......................................................................................... 2-7
2.2.5 Cleaning the Machine .................................................................................... 2-8
2.2.6 Appropriate Working Apparel ......................................................................... 2-8
2.2.7 Personal Protective Equipment...................................................................... 2-8
2.2.8 Using the Correct Tools.................................................................................. 2-9
2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9
2.2.10 Electrical Dangers ...................................................................................... 2-10
2.2.11 Hoisting a Load .......................................................................................... 2-10
2.3 Before Repair..........................................................................................................2-11
2.3.1 Safe Work Preparations ................................................................................2-11
2.3.2 Preparing yourself ........................................................................................ 2-12
2.3.3 Lockout/Tagout............................................................................................. 2-13
2.3.4 Two people when engine running ................................................................ 2-15
2.3.5 Safety Partners ............................................................................................ 2-15
2.4 Repair Precautions ................................................................................................ 2-16
2.4.1 Running the Machine ................................................................................... 2-16
2.4.2 Mounting and Dismounting .......................................................................... 2-17
2.4.3 Removing Attachments ................................................................................ 2-18
2.4.4 Jacking Up the Machine............................................................................... 2-18
2.4.5 Adding Fluids to a System ........................................................................... 2-18
Shop Manual - April 2017 2-1
Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.6 Aligning Parts or Components ..................................................................... 2-19

2.4.7 Driving Pins .................................................................................................. 2-19
2.4.8 When compressed air is used...................................................................... 2-19
2.4.9 Welding operation ........................................................................................ 2-20
2.4.10 Track Recoil Springs .................................................................................. 2-20
2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21
2.4.12 Air-conditioning system maintenance ........................................................ 2-22
2.4.13 High voltage precautions ........................................................................... 2-22
2.4.14 Disconnecting the System Power .............................................................. 2-23
2.4.15 Accumulator ............................................................................................... 2-23
2.4.17 Battery Hazards ......................................................................................... 2-24
2.4.18 Jump-Start Safety ...................................................................................... 2-25
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
2.4.20 Chemical hazard ........................................................................................ 2-27
2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27
2.4.22 Proper disposal of wastes .......................................................................... 2-28
2.5 Other Precautions .................................................................................................. 2-29
2.5.1 Sling work and giving signals ....................................................................... 2-29
2.5.2 Using mobile crane ...................................................................................... 2-31
2.5.3 Using overhead hoist crane ......................................................................... 2-31
2.5.4 Selecting wire ropes..................................................................................... 2-33

2-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2 SHOP SAFETY
2.1 Hazard Alert Information
Most accidents are usually caused by the failure to follow fundamental repair procedures and
safety rules for the system under repair. To avoid accidents it is important to read and understand
all information outlined in this manual before performing repairs on the machine system.
The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazard-
ous situation that may lead to damage, personal injury or even death. In this manual, on the ma-
chine, part or component decals and different signal words are used to express the potential level
of a hazard.

DANGER WARNING

● Indicates an imminent hazard which ● Indicates a potentially hazardous situ-

WILL result in serious injury or death if ation which COULD result in serious
message is ignored. injury or death if message is ignored.

CAUTION NOTICE

● Indicates a potentially hazardous situ- ● Indicates THE MACHINE MAY BE DAM-

ation which COULD RESULT IN MINOR AGED if improperly operated or main-
OR MAJOR INJURY if message is ig- tained.
nored.

This is to alert the user of a hazard. It is This symbol is used in a graphic to alert
usually used in a graphic. the user to not do something.

Besides the above signals words, the following words are also used to remind you of rules to be
followed or to provide you with very useful information.
Note: It is followed by measures that must be taken to prevent reduction of machine service life.
Remark: It is followed by very useful information.

Shop Manual - April 2017 2-3

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

WARNING

● Improper repair procedures on this machine can be hazardous and could result in serious in-
jury or even death.
● All personnel involved with the repair of this machine must read this manual thoroughly before
performing any procedures on this equipment.
● Some actions involved in the operation or repair of this machine could cause a serious acci-
dent if they are not performed in the manner described in this manual.
● All precautions outlined in this manual apply only to intended repair procedures of the ma-
chine or system. If you perform any repairs not specifically prohibited, you must be sure that it
is safe for you and others. In no event should you or others engage in prohibited uses or ac-
tions as described in this manual.
● SANY delivers machines that comply with all applicable regulations and standards of
the country to which the machines have been shipped. If this machine has been pur-
chased in another country or purchased from someone in another country, it may lack
certain safety features and specifications that are necessary for use in your country. If
there is any question about whether your product complies with the applicable stan-
dards and regulations of your country, contact your SANY representative before per-
forming repairs on this machine.

2-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.2 General Shop Safety

It's important to establish good shop safety
rules for everyone who enters or uses the
shop area. Implementing shop safety rules
will keep employees safe and provide the
most productive environment for working or
learning. Post rules where they can clearly be
viewed at all times. If necessary, provide shop
personnel with a written copy of the rules and
discuss any questions or confusion with them.
Always keep in mind, shop safety is NOT
something to be studied at the start of a proj-
ect and then forgotten; most accidents are
caused by carelessness, being in a hurry or by
simply disregarding safety rules. Remember
this, if you are DILIGENT and follow instruc-
tions outlined in this shop manual with care,
repair operations can be safe and enjoyable.
Safe work practices, should become a force of
habit.

WARNING

● Mistakes in operation are extremely

hazardous. Read the Safety, Operation
& Maintenance Manual that came with
the machine carefully before operating
the machine. Failure to follow this alert
could result in serious injury or death.

Shop Manual - April 2017 2-5

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.2.1 Rules and shop behavior

● Study all shop rules relating to the proce-
dure carefully and constantly apply them.
When in doubt about any task, get help!
DO NOT take chances.
● Know your job. It is foolish, and often di-
sastrous, to make repairs to a machine
without first receiving proper instructions.
Always use the shop manual when per-
forming any repair tasks. Get additional
help if you are NOT sure what must be
done or how a task should be performed.
● The shop is a place to work, not play. It is
NOT a place for “horseplay”. A “joker”
in a repair shop is a “walking hazard” to
everyone. Daydreaming or socializing on
the job also increases your chances of in-
jury. Fig. 2-2
● If you must smoke, smoke only in the area
provided for smoking. Never smoke while
on the shop floor or work area.

2.2.2 Housekeeping
● Oils, grease, fuel, antifreeze or any fluid
spills should be mopped up immediately.
These items pose a serious slip hazard.
Regardless of who was responsible for the
spill, it is your job as a shop employee to
secure and clean up the spill area.
● Keep the shop clean. Scrap or old parts
should be disposed of properly. Never al-
low them to remain on the bench or shop
floor.
● All equipment and tools must be put back
in their proper storage areas after each
Fig. 2-1
use. It's imperative that you do not let a
shop become cluttered and disorganized in
order to prevent accidents.
● Always keep in mind, proper house clean-
ing is vital for a safe and pleasant work en-
vironment.

2-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.2.3 Shop Liquids Storage

● Liquids, cleaning solvents or machine flu-
ids should be properly stored in an area
away from work locations. These storage
areas should be ventilated to an outdoor
location to avoid any vapor accumulation
in a confined shop area. Follow all OSHA
regulations regarding fluid storage.
● Never leave open containers of liquids sit-
ting around. These could spill or catch fire.
Always read the container label for infor-
mation on storage and handling of the liq-
uids.
● Never store liquids in containers that are Fig. 2-3
not properly labeled for that liquid. Confu-
sion could result in equipment damage, fire
or an unexpected explosion.
● Never smoke or bring open flames around
liquids, doing so could result in an unex-
pected fire or explosion.
● Never handle liquids without using person-
al protective equipment. Treat all liquids
with caution.

2.2.4 Cleaning the Parts

Never use gasoline, diesel fuel or similar flam-
mable liquids to clean parts. Always use ap-
proved non-flammable solvents to clean parts.
Failure to do so could result in explosion or
fire.

Fig. 2-4

Shop Manual - April 2017 2-7

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.2.5 Cleaning the Machine

● Always use high-pressure hot water and
mild, nonflammable grease-cutting soaps
or cleaning agents to clean the machine
parts. Never use flammable or caustic
cleaning agents.
● Never use high-pressure steam cleaners
to clean the machine. Steam cleaners will
damage the paint, hoses or electrical sys-
tem.
● Never pressure-wash or flood the inside of
an operator cab. This will damage sensi-
tive electrical components.
Fig. 2-5

2.2.6 Appropriate Working Apparel

Improper or loose clothing, casual dress cloth-
ing, jewelry, incorrect shoes or long hair can
result in possible injury.
Make a list of the types of clothing that are not
allowed in the shop area. Go over the list with
personnel before they start a job.

Fig. 2-6

2.2.7 Personal Protective Equipment

If your shop specifies the use of safety equip-
ment, OSHA requires this equipment to be
used when on the shop floor or in the area
where this equipment is required.
Never allow personnel in the shop area with-
out the proper personnel protective equipment
even for a moment.
Always keep personnel protective equipment
in good condition and replace them as re-
quired.
Fig. 2-7

2-8 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.2.8 Using the Correct Tools

● Always use the proper authorized tools for
the job. Using tools that are not authorized,
incorrect for the job, defective or damaged
could cause serious injury.
● Keep all tools in good condition, learn the
correct way to use them.
● Before starting the work, thoroughly check
the tools, machine, forklift, crane, service
car, etc.
● Keep your tools clean, and when the job is
complete, take inventory of the tools you Fig. 2-8
were using to be sure no tools were left in
the machine.
● Always put shop tools back in there proper
storage location when finished.
● If welding repairs are needed, always have
a trained, experienced or certified welder
carry out the work.

2.2.9 Fire Extinguisher and Emergency

Exits
● It is important to know where all emergen-
cy exits and fire extinguishing equipment
are located if a fire should occur in the
shop.
● Before preparing for work, take time and
walk around the shop to make a mental
note of where all exits and fire equipment
are located. If you are performing repairs
in the field, always have a fire extinguisher
handy and within reach.
● If you do not know how to use a fire extin-
guisher contact someone who can instruct
you in the proper use of this equipment. Fig. 2-9

Shop Manual - April 2017 2-9

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.2.10 Electrical Dangers

● When testing electrical circuits, always be
aware of what you will be checking in these
systems. High voltage or high amp circuits
could damage your equipment or cause a
spark, explosion or possible fire.
● Before performing any repairs or testing on
an electrical system be sure of the system
voltage dangers. Always check the circuit
to be sure it is off before performing any
repairs.
● When working around flammable liquids or
explosive systems, use only approved anti-
explosion proof work lamps. Non-approved
work lamps can cause an explosion or fire.

Fig. 2-10

2.2.11 Hoisting a Load

If you will be lifting parts or components that
weigh more than 35 lbs (16 kg), it is important
to follow some basic rules.
● Always use the appropriate lifting equip-
ment such as hoist, crane, forklift etc. to
handle a loads if possible.
● Be sure the lifting equipment is in good
condition and rated for the load you are
about to lift.
● If straps are to be used, ensure they are in
good condition and rated for the load to be
lifted with them.
● If you must lift the load by hand, keep your
Fig. 2-11
back straight and parallel with the load,
and lift the load using your leg muscles to
avoid back injuries. Always ask for a lifting
assistant.

2-10 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.3 Before Repair

2.3.1 Safe Work Preparations
Before starting any repairs, be sure the ma-
chine is sitting on a level stable surface.
Lower all the work equipment to a safe and
stable position on the ground. Turn the engine
OFF and neutralize the work equipment con-
trols by rotating them to the left and right (joy-
stick control) or moving them back and forth
(lever control). This function will relieve system
pressure.
Block the tracks (if equipped) or wheels (if
equipped) with chocks to prevent the machine
from moving.
If equipped, set the hydraulic lock lever in the
LOCKED position. If equipped, set the parking
brake in the PARK position.
Fig. 2-12
Be sure all personnel and equipment is clear
of your work area and you can be seen by all
working personnel especially if performing re-
pairs in the field.

Shop Manual - April 2017 2-11

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.3.2 Preparing yourself

Only approved personnel can maintain or
repair the machine. An observer may be as-
signed if necessary.
● Wear protective clothing and shoes neces-
sary for the job.
● Wear rubber apron and rubber gloves
when handling corrosive materials. Wear
heavy gloves when handling wooden ma-
terials, wire ropes or sharp-edged metals.
Fig. 2-13
● Wear a face shield when removing spring
or elastic parts, or adding acid to battery.
Wear safety hat and goggles when you
weld or cut with a torch.
● Never carry out grinding, flame cutting or
welding without an aspirator and ventilation
equipment. If you have to weld on the ma-
chine, refer to related instructions and un-
derstand the correct operating procedure.

Fig. 2-14

2-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.3.3 Lockout/Tagout
Due to the size and complexity of this ma-
chine, Lockout and Tagout procedures may
be required by your company to ensure the
safety of yourself and others involved in the
repair process of the machine. While work
is in progress, all power sources must be
disabled, locked and tagged with a warning
label. Lockout/Tagout procedure establishes
the minimum requirements used to isolate all
power sources from potentially hazardous en-
ergy, and to ensure that the machine is“locked
out and tagged out” before anyone performs
repairs on the machine.

Sequence of procedures
Only authorized employees performing repairs
on the machine shall perform Lockout/Tagout
in accordance with this procedure listed below.
If the employee performing repairs to the ma-
chine is issued a lock and key, the employee
shall not share the lock or key with other em-
ployees until all repair procedures are com-
plete and the machine is ready to put back into
service.
The following steps shall be performed in the
sequence listed when the equipment is to be
either locked-out or tagged-out for repair.

Locking out of service

1. Notify all employees who may be poten-
tially affected by the repair process on the
machine.
Fig. 2-15
2. Secure the machine in a safe position.
If equipped, set the parking brake or hy-
draulic lock lever in the PARK or LOCKED
position.
3. Identify, remove or disconnect all power

Shop Manual - April 2017 2-13

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

or energy sources and be sure to install

a Lockout/Tagout device on them. If the
machine is equipped with a Maintenance
Alert Tag, attach this tag to the machine
controls.
4. Be sure all employees involved in the
repairs have installed there lock on the
power source before performing any
repairs. Once an employee has completed
there repair procedure, they must remove
there lock and not access the machine in
any manor. Fig. 2-16

Returning to service
1. The authorized person who performed the
Lock out/Tagout procedure shall check the
area around the machine to ensure that no
one is exposed to any hazard before start-
up.
2. The authorized person who performed
the Lock out/Tagout shall ensure that
all guards have been reinstalled to their
proper place, all tools and equipment have
been removed and all locks are removed.
3. The authorized person who performed the
Lock out/Tagout shall verify that all controls
are in the neutral or “off” position and
all personnel are aware of the time the
machine will be back in service.
4. Remove the Lockout/Tagout equipment
and any additional alert equipment and re-
energize the machine for return to service.

2-14 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.3.4 Two people when engine running

In order to prevent injury, do not perform the

service while the engine is running. If the ser-
vice must be performed while the engine is
running, operate only when two people are on
the spot and follow the regulations below:
● Always have one operator sit on the op-
eration seat and be ready to turn off the
engine at any time. All the operators must
keep in touch with each other.
● Set the safety lock control lever to the lock
position.
● Do not touch any control lever. If some
control lever must be operated, send signal
to other people and warn them to transfer
to safe place quickly.
● Do not drop or insert the tools and other
objects into the fan or fan belt, or the parts
will be broken or thrown out.

2.3.5 Safety Partners

No one should be allowed to perform work
operations in any shop alone. It should be a
general shop safety rule for a minimum of two
people in the shop area at all times when work
procedures are performed. A person alone in
the shop might not be able to get emergency
help in the event of a shop accident.
When working together always maintain clear
contact with each other at all times to avoid
the occurrence of unexpected incidents.
When carrying out any operation with two or
more workers, always agree on the operating Fig. 2-17
procedures and signals before starting.

Shop Manual - April 2017 2-15

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4 Repair Precautions

2.4.1 Running the Machine

Run the machine during repair procedures
ONLY if directed to do so in this shop manual.
If the machine must be run when making re-
pairs, it is important to follow some basic safe-
ty rules.
● Always be aware of rotating components.
● During repair operations while the engine
is running, one worker must remain in the
operator seat of the machine with clear
contact between the person performing the
repairs on the machine at all times.
Fig. 2-18
● If equipped, all lock levers must be in the
LOCK position or the parking brake must
be in the PARK position.
● The person in the cab must never touch
any controls. If a control lever must be op-
erated, always maintain a clear view to the
person doing the repair and signal them
when you are about to move the control le-
ver.
● Be aware of hot surfaces. During running
operations, most surfaces will be hot, and
some surfaces will be extremely hot. If
necessary, use personnel protective equip-
ment when working around high tempera- Fig. 2-19
ture surfaces.
● Keep in mind that during running opera-
tions, hydraulic systems, cooling systems
and fuel systems will be under extremely
high pressure and at high temperatures.
● Always use caution when working on or
near these systems.

Fig. 2-20

2-16 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.4.2 Mounting and Dismounting

It is important to follow these procedures when
mounting or dismounting the equipment:
● Use all hand-holds and step plates on your
equipment.
● Never jump off or onto the equipment.
● Wipe off any oil, grease, or mud from your
shoes, rails, steps or platforms before get-
ting on the equipment; always keep these
areas clean and in good condition.
● Never get on or off moving equipment.
These actions may lead to serious injury. Fig. 2-21
Always bring the equipment to a full stop
and turn the engine OFF.
● When getting on or off the equipment,
always face the equipment and maintain
a three-point contact (both feet and one
hand or one foot and both hands) with the
handrails, steps and platforms to ensure
that you support yourself correctly.
● Never climb on areas of the machine that
are not designated walk areas.
● Never climb on or off the machine with
tools, parts or similar objects in your
hands.
● Never use machine controls or non-spec-
ified points on the equipment to get on or
off the machine.
● Use all hand-holds when on the machine. Fig. 2-22

Shop Manual - April 2017 2-17

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.3 Removing Attachments

● If you will be removing large heavy attach-
ments from the machine, always be sure to
use the correct lifting equipment rated for
the capacity of the load you will be lifting.
● After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure what you are stor-
ing is sitting stable on a stable surface and
clear of all walkways or fire exits.

Fig. 2-23

2.4.4 Jacking Up the Machine

● If you will be working under the machine
always use approved jack stands that will
support the weight of the machine you are
working on.
● Never rely on the hydraulics of the ma-
chine or a hydraulic jack to support the
machine during repairs.
● Always lower the work equipment to the
ground and check the stability of the ma-
chine before going under the machine.
Fig. 2-24

2.4.5 Adding Fluids to a System

If it should be necessary to add fluids to a
system during running operations, always be
aware that these systems may be hot and un-
der high pressure.
Before adding fluids, shut the machine down
and allow the systems to cool down to outdoor
ambient temperatures before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid.

Fig. 2-25

2-18 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.4.6 Aligning Parts or Components

● Be careful when installing or aligning parts
or components.
● Avoid using your fingers or hands to posi-
tion holes or part mating surfaces, serious
injury could result if your hand or fingers
should get ought between the surfaces.
● Always use tools to align a part or compo-
nent to avoid any finger or hand injuries.

Fig. 2-26

2.4.7 Driving Pins

When using a hammer to drive pins, metal
particles may fly off. This may lead to serious
eye injuries. Always do the following:
● Always wear a face shield or goggles when
striking a metal object with a metal ham-
mer.
● Before performing any of these proce-
dures, be sure all personnel are clear of
your work area.
● If possible, avoid using a steel hammer to
drive a component or pins in place. Dam- Fig. 2-27
age to the component may result. Always
use a soft or non-ferrous hammer to drive
a component or a pin.

2.4.8 When compressed air is used

When compressed air is used for cleaning, fly-
ing particles may cause personal injury. In this
case, wear goggles, dust-preventive mask,
gloves and other protective gear.

Shop Manual - April 2017 2-19

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.9 Welding operation

There is possibility of fire or electrocution dur-
ing welding. Therefore, welding must be per-
formed by qualified personnel with suitable
equipment. Never allow other people to do the
welding.

Fig. 2-28

2.4.10 Track Recoil Springs

If you are making repairs to a machine
equipped with tracks, always be aware of the
dangers involved with track recoil springs. This
spring is under extreme pressure at all times.
If it is disassembled by mistake, the spring
may fly out and cause serious injury.
Be careful when removing or installing tracks
on track-type machines. When removing the
master track link the track system may sepa-
rate suddenly and cause possible injury.
Always stand clear of the track travel path
Fig. 2-29
when separating the master link section of the
track.

2-20 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.4.11 High-Pressure Fluid Lines

Always keep in mind that these systems are
under high pressure. When inspecting or re-
placing piping or hoses, always check to be
sure the pressure in the system has been
relieved before proceeding. Working on a sys-
tem still under pressure could lead to serious
injury, always do as follows:
● If you will be removing a line or component
with fluid in the system, always cap and
seal the opening to avoid leakage or sys-
tem contamination.
● Never carry out inspections or replace
items while the system is under pressure.
● Never use any part of your body to check
or feel for leaks. Always wear safety
glasses and leather gloves when checking
for leaks and use a piece of wood or card-
board when checking for leaks from small
holes.
● If high pressure fluids should penetrate
your skin or get into your eyes, seek medi-
cal attention immediately.
Fig. 2-30

Shop Manual - April 2017 2-21

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.12 Air-conditioning system maintenance

WARNING

● Refrigerant R134 a is a harmless gas

under room temperature. It will change
into highly toxic gas when burning.
● Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.

● Keep fire source away when servicing air-

conditioning system.
● In maintenance of air-conditioning system,
observe the instruction on the refrigerant
cylinder and use it correctly. The type of
refrigerant is R134a. Use of other refriger-
ants may damage the air-conditioning sys-
tem.
● Obey local material disposal regulations.
Never discharge refrigerant directly into the
air.
Fig. 2-31

2.4.13 High voltage precautions

You must understand the elements before
testing electric circuit. High voltage or current
could lead to machine damage, spark, explo-
sion or fire.
You must know the voltage before repairing
or testing electrical system. Always check the
circuit and make sure it is disconnected before
doing repair job.
Only explosion-proof light can be used when
you work near flammable fluids or explosive
system. Unapproved illumination equipment
Fig. 2-32
could lead to explosion or fire.

2-22 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.4.14 Disconnecting the System

Power
Before starting any repair operations, remove
the battery leads from the battery or set the
main disconnect on the machine in the OFF
position.
For the location of the machine main electri-
cal disconnect switch, refer to the machines
Safety, Operation & Maintenance Manual for
location and procedures.
If the battery must be disconnected, remove
the negative (-) terminal clamp first then re-
move the positive (+) clamp last.
When reconnecting the battery, be sure every Fig. 2-33
electrical system switch is in the OFF position,
connect the positive clamp (+) first, then the
negative clamp(-) last.

2.4.15 Accumulator
If the machine is equipped with an accumula-
tor charged with high-pressure nitrogen gas, it
is important to follow these basic precautions.
● Do not disassemble the accumulator.
● Never expose the accumulator to high heat
or open flames.
● Never weld on the accumulator.
● Never drill or cut on the accumulator.
● Never strike the accumulator.
● Use only nitrogen gas to charge the ac-
Fig. 2-34
cumulator. Unapproved gases could be
explosive.

Shop Manual - April 2017 2-23

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.17 Battery Hazards

Working around batteries always poses a haz-
ard, especially if the battery has been in ser-
vice for a long period of time.
Listed below are some basic precautions to
be aware of when servicing or working around
batteries.
● Always wear personal protective equip-
ment when working around batteries.
● Battery gasses are extremely explosive.
When opening a battery compartment, al-
ways allow ample time for the gasses to Fig. 2-35
escape before servicing the battery.

● When working with batteries, always work

in a well ventilated area.
● If the battery is corroded, flush the area
with a baking soda and warm water mix.

Fig. 2-36

● If battery acid should get on your skin or in

your eyes, flush the area immediately with
fresh water and seek medical attention.

Fig. 2-37

2-24 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.4.18 Jump-Start Safety

CAUTION

● Never use a welder or a machine with a

higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an
unexpected explosion or fire resulting
in minor or major injury.

When using jumper cables to start the ma-

chine, connect the positive (+) jumper first, Fig. 2-38
then the negative (-) jumper to a remote loca-
tion on the chassis away from the battery.

Shop Manual - April 2017 2-25

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.19 Avoiding fire and explosion

WARNING

● Never smoke when handling the fuel or

maintaining the fuel system. The gases
in empty fuel tank can cause explosion
easily. Never carry out flame-cutting or
welding operation on fuel pipe, fuel tank
or fuel vessels, which can lead to fire,
explosion, injury or death.

● Then engine must be shut down and elec-

trical equipment must be switched off when
refueling the tank. Be extremely care-
ful when adding fuel to a hot engine. No
sparks shall occur around the grounding
nozzle.
● Handle all solvents and dry chemicals in a
place with good ventilation according to the
steps indicated on vessel.
● Clean the machine of all dust and residu-
als. Never place greasy rag or other flam- Fig. 2-39
mable materials on machine.
● When cleaning the parts and components,
use nonflammable solvents instead of gas-
oline, diesel oil or other flammable fluids.
● Store flammable liquids and materials in
suitable vessels as required by safety laws
and regulations.
● Check fire extinguishers, fire-fighting sys-
tem and fire detectors (if equipment) and
make sure they are ready for use.

2-26 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.4.20 Chemical hazard

Exposure to hazardous chemicals pose a
serious danger if released or mishandled.
Handling hazardous materials often releases
substances that could pose a hazard. Tempo-
rary implication or possible residual injury may
result unless proper precautions are observed
while working with these materials. All work-
ers involved in handling hazardous materi-
als should use approved personal protective
equipment and follow all environmental safety
regulations.

2.4.21 Material Safety Data Sheets

(MSDS)
Material Safety Data Sheet (MSDS) informa-
tion relating to the materials the workers could
be exposed to.
● MSDS data sheets provide both workers
and emergency personnel with the proper
procedures for handling or working with a
particular substance. Information includes
physical data, health effects, first aid, re-
activity, storage, disposal and protective
equipment required.
● Be sure all personnel involved are familiar Fig. 2-40
with all MSDS-related information as it re-
lates to the hazardous materials they could
be exposed to. Keep MSDS data sheets
handy in site of all employees and emer-
gency personnel where they can be easily
accessed.
● Never handle hazardous materials with-
out the proper MSDS information. Always
verify the data on the MSDS sheet before
handling any hazardous materials.

Shop Manual - April 2017 2-27

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2.4.22 Proper disposal of wastes

Improper disposal of wastes harms the envi-
ronment and ecology. Consult local environ-
mental protection department or Sany dis-
tributors for methods of recycling and waste
disposal.
● Potential harmful substances used in Sany
products include hydraulic oil, fuel, cooling
liquid, refrigerant, filter and batteries etc..
● Use leak-proof vessels to hold discharged
fluids. Never use food or beverage contain-
ers.
Fig. 2-41
● Never dump waste fluids directly to the
ground, sewage or water source.
● Leaking of refrigerant from air conditioner
can spoil the atmosphere of the globe.
Related laws and regulations must be fol-
lowed to recover or regenerate the refriger-
ant.

Fig. 2-42

2-28 Shop Manual - Arpil 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.5 Other Precautions

2.5.1 Sling work and giving signals
1. Only one appointed worker is allowed to
give signals and co-workers must commu-
nicate with each other frequently. The ap-
pointed signal person must give specified
signals clearly at a place where he is seen
well from the operator's seat and where he
can see the working condition easily. The
signal person must always stand in front of
the load and guide the operator safely.
● Do not stand under the load.
● Do not step on the load.
2. Check the slings before starting sling work. Fig. 2-43
3. Always wear gloves during sling work.
(Wear leather gloves, if available.)
4. Measure the weight of the load by the eye
and check its center of gravity.
5. Use proper sling according to the weight of
the load and method of slinging. If too thick
wire ropes are used to sling a light load,
the load may slip and fall.
6. Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire ropes
symmetrically.
7. Limit the hanging angle to 60º, as a rule.
Do not sling a heavy load with ropes
forming a wide hanging angle from the
hook. When hoisting a load with 2 or more
ropes, the force subjected to each rope will
increase with the hanging angle. The table
below shows the variation of allowable
load in kN {kg} when hoisting is made with
2 ropes, each of which is allowed to sling
up to 9.8 kN {1,000 kg} vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 19.6 kN {2,000 kg} of
total weight can be suspended. This weight
is reduced to 9.8 kN {1,000 kg} when the 2
ropes make a hanging angle of 120 ° . If
the 2 ropes sling a 19.6 kN {2,000 kg} load
Shop Manual - April 2017 2-29
Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

at a lifting angle of 150 ° , each of them

is subjected to a force as large as 39.2 kN
{4,000 kg}.
8. When installing wire ropes to an angular
load, apply softeners to protect the wire
ropes. If the load is slippery, apply proper
material to prevent the wire rope from slip-
ping.
9. Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10. Apply wire ropes to the middle portion of
the hook.
● Slinging near the tip of the hook may
cause the rope to slip off the hook dur- Fig. 2-44
ing hoisting. The hook has the maxi-
mum strength at the middle portion.
11. Do not use twisted or kinked wire ropes.
12. When lifting up a load, observe the follow-
ing.
● Wind in the crane slowly until wire
ropes are stretched. When settling the
wire ropes with the hand, do not grasp
them but press them from above. If
you grasp them, your fingers may be
caught.
● After the wire ropes are stretched, stop
the crane and check the condition of
the slung load, wire ropes, and soft-
ener.
● If the load is unstable or the wire rope
or chains are twisted, lower the load
and lift it up again.
● Do not lift up the load slantingly.
13. When lifting down a load, observe the fol-
lowing.
● When lifting down a load, stop it tempo-
rarily at 30 cm above the floor, and then
lower it slowly.
● Check that the load is stable, and then
remove the sling.

2-30 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

● Remove kinks and dirt from the wire

ropes and chains used for the sling
work, and put them in the specified
place.

2.5.2 Using mobile crane

CAUTION

● Read the Operation and Maintenance

Manual of the crane carefully in ad-
vance and operate the crane safely.

2.5.3 Using overhead hoist crane

1. Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention
earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2. Observe the signals for sling work.
3. Operate the hoist at a safe place.
4. Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail
5. Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6. Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7. Do not drag a sling.
8. When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9. Consider the travel route in advance and
lift up a load to a safe height.
10. Place the control switch on a position
where it will not be an obstacle to work and
passage.

Shop Manual - Arpil 2017 2-31

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

11. After operating the hoist, do not swing the

control switch.
12. Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
13. If the hoist stops because of a power
failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth leak-
age breaker, check that the devices related
to that switch are not in operation state.
14. If you find an obstacle around the hoist,
stop the operation.
15. After finishing the work, stop the hoist at
the specified position and raise the hook to
at least 2 m above the floor. Do not leave
the sling installed to the hook.

2-32 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Shop Safety

2.5.4 Selecting wire ropes

Select adequate ropes according to the weight of parts to be hoisted. See the table below.

Wire Rope
(Standard Z or S type of strand, ungalvanized)
Nominal Diameter Allowable 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

● The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).

Shop Manual - April 2017 2-33

Shop Safety SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

2-34 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Specifications

Specifications
3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working ranges........................................................................................................ 3-4
3.3 Technical Specifications........................................................................................... 3-5
3.4 Table of Weights ...................................................................................................... 3-7
3.5 Engine Oil, Fuel and Coolant ................................................................................... 3-8
3.6 Engine Performance Curve ................................................................................... 3-10

Shop Manual - April 2017 3-1

Specifications SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Specifications

3 SPECIFICATIONS
3.1 Dimensions

A
D
I

C
E

G F
B
J
K

ZX425-1001001

Fig. 3-1

Item Unit SY215C9C5K

A Shipping length mm 9728

B Overall width mm 3180

C Shipping height mm 3370

D Top width mm 2710

E Overall height (to cab top) mm 3050

Standard width of track
F mm 800
shoe
G Gauge mm 2380

H Min. ground clearance mm 480

I Tail swing radius mm 2890

J Track grounding length mm 3640

K Track length mm 4450

Shop Manual - April 2017 3-3

Specifications SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3.2 Working ranges

a
g

d
c

e
ZX425-1001002

Fig. 3-2

Item Unit SY215CLC

a Max. cutting height mm 9180
b Max. dumping height mm 6670
c Max. digging depth mm 6600
d Max. vertical wall depth mm 5980
e Max. digging reach mm 10307
f Min. swing radius mm 3730
g Max. height at min. swing radius mm 7680

3-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Specifications

3.3 Technical Specifications

Machine Model SY215C9C5K

Operating weight kg 23500

3
Bucket capacity m 0.9
Overall performance

Travel speed (high/low) km/h 5.3/3.1

Swing speed rpm 10.9
Gradeability Degrees 35
Ground pressure kPa 36.3
Max bucket-dig force kN 127
Max arm-in force kN 102
CUmmins
Model
QSB6.7-C164
6 cylinders, 4 cycles, water cooling, electric control,
Type
turbocharging, and air-air intercooler
Number of cylinders - cylinder
mm 6-Φ10007×124
5
bore × stroke
Total displacement L 6.7
Rate power kW/rpm 125 /1950 （Calibrated）
Engine

Max torque N·m/rpm 732/ 1500 （Calibrated）

Performance

Maximum speed,
rpm 1950±50
unloaded
Minimum speed,
rpm 900±50
unloaded
Minimum fuel
g/kWh 205
consumption
Start motor 24V/7W
Alternator 24V/70A
Carrier rollers (one side) pcs 2
Undercarriage

Track rollers (one side) pcs 9

Number of track shoes (on

pcs 51
one side)

Shop Manual - April 2017 3-5

Specifications SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Machine model SY215C9C5K

Type Kawasaki (dual pumps, plunger, variable swash plate)

Hydraulic

Main safety valve

pump

MPa 34.3
pressure
Maximum main
L/min 2×222
pump flow
Control

Type × quantity KMX15RB/B45201F

×1
valve

Control method Hydraulic

Hydraulic motor

Doosan/Ste TM40VD-A-99/163-1 /GT40D43B

Travel motor
Hydraulic system

（Brake valve, parking brake）

Kawasaki plunger motor, oblique axis
Swing motor
（Swing stop controller）
Type Reciprocal
Hydraulic cylin-

Boom cylinder mm Φ120×Φ85-1285

ders

Arm cylinder mm Φ135×Φ95-1450

Bucket cylinder mm Φ115×Φ80-1120
Hydraulic tank Enclosed
Hydraulic oil filter ele-
Tank return side
ment
Hydraulic oil cooler Air cooling

3-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Specifications

3.4 Table of Weights

Unit：kg
Machine model SY215C9C5
Engine 520
Radiator assembly 195
Hydraulic tank assembly
162
(excluding hydraulic oil)
Fuel tank assembly
145
(excluding fuel)
Swing platform 1846
Operator station 340
Operator seat & console 70
Counterweight 3950
Hydraulic pump 120
Main control valve 185
Swing reducer assembly 200
Travel reducer assembly 300×2
Swivel joint 56
Track frame
2985
Swing bearing 286
Idler 116×2
Tensioning device 135×2
Carrier roller 25.5×4
40×18
Track roller
Boom assembly 1628
Arm assembly 756
Bucket assembly /
Boom cylinder assembly 206 ×2
Arm cylinder assembly 262
Bucket cylinder assembly 188
Connecting rod 68
Rocker arm 22

Note: The table of weights is only a reference for handling the components or transportation.

Shop Manual - April 2017 3-7

Specifications SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3.5 Engine Oil, Fuel and Coolant

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

SAE 30

SAE 10W
Engine oil pan
SAE 10W-30

SAE 15W-40

Swing mecha-
nism case Engine
Idler oil SAE 30
Track roller
Carrier roller

SAE 10W

SAE 10W-30

SAE 15W-40
Hydraulic sys-
tem
L-HV32 low-temp, wear-resistant
Hydraulic
L-HM46 wear-resistant
oil
L-HM68 wear-resistant

ASTM D 975 No.2

Fuel tank Diesel oil GB252 super -20#

GB252 super -35#

Grease fitting Grease NLGI No.2

Cooling system Coolant With antifreeze

3-8 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Specifications

Note:
● Sany recommend to use the type of engine oil with a grade over API CF-4, or at least not low-
er than API CD.
● Sany recommends to use the type of gear oil GL-5.
● To ensure oil quality, please purchase genuine oils from Sany or Sany dealer.

Shop Manual - April 2017 3-9

Specifications SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3.6 Engine Performance Curve

Columbus QSB6.7
Testing condition:
● Temperature: 298K, under standard atmospheric pressure.
● With fan.

WX500-16051301

3-10 Shop Manual - June 2016

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Specifications

E
G
PA
K
AN
BL

Shop Manual - April 2017 3-11

Specifications SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

3-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Structure and Functions

4 Structure and Functions
4.1 Engine and Cooling System .................................................................................... 4-5
4.1.1 Engine-relate parts......................................................................................... 4-5
4.1.2 Radiator and intercooler................................................................................. 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Power train ..................................................................................................... 4-7
4.2.2 Travel reducer AS .......................................................................................... 4-8
4.2.3 Swing reduction mechanism ........................................................................ 4-10
4.2.4 Swing bearing .............................................................................................. 4-12
4.3 Undercarriage ........................................................................................................ 4-14
4.3.1 Track frame and tensioning mechanism ...................................................... 4-14
4.3.2 Idler .............................................................................................................. 4-16
4.3.3 Carrier roller ................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Tracks .......................................................................................................... 4-21
4.4 Hydraulic System, Part 1 ....................................................................................... 4-25
4.4.1 Deployment of hydraulic parts ..................................................................... 4-25
4.4.2 Hydraulic Pump (SY215C9C5K).................................................................. 4-26
4.4.3 Pilot pump .................................................................................................... 4-28
4.4.4 Regulator (KR3S-9T1L-V)............................................................................ 4-29
4.4.4.1 Oil delivery control .............................................................................. 4-44
4.4.5 Pilot pump .................................................................................................... 4-45
4.4.6 Regulator (KR3K-9N1H-V)........................................................................... 4-46
4.5 Hydraulic System, Part 2 ....................................................................................... 4-58
4.5.1 Control valve ................................................................................................ 4-58
4.5.1.1 Main valve structure ............................................................................ 4-60
Shop Manual - April 2017 4-1
Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-65

4.6 Hydraulic System, Part 3 ....................................................................................... 4-88
4.6.1 Swing motor ................................................................................................. 4-88
4.6.2 Relief valve section ...................................................................................... 4-91
4.6.3 Anti-jerk valve............................................................................................... 4-93
4.6.4 Central swivel joint ....................................................................................... 4-95
4.6.5 Travel motor ................................................................................................. 4-96
4.6.5.1 Operation of parking brake ............................................................... 4-103
4.6.5.2 Operation of braking valve ................................................................ 4-104
4.6.6 Control system ............................................................................................4-112
4.6.7 Pilot valve....................................................................................................4-113
4.6.8 Travel pilot valve .........................................................................................4-117
4.6.9 Solenoid valves .......................................................................................... 4-121
4.6.10 Pilot accumulator ..................................................................................... 4-122
4.6.11 Pilot oil filter .............................................................................................. 4-123
4.7 Work Equipment .................................................................................................. 4-124
4.7.1 Component dimensions ............................................................................. 4-124
4.7.2 Arm dimensions ......................................................................................... 4-126
4.7.3 Bucket dimensions ..................................................................................... 4-128
4.8 Air Conditioning System....................................................................................... 4-130
4.8.1 Layout of A/C components ......................................................................... 4-131
4.8.2 A/C control panel........................................................................................ 4-132
4.8.3 Diagram of electrical circuit ........................................................................ 4-133
4.8.4 Refrigeration principle ................................................................................ 4-135
4.8.5 Compressor ............................................................................................... 4-136
4.8.6 Clutch ......................................................................................................... 4-138
4.8.7 Condenser ................................................................................................. 4-139
4.8.8 Expansion valve ......................................................................................... 4-140
4.8.9 Evaporator ................................................................................................ 4-140
4.8.10 Dehydrator .............................................................................................. 4-141
4.8.11 Pressure switch ........................................................................................ 4-142
4.8.12 Refrigerant ............................................................................................... 4-143
4.8.12.1 Evacuation ...................................................................................... 4-146
4.8.12.2 Refrigerant filling operation ............................................................. 4-148
4.8.12.3 Troubleshooting with manifold pressure gauge .............................. 4-153
4.8.13 Compressor oil ......................................................................................... 4-162

4-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.9 Engine Control ..................................................................................................... 4-163

4.9.1 System operation ....................................................................................... 4-164
4.9.2 System components .................................................................................. 4-165
4.9.2.1 Fuel control dial................................................................................. 4-165
4.9.2.2 Engine control unit (ECU) ................................................................. 4-166
4.10 Electrical Control System................................................................................... 4-170
4.10.1 Control function ........................................................................................ 4-170
4.10.2 Diagram of machine control system......................................................... 4-171
4.10.3 Engine-pump combination control ........................................................... 4-173
4.10.4 Valve control function ............................................................................... 4-176
4.10.5 Travel control function .............................................................................. 4-177
4.10.6 Low engine oil pressure alarm and protection ......................................... 4-178
4.10.7 High engine coolant temperature alarm and protection ........................... 4-179
4.10.8 Engine preheating control ........................................................................ 4-180
4.10.9 Engine starting and energizing delay control ........................................... 4-181
4.10.10 System parts and components .............................................................. 4-182
4.10.10.1 Pump pressure sensor .................................................................. 4-182
4.10.10.2 Pilot pressure sensor .................................................................... 4-183
4.10.10.3 Engine speed sensor .................................................................... 4-184
4.10.10.4 Coolant temperature sensor ......................................................... 4-185
4.10.10.5 Fuel level sensor ........................................................................... 4-186
4.10.10.6 Oil pressure switch........................................................................ 4-187
4.11 Monitor System .................................................................................................. 4-188
4.11.1 Monitor ..................................................................................................... 4-189
4.11.2 Monitor panel ........................................................................................... 4-190

Shop Manual - April 2017 4-3

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4 STRUCTURE AND FUNCTIONS

4.1 Engine and Cooling System
4.1.1 Engine-relate parts

2 3 4 5

Fig. 4-1

(1) Air cleaner Specifications

(2) Radiator assembly Oil pan capacity: 22.7L
(3) Rubber damper AS
(4) DOC
(5) DPF
(6) SCR

Shop Manual - April 2017 4-4

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.1.2 Radiator and intercooler

Fig. 4-2

(1) Engine intake pipe Specification

(2) Engine outlet pipe Radiator AS: ZH1100×620×1490-S160Y90Z40
(3) Oil radiator Aluminum pipe, belt-type radiator
(4) Water radiator Radiators for the air conditioner, intercooler,
(5) Air intercooler hy-draulic oil and water are arranged serially.
(6) Fuel radiator Water tank capacity: 20 L

4-5 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.2 Power Train

4.2.1 Power train

3 2 1

4 5 6 7 8 9

10

ZX425-1002003

Fig. 4-3

(1) Swing motor (6) Accumulator

(2) Swing reducer (7) Main control valve
(3) Swing bearing (8) Reducer AS
(4) Idler (9) Main pump
(5) Swivel joint (10) Engine

Shop Manual - April 2017 4-6

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.2.2 Final drive assembly

Final drive AS (KYB)

1 2 3 19 4 17
73±3.6 N·m

205±10 N·m
5

59±4.9 N·m

20

18

157±8 N·m
12
11 16 10 9

ZX215-1002004-1

13

14

15

ZX215-1002005

4-7 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

1) Cylinder GP 9) No. 2 sun gear (No. of teeth: 19)

2) Shaft 10) No. 2 planetary gear (No. of teeth: 36)
3) Gear hub (No. of teeth: 85) 11) Seal ring
4) No. 2 planetary carrier 12) Travel motor
5) No. 1 planetary carrier 13) Fill port
6) No. 1 planetary gear (No. of teeth: 36) 14) Level port
7) No. 1 sun gear (No. of teeth: 12) 15) Drain port
8) End cover

Specifications

Reduction ratio:

( (12+85) /12) × ( (19+85) /19) ) -1= 43.246

Criteria
No. Check item Remedy
Standard clearance Clearance limit
Backlash between No. 2 sun gear
16 0.13 – 0.47 1.00 Replace
and No.2 planetary gear
Backlash between No. 1 planetary
17 0.17 – 0.57 1.10
gear and gear hub
Backlash between No. 1 sun gear
18 0.14 – 0.46 1.00
and No.1 planetary gear
Replace
Backlash between No. 2 planetary
19 0.16 – 0.56 1.10
gear and gear hub
Backlash between No. 1 planetary
20 0.38 – 0.66 1.00
carrier and No. 2 sun gear

Shop Manual - April 2017 4-8

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Final drive AS (Nabtesco)

2 3 4 5 6
102 ±16 Nm

98 ±20 Nm

7
8

10

98 ±20 Nm

12 ±2.5 Nm
12 709 ±108 Nm
11
ZX215-1002006

14 13

IN

OIL LEVEL

DRAIN

15 ZX225-1102047

4-9 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

1) Plunger GP 9) Shaft coupling

2) Crankshaft 10) Retainer
3) Gear hub 11) Motor output shaft
4) Roller bearing 12) Travel motor
5) RV drive gear A 13) Fill port
6) RV drive gear B 14) Level port
7) No. 1 planetary gear (42) 15) Drain port
8) No. 1 sun gear (18)

Specifications

Reduction ratio: 60

Shop Manual - April 2017 4-10

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.2.3 Swing machinery

20

19
8
21
7

22
59~74 Nm

10
6
23
5 24

11
4
12
25
26

13

3
27

1 14

15

16

17

18

28
ZX215-1002007

4-11 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

1) Plug 11) No. 2 planetary gear GP

2) Oil seal 12) No. 2 planetary gear (No. of teeth:17)
3) Self-aligning bearing 13) Spring pin
4) Ring gear (No. of teeth:52) 14) Swing reducer screw plug
5) No. 2 planetary carrier 15) Grease fitting
6) No. 1 planetary carrier 16) Self-aligning bearing
7) No. 2 sun gear (No. of teeth: 16) 17) Bearing sealing
8) No. 1 sun gear (No. of teeth:14) 18) Swing pinion
9) Swing motor 19) Dipstick
10) No. 1 planetary gear (No. of teeth:18) 20) Oil filling pipe

Specifications

Reduction ratio:

(14+25) /14× (16+25) /14= 20.04

Criteria
No. Check item Remedy
Standard clearance Clearance limit
Backlash between swing motor shaft
21 0.18 – 0.28 — Replace
and No. 1 sun gear
Backlash between No. 1 sun gear
22 0.16 – 0.50 1.00
and No.1 planetary gear
Backlash between No. 1 planetary
23 0.18 – 0.59 1.10
gear and ring gear
Backlash between No. 1 planetary
24 0.39 – 0.71 1.20
carrier and No. 2 sun gear
Backlash between No. 2 sun gear
25 0.16 – 0.50 0.90 Replace
and No.2 planetary gear
Backlash between No. 2 planetary
26 0.18 – 0.59 1.00
gear and ring gear
Backlash between No. 2 planetary
27 0.07 – 0.23 —
carrier and swing pinion
Backlash between swing pinion and
28 0.22 – 1.32 2.00
swing bearing

Shop Manual - April 2017 4-12

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.2.4 Swing bearing

A
A

549±50 Nm 549±50 Nm
A-A
ZX215-1002008

1) Swing bearing inner race (Teeth: 91) Specifications

2) Ball
Reduction ratio: 91/13= 7
3) Swing bearing outer race
Amount of filled grease: 13±1 Kg

a. Inner race soft zone S position

b. Outer race soft zone S position

Check item Criteria Remedy

Axial clearance of bearing Standard clearance Clearance limit

Replace
(when mounted on chassis) 0.5~1.6 3.2

4-13 Shop Manual - April 2017

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.3 Undercarriage
4.3.1 Track frame and tensioning mechanism

1 2 3 4

8 11 7 6 5 10

ZX425-1002008

Fig. 4-8

(1) Idler ● Dimension and number of track rollers may

(2) Track frame vary depending on the machine model, but
(3) Carrier roller the basic structure is the same.
(4) Sprocket ● Number of track rollers
(5) Track roller
(6) Track shoe Model Quantity (One side)
(7) Center guard SY215C9C5K 9
(8) Front guard

4-14 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Standard track shoe

Model
SY215C9C5K
Item
Shoe width (mm) 800
Link pitch (mm) 190
Number of track shoes at one
51
side

SY215C9C5K Unit: mm

No. Check Item Standard Remedy

Vertical width Standard size Tolerance Repair limit
9 of idler guide Track frame 107 — — Build-up
Idler support 105 — — welding
Horizontal or re-
Track frame 250 — —
10 width of idler place
Idler support 248 — —
guide
Standard size Repair limit
Free
length Installation Installation Free Installation
Tension
11 × Outer length load length load Replace
spring
diameter
572 ×
466 157.9 kN 545 133.9 kN
235

Shop Manual - April 2017 4-15

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.3.2 Idler

4
3
7
8

157~255 Nm 9

1 2

ZX425-1002009

Fig. 4-9

4-16 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

SY215C9C5K
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Protrusion outer dia.
560 —
2 Tread outer dia. 520 660
Build-up
3 Tread thickness 30 25 welding
or replace
4 Tread difference 22 27
5 Overall width 164 —
6 Tread width 39.5 —

Standard Tolerance Standard clear- Clearance

Clearance between size Shaft Hole ance limit
7
shaft and bushing -0.25 +0.164 0.049 ～
φ65 —
-0.35 -0.074 0.199
Standard Tolerance Standard Interference
Interference be- size Shaft Hole interference limit Replace
8 tween idler and
+0.108 -0.032 0.004 ～ bushing
bushing
φ72 —
+0.008 -0.062 0.17
Standard clearance Clearance limit
Clearance between
bushing and support
9
(Sum of clearances 0.5 ～ 1.0 —
at both sides)

Shop Manual - April 2017 4-17

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.3.3 Carrier roller

5 3

6 7 2 1

ZX425-1002010

Fig. 4-10
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Flange outer dia.
φ169 —
2 Tread outer dia. φ144 146
3 Tread width 43 —
4 Tread thickness 34 38.5
5 Flange width 17 —

Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
6 Replace
shaft and bushing – 0.05 +0.1
φ40 0.05 ～ 0.2 —
– 0.1 0
Standard Tolerance Standard in- Interference
size Shaft Hole terference limit
Interference between
7
roller and bushing +0.16 0
φ47 0.14 ～ 0.24 —
+0.12 -0.08

Axial clearance of Standard clearance Clearance limit

8
roller 0.44 ～ 0.76 —

4-18 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.3.4 Track roller

10

8 9 2 1

549±59 Nm

7 5 6

ZX425-1002011

Fig. 4-11

Shop Manual - April 2017 4-19

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

SY215C9C5K
Unit: mm

No. Check item Criteria Remedy

Standard clearance Repair limit

1 Flange outer dia.
φ193 —

2 Tread outer dia. φ160 148 Build-up

welding
3 Tread thickness 46.5 40.5
or replace
4 Overall width 237 —
5 Tread width 46.5 —

6 Flange width 32 —

7 Inner width 80

Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
8
shaft and bushing
– 0.185 +0.3
φ60 0.225 ～ 0.4 —
– 0.18 +0.04 Replace
Tolerance bushing
Standard Standard Interference
Interference be- size interference limit
9 tween roller and Shaft Hole
bushing +0.14 +0.02
φ67 0.07 ～ 0.16 —
+0.09 -0.02
Clearance between
Standard clearance Clearance limit
bushing and collar
10 Replace
(Sum of clearance
0.5 – 1.0 —
at both sides)

4-20 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.3.5 Tracks

20

22 24
8
16 12
13
5

11 21
23 25

7 6 15 2 9 3 14

10

18 17 19
ZX425-1002012

Fig. 4-12

Shop Manual - April 2017 4-21

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

SY215C9C5K
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Link pitch
190 193 Reverse or
Standard size Reverse replace
2 Bushing outer diameter
58.7 53.7
3 Thickness of bushing metal 10.75 5.75
Standard size Repair limit
4 Link height Repair or replace
106 98
Thickness of link metal (bushing
5 30.65 22.5
press-fitting portion)
6 155.57
7 Shoe bolt pitch 119.57
8 62
9 Inside width 82.69
10 Link Overall width 40
11 Tread width 38
Protrusion of Regular 2.65
12
pin Master 2.65 Adjust or replace
Protrusion of Regular 3.7
13
bushing Master 0
Overall length Regular 207
14
of pin Master 209
Overall length Regular 136.1
15
of bushing Master 128.7
16 Thickness of spacer —
17 Bushing 88.2～ 245 kN{9 ～ 25 tons}
Press-fitting
18 Regular pin 127.4～ 274.4 kN{13
～ 28 tons} —
force
19 Master pin 78.4～ 147 kN{8 ～ 15 tons}

4-22 Shop Manual - April 2017

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Unit: mm

No. Check item Criteria Remedy

Tightening torque (Nm {kgm}) Retightening angle (°)

a. Regular link Triple grouser 750±22.5
120±10
Shoe bolt shoe {62.5±2.3} Retighten
Tightening torque Retightening angle Lower limit torque
20
b. Master link (Nm {kgm}) (°) (Nm {kgm})
— — —
49 (SY215CLC)
No. of shoes (each side) —
51 (SY235CLC)
Tolerance Standard interfer-
Standard size
Interference between Shaft Hole ence
21
bushing and link 0 -0.25
58.7 0.20 – 0.32
-0.05 -0.32
Interference between regu- 0 –0.23
22 36.7 0.19 – 0.29
lar pin and link -0.04 –0.29
Tolerance Standard clear-
Standard size
Clearance between regular Shaft Hole ance
23
pin and bushing 0 0.8 Adjust or
36.7 0.50 – 0.84
-0.04 0.5 replace
Tolerance Standard interfer-
Standard size
Interference between mas- Shaft Hole ence
24
ter pin and link -0.08 -0.23
36.7 0.12 – 0.21
-0.11 -0.29
Tolerance Standard clear-
Standard size
Clearance between master Shaft Hole ance
25
pin and bushing -0.5 1
36.7 1 – 1.7
-0.7 0.5

4-23 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.3.6 Triple grouser shoe

5 6 7

1
8

2
3 4

ZX215-1002014

Model
SY215CLC SY235CLC
Item
Shoe width(mm) 800 800
Link pitch(mm) 190 190
Q'ty (One side) 49 51

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Height
26 16
2 Thickness 10
3 29.5
Length of base
4 22 Build-up welding
5 20.5 or replace
6 Length at tip 17
7 18
Standard size Repair limit
8 Thickness
36 26

Shop Manual - April 2017 4-24

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.4 Hydraulic System, Part 1

4.4.1 Hydraulic equipment layout drawing

1) Bucket cylinder
2) Arm cylinder
3) Boom cylinder
4) Hydraulic tank
5) Hydraulic oil filter
6) Control valve
7) Hydraulic pump
8) Radiator
9) Accumulator
10) Left travel motor
11) Right travel motor
12) Swing motor
13) Lockout lever
1
14) Left pilot valve
15) Center swivel joint
16) Right pilot valve
17) Travel pilot valve
18) Solenoid valve assembly

18A. Pilot lockout solenoid valve

18B. Boom priority solenoid valve
18C. Bucket confluence solenoid valve
18D. Swing priority solenoid valve
18E. Hi/Lo travel speed solenoid valve
18F. Secondary boosting solenoid
valve

4-25 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

3 4 5 6 7 8

10

11
A
12
18A
13 18B
14 18C
18D
15 18E
16 18F
17

18
W14011601

Shop Manual - April 2014 4-26

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.4.2 Hydraulic tank and filter

3 4 5 6

A
A

7
A-A
ZX215-1002017

1) Hydraulic tank Specifications

2) Level gauge Tank capacity: 239 L
3) Oil filler cap Available capacity: 172 L
4) Return oil filter element
Breather valve
5) Bypass valve
Filter fineness: 10μm
6) Breather valve
Ambient temperature: -30~100°C
7) Oil-suction filter element
Set pressure:
Air inlet side: 0.004MPa (at 1Lmin)
Air outlet side: 0.017MPa (at 1L/min)

4-27 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.4.3 Hydraulic pump

a1 PH1 PH2 a2
{36N·m} {36N·m}

a5
A1 A2 {16N·m}
a4
{36N·m}

Clockwise
B3

DR1{170N·m}
B1 DR2{170N·m}
a3
5 Psv2 {36N·m}
4

A3
DR3{170N·m} DR4{170N·m}

3 2 1

ZX215-1002018

Shop Manual - April 2017 4-28

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Outline

● This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pi-
lot gear pump.

a1: F. pump main pressure detection port 1) Front pump

a2: R. pump main pressure detection port 2) Rear pump
a3: F. pump regulator pressure detection port 3) Pilot gear pump
a4: Adjustor control pressure detection port 4) Front pump regulator
a5: Pilot gear pump output pressure detection port 5) Rear pump regulator
PH1: F. pump pressure sensor assembly port
PH2: R. pump pressure sensor assembly port
A1: F. pump delivery port
A2: R. pump delivery port
A3: Pilot gear pump delivery port
Psv1: F. pump regulator control port
Psv2: R. pump regulator control port
Dr1: F. pump drain plug
Dr2: R. pump drain plug
Dr3: Air bleeder
Dr4: Drain plug
B1: Pump suction port
B3: Pilot gear pump oil suction port

4-29 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

2 3 13 6 7 14 8 9 16 10

15

1
12

4 5 11

ZX215-1002019

1) Front shaft 9) End cover

2) Min. delivery adjusting screw 10) Rear shaft
3) Front casing 11) Rear casing
4) Swash plate 12) Gear pump
5) Slipper 13) Piston
6) Plunger 14) Max. delivery adjusting screw
7) Cylinder block 15) Gear shaft
8) Valve plate 16) Driving pin

Shop Manual - April 2017 4-30

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

B 6 13 7 8

18
18 4 5
A 17

ZX215-1002020

Function

● The torque of the engine is transmitted

to the pump shaft (1), and drives cylinder
block (7) to rotate. At the same time, nine
plungers (6) slide along the thrust plate (8).
Plunger (6) moves back and forth inside
cylinder block (7) and pressurized oil is
sucked and discharged alternatively.

● It is possible to change the discharge

amount by changing the swash plate an-
gle.

4-31 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Structure

● Cylinder block (7) is supported to shaft (1)

by spline (17).

● Shaft (1) is supported by front and rear

bearings (18).

● Tip of plunger (6) is shaped as a concave

ball and slipper (5) is caulked to it to form
one unit.

● Plunger (6) and slipper (5) constitute the

spherical bearing.

● Swash plate (4) has flat surface (A), and

slipper (5) is always pressed against this
surface while sliding in a circular move-
ment.

● Swash plate (4) conducts high pressure oil

to cylinder surface (B), and forms a static
pressure bearing when it slides.

● Plunger (6) carries out relative movement

in the axial direction inside each cylinder
chamber of cylinder block (7).

● Cylinder block (7) seals the pressurized oil

to thrust plate (8) and carries out relative
rotation.

● This surface is designed so that the oil

pressure balance is maintained at a suit-
able level.

● The oil inside the respective cylinder cham-

bers of cylinder block (7) is sucked in and
discharged through thrust plate (8).

Shop Manual - April 2017 4-32

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Operation of pump

● Cylinder block (7) rotates together with

shaft (1), and slipper (5) slides on flat sur- 1 4 5 7
face (A). A

● When this happens, swash plate (4) moves

along cylindrical surface (B), so angle (a)
between central line (X) of swash plate (4)
and the axial direction of cylinder block (7) a
changes. X

● (a) is named the swash plate angle. B

ZX215-1002021

● With central line (X) of swash plate (4) at

a swash plate angle (a) in relation to the 4 5 6
A F
axial direction of cylinder block (7), flat sur-
face (A) acts as a cam in relation to slipper
(5).

● In this way, plunger (6) slides on the in-

side of cylinder block (7), so a difference a
between volumes (E) and (F) is created X
inside cylinder block (7). E
7
● A single plunger sucks and discharges the ZX215-1002022

oil by the amount (F) – (E).

● As cylinder block (7) rotates and the vol-

ume of chamber (E) becomes smaller, the
pressurized oil is discharged.

● On the other hand, the volume of chamber

(F) grows larger and, in this process, the
oil is sucked.

● As central line (X) of swash plate (4) over- F

laps the axial direction of cylinder block (7)
(swash plate angle (a) = 0), the difference
between volumes (E) and (F) inside cylin-
der block (7)becomes 0.

● Suction and discharging of pressurized

oil is not carried out in this state. Namely
pumping action is not performed. (In real- E

ity, however, the swash plate angle is not 4 7

set to 0) ZX215-1002023

4-33 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Control of delivery

● If swash plate angle (a) becomes larger,

13 16 F
the difference between volumes (E) and
(F) becomes larger and pump delivery (Q)
increases.

● Piston (13) is used for changing swash

plate angle (a).

● Piston (13) carries out linear alternating

motion under the control of the adjustor. a

● This linear motion is transmitted to swash

plate (4) via drive pin (16). The sliding of 4 E
ZX215-1002024
the swash plate changes the swash plate
angle and changes the discharge amount
of the main pump.

Shop Manual - April 2017 4-34

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.4.4 Pilot pump

435 433 710 700 354 351

434

310
355

732

311

312

309 307 308 434 850 466 725 435 361 353

ZX215-1002025

307: Valve stem 361: Body

308: Valve base 433: Screw
309: Retainer 434: Screw
310: Spring 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 actuates the main pump and

the drive shaft of the pilot pump through
the transmission case, and drives the pilot
pump through gear engagement.

4-35 Shop Manual - April 2017

 SKY5P 079
- 17 - S
496 418 4.4.5 Regulator

(KR3G-0E11-AV)
PSV B

KDRDE5C-1
624 627 646 897 415
A
325

408 a
496
924
801 601
755 402 614
466
543
656
407 643 755
A 756
733
631 708 545
724
731 887 611
651 652 733 541
SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Shop Manual - April 2017

A-A
(KDRDE5K) PSV Tightening torque
Name plate and s/n
Tightening torque
Part No. Thread size
a N•m Type
402, 407
408 M6 12
415 M8 29 s/n
G-OE11-V
418 M5 6.9
466 G1/4 16
496 NPTF1/16 8.8
614 G1/4 36 Direction B
801 M10 29

Hydraulic schematic diagram

ZX225-1102002

4-35
Structure and Function
Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Category Part No. Part name Q’ty Remark

C 924 Hexagon socket head locating screw 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 Spool valve 1
/ 651 Sleeve 1
/ 646 Guide spring 1
/ 643 Pilot plunger 1
/ 631 Pf pilot sleeve 1
/ 627 Adjusting roller 1
/ 624 Spring seat 1
/ 614 Plug 1
/ 611 Feedback lever 1
/ 601 Casing 1
/ 545 Ball 2
/ 543 Stopper 2
/ 541 Valve seat 2
C 496 Embedded plug 9
C 466 VIP plug 1
D 418 Hex socket head bolt 2 JIS B 1176 M5-12
D 415 Hex socket head bolt 6 JIS B 1176 M8-50
D 408 Hex socket head bolt 1 JIS B 1176 M6-40
D 407 Hex socket head bolt 4 JIS B 1176 M6-30
D 402 Hex socket head bolt 4 JIS B 1176 M6-16
/ 325 Valve body 1
B 079 Sol proportional reducing valve 1
B — Regulator assembly 1

B: Assembly obtainable at the dealers (individual parts not purchasable)

/: Individual components included in assemblies of category B
C: Parts obtainable at the dealers
D: Parts obtainable on the market

4-36 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Function

● The regulator controls the pump discharge PSV

amount according to the command signal
pressure, keeping the driving power of the
pump lower than the engine output.
a
● Pumps 1 and 2 are both equipped with a
regulator. Key components of the regulator 1
include a solenoid proportional pressure
reducing valve (1), a positive flow regulator
(2), a servo reversing valve (3) and a servo
piston (4). The regulator opens and shuts 2
the oil circuit of the servo piston (3) and
changes the tilting angle of the hydraulic
tank according to various command signal
3
pressure so as to control the pump dis- 4
charge amount.
ZX225-1102003

4.4.5.1 Control mechanism makeup

Current control

● The inclination (output delivery amount)

of the pump can be controlled freely by
changing of the command current I flow-
ing into the solenoid proportional pressure
reducing valve. This regulator applies posi-
tive flow control (positive control), through
which output delivery amount Q changes
according to the increase of command cur-
rent. Necessary current for corresponding
operation can be input through this control
mechanism. The pump only delivers nec-
essary oil amount and wastes no useless
power.

Shop Manual - April 2017 4-37

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.4.5.2 Adjustment of the regulator

806 532 548 531 808 954

953

ZX215-1002028

531: Inclination pin

532: Servo piston
SKY5P
- 17 - S

548: Feedback pin PSV

KDRDE5C-1

806: Retaining nut

808: Retaining nut
924
953: Adjusting screw
954: Adjusting screw

● It is possible to adjust the maximum and

ZX225-1102004
minimum flow by the adjusting screws (953,
954) in the pump block side. Flow control
features can be adjusted with the hexagon
socket head locating screw (924) on the
regulator.

4-38 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Maximum flow adjustment (pump block

side)

Output flow Q
● Loosen the hexagon nut (808), and tighten
(or loosen) hexagon socket head locating
screw (954). No control features except the
maximum flow changes.

Command current I
ZX215-1002033
Minimum flow adjustment (pump block
side)

● Loosen the hexagon nut (806), and tighten

(or loosen) the hexagon socket head locat-
Output flow Q

ing screw (953). Though this action is the

same as the adjustment of maximum flow
and all the other control features do not
change, power required under maximum
output pressure (overflow) is likely to in-
crease if over-tightened. Be careful in this
case.

Command current I
ZX215-1002034

Flow control feature adjustment

● After hexagon nut (810) is loosened, tight-

en (or loosen) the hexagon socket head lo-
cating screw (924) to carry out adjustment.
Output flow Q

When the hexagon socket head locating

screw (924) is being tightened, the control
diagram (as shown) will move to the right.

Command current I
ZX215-1002037

Shop Manual - April 2017 4-39

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.4.5.3 Operation

Output flow Q
Flow control

● The output flow of the pump can be con-

trolled by the command current I, as
shown.

Action of increasing flow rate Command current I

ZX215-1002030
● When command current I increases, the
solenoid proportional pressure reducing
valve secondary pressure P2 will increase, 079
and the spool valve (652) will move the
right with the help of the guide piston (643). 651 652
627 646
When a relative balance between the right- 643
P1 801
ward hydraulic force and the spring force 924
of guide spring (646) is achieved, spool 611

valve (652) stops moving. 808 A 532

806
954 953
● As spool valve (652) moves to the right,
because port cl and tank port are intercon- P1
nected, pressure of the large diameter
portion of the servo piston is released and Tilt angle large
servo piston (532) moves to the left via the ZX225-1102005

output pressure P1 in the shall diameter

portion. The inclination becomes larger.

● Since feedback lever (611) is integrated PSV

with the servo piston and valve sleeve
(651), if servo piston (632) moves to the
left, feedback lever swings with point A as
the pivot. In this way, valve sleeve moves a
to the right.

● Through this movement, the opening por-

tion between the spool and the valve block
is closed slowly. The servo piston stops
moving when the opening portion is com-
pletely closed.

ZX225-1102006

4-40 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Action of reducing flow rate

● When command current I decreases, the 079

solenoid proportional pressure reducing
651 652
valve secondary pressure P2 will decrease,
627 646
and guide piston (643) will move to the left. 643
801
P1
However, as spool valve (652) moves, out- 924
put pressure P1 is introduced into the large 611
532
diameter chamber of the servo piston via 808 A
806
954
the port cl. On the other hand, output pres- 953

sure P1 is introduced into the small diam-

P1
eter chamber of the servo piston and servo
piston moves to the right via are difference.
The inclination becomes smaller. Tilt angle small
ZX225-1102007

● As servo piston (532) moves to the right,

the feedback lever swings with point A as
the pivot and the valve sleeve moves to the PSV

left. Through this movement, the opening

portion between the spool and the valve
block is slowly closed. The servo piston
a
stops moving when the opening portion is
completely closed.

ZX225-1102008

Shop Manual - January 2014 4-41

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Adjustment value of the regulator

Type of regulator KR3G-0E11-AV

-1
Rotating speed (min ) 2050
Adjusting screw (954) screw-in (rotation) +1/4
Adjustment of max. flow
Flow rate change (L/min) -5.9
Adjusting screw (953) screw-in (rotation) +1/4
Adjustment of min. flow
Flow rate change (L/min) +4.7

4-42 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5 Hydraulic System, Part 2

4.5.1 Control valve

(XAo) XBp2 XAa1

BaR XAa2

BoR

BkR
Psp

BbR

XAb1
Dr2
XBtr

XBtL
XAs
(PTa)
XBtr

Dr3

PnA2
Dr6

Dr7
Pns

Bs Btr As Atr
Pz AtL PX PG
PbL

TRAVEL STRAIGHT
Py MR TRAVEL RIGHT

XAtr
TRAVEL LEFT SWING

XAtL BtL Dr1 XBs

XBb1
BOOM1
Bb(Rod) SWING PRIORITY BOOM2

XAb2
AbR
BUCKET OPTION

XAk PCk AkR (XBo)

(Bo)
ARM2 ARM1

XBa2 XBk AoR Dr3 XBa1

(BYPASS CUT 1)

Bk(Rod) DR3 PCV1

(XBp1)
AaR
R2 Ba(Head)
PaL
Aa(Rod) Ak(Head) Ab(Head) (Ao)
P2 P1

R1

R1

ZX225-1102009

Shop Manual - April 2017 4-43

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

XAtr : R. travel (reverse) pilot port XBp2: Bypass cut spool pilot port (P2 side)
XBtr : R. travel (forward) pilot port XAb2: Boom confluence (UP) pilot pressure
(XAo): (Option pilot port) Psp: Swing priority pilot port
(XBo): (Option pilot port) R1: Return port
XAk: Bucket (DIG) pilot port R2: Oil feed port
XBk: Bucket (DUMP) pilot port Atr: R. travel motor port (reverse)
XAb1: Boom 1 (UP) pilot port Btr: R. travel motor port (forward)
XBb1: Boom 2 (DOWN) pilot port (Ao): Option
XAa2: Arm 2 (OUT) pilot port (Bo): Option
XBa2: Arm 2 (IN) pilot port Ak: Bucket cylinder head end port (DIG)
XAtL: L. travel (reverse) pilot port Bk: Bucket cylinder rod end port (DUMP)
XBtL: L. travel (forward) pilot port Ab: Boom cylinder head end port (UP)
XAs: Swing (left) pilot port Bb: Boom cylinder rod end port (DOWN)
XBs: Swing (right) pilot port AtL: L. travel motor port (reverse)
XAa1: Arm 1 (OUT) pilot port BtL: L. travel motor port (forward)
XBa: Arm 1 (IN) pilot port As: Swing motor port (left swing)
Dr1: Drain port Bs: Swing motor port (right swing)
Px: Work equipment signal port Aa: Arm cylinder rod end port (OUT)
Py: Travel signal port Ba: Arm cylinder head end port (IN)
Pz: Main relief valve boosting pressure P1: Pump port (P1 side)
PG: Pilot pressure resource port P2: Pump port (P2 side)
Pns: Swing logic control valve pilot port MR: Main relief valve
PCK: Bucket (DIG) stroke limit pilot port AR: Arm regeneration check valve
PnA2: Arm 2 logic control valve pilot port AbR: Port relief valve
Dr2: Drain port BbR: Port relief valve
Dr3: Drain port AkR: Port relief valve
Dr6: Drain port BkR: Port relief valve
Dr7: Drain port AoR: Port relief valve
Pal: Lock valve pilot port (arm rod end) BoR: Port relief valve
PbL: Lock valve pilot port (boom head end) AaR: Port relief valve
(XBp1):Bypass cut spool pilot port (P1 side) BaR: Port relief valve

4-44 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Specifications

Item Specification
Model KMX15RB
Standard flow rate (equivalent to one pump) 220 L/min
When main relief valve is normal 34.3 MPa
Maximum pressure
When main relief valve is boosting 37.3 MPa
Maximum pressure When port relief valve is normal 39.2 MPa
Working oil temperature -20~90°C
Drained oil maximum pressure 0.3 MPa

Shop Manual - April 2017 4-45

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.2 Hydraulic circuit diagram (with bucket confluence function)

P2 (P3) R1 (P0) P1 PG

d1 d2 d3
Φ0.7 Φ0.7 Φ0.7
MR
CMR2

CMR1
Pz
TRAVEL R XBtr
(PTa) TRAVEL
XAtr STRAIGHT
Px
Atr CPG
Btr
CP1
Dr2
Dr6 LCs Py
XBs
SWING 4-Φ2.1 XBtl TRAVEL L
XAs XAtl

As Btl
Bs Atl
Pns C2
Dr1
SWING
PRIORITY Psp LCb
XBb1

XAb1 BOOM1
BOOM2XAb2 Bb
AbR (ROD)

BbR
CCb
Ab
(HEAD)
HVb
PbL
LCk
LCo
PCk
(XBo)
XBk
OPTION (XAo)
BUCKET
XAk
AoR
(Ao) BkR (ROD)
(Bo) Bk
Ak
AkR (HEAD)
BoR
AR
PnA2
Dr3 Dr7
LCa LCAT2
2-Φ1.0 LCAP2
2-Φ2.0
XAa1 XBa2
ARM2
ARM1 XBa1 XAa2
(HEAD)
AaR
Ba
BaR

Aa
CCo
(ROD)

HVa

CCk PaL

BYPASS (XBp1)
CUT R2

XBp2

(P5)
ZX225-1102010

4-46 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5.3 Operating principle

4.5.3.1 When spool is in neutral position

[Main circuit]

When all the spools are in neutral position,

working oil supplied from the hydraulic pump
(Front) flows in through pump port P1 and is
introduced into the main passage (1). It pass-
es the neutral bypass (2) (neutral M-shaped
spool mechanism) of the spools of straight
travel (308), L. travel (301), boom 1 (303),
bucket (304) and arm 2 (306), and flows back
into the working oil tank via return port (R1).

Working oil supplied from the hydraulic pump

(Rear) flows in through pump port P2 and is
introduced into the main passage (3). It pass-
es the neutral bypass (2) (neutral M-shaped
spool mechanism) of the spools of R travel
(301), swing (305), boom confluence (boom
2: 307), option (309), arm 1 (302), and flows
back into the working oil tank via return port
(R1).

Shop Manual - April 2017 4-47

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

(1)
(2)

(PTa)

XAtL XBtL

XBb1 XAbL

XAk PCk

X8k
XBa2 XAa2

CCo CCk
P2 (P3) R1
(3)
(2)

XBtr XAtr

XAs XBs

Psp XAb2

(XAo) (XBo)

XAa1 XBa1

XBp2 (XBp1)

ZX225-1102011

4-48 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5.3.2 Travel

[Pilot circuit] ● Likewise, when pressure at port XBtr for

the right travel spool (301) rises, neutral
● When the left or right travel spool is bypass (2) at arm 1 side is closed, and
switched, the side bypass circuit is closed working oil supplied from the hydraulic
and pressure at port Py (travel signal port) pump (rear) is introduced into the right
rises. travel motor via port Btr.
[Main circuit] ● On the other hand, return oil from the left
● When pressure at pilot port XBtL for left and right travel motor passes the left (right)
travel spool (301) rises, neutral bypass (2) travel spool via port Atl (Atr), and returns to
at boom 1 side is closed, and working oil working oil tank via return port (R1).
supplied from the hydraulic pump (front) is ● The principle is the same when travel on
introduced into the left travel motor via port the opposite side is operated (when pres-
Btl. sure at pilot port XAtr and XAtl rises).

XAtr XBtr

Atr Btr

Travel motor
ZX225-1102012

Shop Manual - April 2017 4-49

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.3.3 Arm

(1) Arm OUT

[Pilot circuit] ● On the other hand, working oil from port

P1 is introduced into neutral bypass (2) via
● When the arm 2 spool (306) is switched, main passage (1). Neutral bypass is cut off
the side path is closed and pressure at port by switching the arm 2 spool (306). There-
Px (work equipment signal port) rises. fore, working oil in the parallel passage
[Main circuit] pushes open the logic cone valve (256-101)
of the arm 2 logic valve GP, and working oil
● When arm OUT is operated, pilot pres- from neutral bypass pushes open the cone
sure oil is supplied into port XAa1 and port valve (511) of the check valve and flows
XAa2. When pilot pressure oil is applied at into the arm 2 spool (306) via the U pas-
the two sides of port XAa1 and port XAa2, sage. Then, it merges with port As via the
arm 1 spool and arm 2 spool are switched inner passage of arm 2 spool (306) and is
to the left as shown in the illustration. As supplied into the arm cylinder rod end (R).
a result, working oil from P2 is introduced
into neutral bypass (2) via main passage ● Return oil from the arm cylinder head end
(3). Neutral bypass is cut off by switching (H) via port Ba flows into the tank circuit of
arm 1 spool (302). Therefore, working oil arm 1 and arm 2, and returns to working oil
in the parallel passage pushes open the tank via tank port (R1).
cone valve (511) of the check valve, and
flows into the arm 1 spool (302) via the U
passage. Then, it flows into the periphery
of arm 1 spool (302) and arm 2 spool (306)
and is supplied into the arm cylinder rod
end (R) via port As.

4-50 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

R H

Aa 256-101
511

XAa2

XAa1

Ba
511

ZX225-1102013

Shop Manual - April 2017 4-51

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

(2) Arm IN

[Pilot circuit] from neutral bypass pushes open the cone

valve (511) of the check valve and flows
● When the arm 2 spool (306) is switched, into the arm 2 spool (306) via the U pas-
the side path is closed and pressure at sage. Then, it merges with port Ba via the
port Px (work equipment signal port) rises. inner passage of arm 2 spool (306) and is
At the same time, pressure oil is supplied supplied into the arm cylinder head end (H).
to port PaL and the release signal of lock
valve option set (252) is sent out. ● On the other hand, pressure of the return
oil from the arm cylinder rod end (R) rises
[Main circuit] under the weight the arm, and the return
● When arm In is operated, pilot pressure oil oil returns to port Aa. Working oil that re-
is supplied to port XBa1 and port XBa2. turns to port Aa flows into the inside of the
When pilot pressure oil is applied at the valve spool via the holes on the periph-
two sides of port XBa1 and port XBa2, ery of the arm 1 spool (302), and pushes
arm 1 spool and arm 2 spool is switched to open the cone valve (302-317) in the spool
the left. As a result, working oil from P2 is only under light load. It merges with port
introduced into the neutral bypass (2) via Ba through the holes on the spool. This is
main passage (3). Neutral bypass is cut off called the regeneration function of the arm.
by switching arm 1 spool (302). Therefore, ● If the pressure at the arm cylinder head
working oil flown into the parallel passage end and in the U passage rises, arm re-
pushes open the cone valve (511) of the generation check valve spool (257-211)
check valve and flows into the arm 1 spool switches to the left. And, at the same time,
(302) via the U passage. Then, it flows into the back pressure of the cone valve (302-
the periphery of arm 1 spool (302) and is 317) in the spool is closed. Therefore,
supplied into the arm cylinder head end (H) arm regeneration function is released and
via port Ba. return oil from the arm cylinder rod end
● On the one hand, working oil from port P1 (R) flows into the spool via the hole (a) on
is introduced into neutral bypass (2) via the periphery of arm 1 spool (302). Then,
main passage (1). Neutral bypass is cut off it flows into arm regeneration check valve
by switching the arm 2 spool (306). There- set (257) via hole (c) on the periphery of
fore, working oil in the parallel passage arm 1 spool (302), and returns to the work-
pushes open the logic cone valve (256-101) ing oil tank via tank port R1.
of the arm 2 logic valve GP, and working oil

4-52 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

● Light load

Arm weight
R H

Aa

XBa2

(302-317)

XBa1

(b)

(a) Ba

ZX225-1102014

Shop Manual - April 2017 4-53

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● When pressure at arm cylinder head end (H) rises

R H

Aa

XBa2

(302-317)

XBa1

(c)

(257-211) Ba
(a)
ZX225-1102015

4-54 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5.3.4 Boom

(1) Boom UP

[Pilot circuit] ● At the same time, pilot pressure oil is also

supplied to port XAb2 and boom 2 spool
● When the boom 1 spool (303) is switched, (307) moves to the right. Working oil from
the side path is closed and pressure at port port P2 is introduced into neutral bypass.
Px (work equipment signal port) rises. Neutral bypass is cut off by switching the
[Main circuit] boom 2 spool (307). Therefore, working
oil in the parallel passage flows into boom
● When boom UP is operated, pilot pressure 2 spool (307) via the U passage. Then, it
oil is supplied into port XAb1 and boom 1 pushes open the cone valve (511) of the
spool (303) moves to the left. Working oil check valve and merges with port Ab and
from port P1 is introduced into neutral by- is supplied into the boom cylinder head
pass (2) via main passage (1). Neutral by- end (H). This is called the boom conflu-
pass is cut off by switching boom 1 spool ence function.
(303). Therefore, working oil in the parallel
passage pushes open the cone valve (511) ● On the other hand, return oil from the
of the check valve, and flows into the boom boom cylinder rod end (H) via port Bb flows
1 spool (303) via the U passage. Then, it into the periphery of boom 1 spool (303)
flows into the periphery of boom 1 spool and returns to the working oil tank via tank
(303) and is supplied into the boom cylin- port (R1).
der head end (H) via port Ab.

Shop Manual - April 2017 4-55

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H R

511
Ab
Bb

XAb1

XAb2

511
ZX225-1102016

4-56 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

(2) Boom DOWN

[Pilot circuit] passage. Then, it flows into the periphery

of boom 1 spool (303) and is supplied into
● When the boom 1 spool (303) is switched, the boom cylinder rod end (R) via port Bb.
the side path is closed and pressure at
port Px (work equipment signal port) rises. ● On the other hand, return oil from the
At the same time, pressure oil is supplied boom cylinder head end (H) passes the
to port PbL and the release signal of lock hole (a) and the periphery of boom 1 spool
valve option set (252) is sent out. (303).

[Main circuit] ● Return oil pressure rises due to the self

weight of the boom. Cone valve (303-317)
● When boom DOWN is operated, pilot pres- in the spool is pushed to the right. Return
sure oil is supplied to port XBb1. Boom 1 oil flows to the outside of spool. The pres-
spool (303) moves to the right. As a result, sure oil is supplied into the boom cylinder
working oil from P1 is introduced into the rod end (R) as the working oil for boom
neutral bypass (2) via main passage (1). DOWN operation. This is called the boom
Neutral bypass is cut off by switching boom regeneration function. Part of the oil that
1 spool (303). Therefore, working oil flown flows into the inside passage of the spool
into the parallel passage pushes open the via hole (a) returns to the working oil tank
cone valve (511) of the check valve and via hole (b).
flows into the boom 1 spool (303) via the U

H R

511

Ab Bb

XBb1

(b) (a)
(303-317)
ZX225-1102017

Shop Manual - April 2017 4-57

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.3.5 Bucket

(1) Bucket DIG

[Pilot circuit] Then, it flows into the periphery of bucket
spool (304) and is supplied into the bucket
● When the bucket spool (304) is switched, cylinder head end (H) via port Ak.
the side path is closed and pressure at port
Px (work equipment signal port) rises. At ● On the other hand, return oil from the buck-
the same time, pressure oil is supplied at et cylinder rod end (R) flows in via port Bk.
port XBp2. Then, it flows to oil tank port (R1) via the
spool periphery and returns to working oil
[Main circuit] tank.
● When bucket DIG is operated, pilot pres- ● When boom UP and bucket DIG are oper-
sure oil is supplied into port XAk and buck- ated simultaneously, pilot pressure oil is
et spool (304) moves to the right. Working supplied to port Pck. Therefore, the stroke
oil from port P1 is introduced into neutral of bucket spool is not limited at stroke end,
bypass (2) via main passage (1). Neutral but on any position halfway. As a result,
bypass is cut off by switching bucket spool bucket cylinder passage is throttled and
(304). Therefore, working oil in the paral- working oil flows into boom 1 spool (303)
lel passage pushes open the cone valve via bucket spool (304). In this way, boom
(511) of the check valve, and flows into UP operation takes precedence.
the bucket spool (304) via the U passage.

H R

Ak Bk

H
XAk
Pck

ZX225-1102018

4-58 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

(2) Bucket DUMP

[Pilot circuit] tral bypass is cut off by switching bucket

spool (304). Therefore, working oil in the
● When the bucket spool (304) is switched, parallel passage pushes open the cone
the side path is closed and pressure at port valve (511) of the check valve, and flows
Px (work equipment signal port) rises. At into the bucket spool (304) via the U pas-
the same time, pressure oil is supplied at sage. Then, it flows into the periphery of
port XBp2. bucket spool (304) and is supplied into the
[Main circuit] bucket cylinder rod end (R) via port Bk.

● When bucket DUMP is operated, pilot ● On the other hand, return oil from the buck-
pressure oil is supplied into port XBk and et cylinder head end (H) flows in via port
bucket spool (304) moves to the left. Work- Ak. Then, it flows to oil tank port (R1) via
ing oil from port P1 is introduced into neu- the spool periphery and returns to working
tral bypass (2) via main passage (1). Neu- oil tank.

H R

Ak Bk

XBk

ZX225-1102019

(3) Bucket confluence

● When bucket DIG is operated, pilot pres- switching neutral bypass valve spool (310).
sure oil is supplied into port XBp2 and the Therefore, working oil pushes open the
neutral bypass cutoff valve spool (310) is check valve, and interconnects with the U
switched. Working oil from port P2 is in- passage via the inside path, and converg-
troduced into neutral bypass (2) via main es with bucket spool (304).
passage (3). Neutral bypass is cut off by

Shop Manual - April 2017 4-59

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.3.6 Swing

(1) Swing operation

[Pilot circuit] (305). Therefore, working oil in the parallel

passage pushes open the logic cone valve
● When the swing spool (305) is switched, (2540-101) of the swing logic valve GP,
the side path is closed and pressure at port and flows into the swing spool (305) via the
Px (work equipment signal port) rises. U passage. Then, it flows into the periph-
[Main circuit] ery of swing spool (305) and is supplied
into the swing motor via port As (or Bs).
● When swing is operated, pilot pressure
oil is supplied into port XAs (or XBs) and ● On the other hand, return oil from the
swing spool (305) is switched. Working swing motor flows in via port Bs (or port
oil from port P2 is introduced into neutral As). Then, it flows into tank port (R1) via
bypass (2) via main passage (3). Neutral the spool periphery and returns to the
bypass is cut off by switching swing spool working oil tank.

XBs XAs

As Bs

(254-101)

Swing motor
ZX225-1102020

4-60 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

(2) Swing priority function

[Pilot circuit] ● Switch swing priority spool (311). The

opening area of the swing priority reduces.
● Pilot pressure oil is supplied to port Psp As a result, working oil from arm 1 spool
and swing priority spool (311) is switch. (302) flows into swing spool (305) and
[Main circuit] swing operation takes precedence.

Psp

ZX225-1102021

Shop Manual - April 2017 4-61

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.3.7 Option

Option spool is used to control optional equipment.

(1) Option operation

[Pilot circuit] (309). Therefore, working oil in the parallel
passage pushes open the cone valve (511)
● When the option spool (309) is switched, of the check valve, and flows into the op-
the side path is closed and pressure at port tion spool (309) via the U passage. Then,
Px (work equipment signal port) rises. it flows into the periphery of option spool
(309) and is supplied into the optional
[Main circuit] equipment via port Ao (or Bo).
● When option is operated, pilot pressure ● On the other hand, return oil from the op-
oil is supplied into port XAo (or XBo) and tional equipment flows in via port Bo (or
option spool (309) is switched. Working port Ao). Then, it flows into tank port (R1)
oil from port P2 is introduced into neutral via the spool periphery and returns to the
bypass (2) via main passage (3). Neutral working oil tank.
bypass is cut off by switching option spool

XAo
XBo

Ao Bo

ZX225-1102022

(2) Option confluence Neutral bypass is cut off by switching by-

pass valve spool (310). Therefore, work-
● To achieve option confluence, pilot pres- ing oil pushes open the cone valve (514)
sure oil is supplied into port XBp1 and the of check valve, and converges with option
bypass cutoff valve spool (310) is switched. spool (309) via the inside path and the U
Working oil from port P1 is introduced into passage.
neutral bypass (2) via main passage (1).

4-62 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5.3.8 Travel straight

When travel spool (301) and other spool are [Main circuit]
operated simultaneously.
● When straight travel spool (308) is
The following case shows when travel spool switched, the right/left travel spool (301)
(301) and swing spool (305) are operated si- are interconnected with port P2. The paral-
multaneously. (When pilot pressure oil is sup- lel passage of swing/boom 2/option/arm
plied to port XAtL, port XAtr and port Xas) 1 circuit and boom 1/bucket/arm 2 circuit
are interconnected with port P1. Therefore,
[Pilot circuit] working oil supplied from port P2 flows into
● The side path of right/left travel spool (301) port Atl and port Atr, and is supplied to the
and the side path of the swing spool (305) two travel motors equally.
at the downflow side are closed. ● On the other hand, working oil from port P1
● Pilot oil from port PG is supplied to port is supplied to the swing motor via port As.
PTa and straight travel spool (308) is ● When oil pressure at port P2 is lower than
switched. that at port P1, part of the working oil form
port P1 is supplied to port P2. In this way,
sharp decrease of travel speed is averted.

P1 P2

PTa

ZX225-1102023

Shop Manual - April 2017 4-63

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.3.9 Lock valve function

● The lock valve option set (252) is installed ● When boom 1 spool (303) is in neutral po-
between the arm cylinder rod end (R) and sition, spool (252-511) in the lock valve op-
arm 2 spool (302) and arm 2 spool (306). tion set is pressed against the valve seat
It is used to reduce the internal leakage of of the valve sleeve (252-541) inside the
the spool due to cylinder pressure. lock valve option set, as shown in the illus-
tration, via the spring force of spring (252-
● Likewise, lockout option set (252) is also 321).
installed between boom cylinder head end
(H) and boom 2 spool (303) to reduce the ● At this position, working oil at the boom
internal leakage of he spool due to cylinder cylinder head end (H) flows in via hole (a)
pressure. and flows out from hole (b) through the
periphery of the lock valve option set spool
(1) Spool in neutral position (252-511), pressing the cone valve (513)
● The following shows when boom 1 spool against the valve seat of the valve block
(303) is in neutral position. (The same is via hole (b). By this means, oil leakage is
with arm 2 spool (306)) reduced.

252-321 252-511

252-541

(b)

513

(a)

ZX225-1102024

4-64 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

(2) Boom DOWN operation

● When boom DOWN is operated, pilot pres- into spring chamber (RH). In addition, oil
sure oil is supplied to port PbL and port in the spring chamber (RH) flows into drain
XBb1. Spool (252-511) inside the lock circuit via hole (b). In this way, the cone
valve option set moves to the top by via pi- valve (513) is pushed up by the pressure
lot pressure oil. Through the movement of at boom cylinder head end (H) and the
spool (252-511) inside the lock valve option function of the lock valve option set (252)
set, hole (a) is cutoff and working oil from is released.
boom cylinder head end (H) does not flow

252-511

(b) (RH)

513

(a)

PbL

XBb

ZX225-1102025

(2) Boom UP operation

● When boom DOWN is operated, pilot pres- boom 1 spool (303) and working oil flows
sure oil is supplied to port XAb1. The cone into port Ab.
valve (513) is pushed ope by the oil from

Shop Manual - April 2017 4-65

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.5.3.10 Main relief valve function

The main relief valve is installed on the valve and enters low-pressure path (R).
block A (101). Its function is described below:
● Opening of cone valve (611) causes pres-
● Working oil flows into chamber (a) from sure in chamber (a) to drop and valve rod
passage (P) via the hole of valve seat (541) (512) is open. In this way, working oil in
and hole on valve rod (512). Valve rod (512) passage (P) flows into low-pressure path
is pressed against valve seat (541), form- (R) directly.
ing a tight seal.
● When pressure oil high than 3MPa is sup-
● When pressure in passage (P) exceeds plied to port Pz, this pressure oil pushes
the elastic force of spring (621), cone valve plunger (614) to the left. The set load of
(611) is pushed open. Therefore, working spring (621) is changed and pressure of
oil flows through the hole on valve sleeve the main relief valve rises.
(103) via the periphery of cone valve (611)

541 611 621

R
Pz

512 (a) 103 614

ZX225-1102026

4-66 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5.3.11 Port relief valve function

The port relief valve is installed between the

tank port and low-pressure path. In addition
to the function as relief valve, it has also the
function of anti-cavitation oil complement
check valve. Its function is described below:

(1) Relief valve function

● Working oil flows into chamber (B) via the

hole (A) on plunger (301). Valve rod (511)
is pressed against valve seat (541), and
valve seat (541) is pressed onto the valve
seat of the valve block, forming a tight seal.

B
A

R
301 511 541
ZX225-1102027

A B

301 R
511 541
ZX225-1102028

Shop Manual - April 2017 4-67

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● When pressure in passage (P) exceeds

the elastic force of spring (621), cone valve
(611) is pushed open. Therefore, working
oil flows through hole (C) via the periphery
of cone valve (611) and enters low-pres-
sure path (R).

R
611 621
ZX225-1102029

R
621
611
ZX225-1102030

4-68 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

● Opening of cone valve (611) causes pres-

sure in chamber (B) to drop and valve rod
(511) is open. In this way, working oil in
passage (P) flows into low-pressure path
(R) directly.

511 611
ZX225-1102031

R
511 611
ZX225-1102032

Shop Manual - April 2017 4-69

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

(2) Anti-cavitation oil complement check

valve

● When negative pressure is formed in path

(P), working oil is supplied from path (R).
When pressure in path (R) gets higher
than pressure in path (P), valve seat (541)
moves to the right direction. Therefore,
working oil is supplied from path (R) to
path (P) via the periphery of valve seat
(541) in order to prevent cavitation.

541
ZX225-1102033

541
ZX225-1102034

4-70 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.5.4 Section view

B A 273×10
153
(Po)

XAtr
561 TRAVEL
TRAVEL R STRAIGHTC
C 273×12 HR

XBs XAtl TRAVEL L

SWING 252
D D

Dr8 PnS XAb2 XBbl

BOOM1
BOOM2 977
978×2 E
E
AbR
XAk
XBo BUCKET
OPTION
F F
AoR AkR

XBa1 XBa2
ARM1 ARM2
G AR G

(BYPASS CUT1) (XBp1)

PnA2 Dr7
H BYPASS CUT2
O AaR O 252
PCV1 H AaR
602
A
B
XBa2
(XBp1)

Dr3

View O-O

274×4

CCo
Pns (P5)
Dr6 Dr7
PnA2
CCk P P

210
153 561
(P5)

Viw P-P

XAa2

273×12 XBk 273×10

XBp2 PCk
ZX225-1102035

Shop Manual - April 2017 4-71

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Section A-A, N-N

N
543
101 159 541 542 166

550

(PTa)

XAtL XBtL

XBb1 XAbL

XAk PCk

XBk
XBa2 XAa2

CCo CCk
514 521 561 551 551 561 521 514
View A-A

151 168 151 168 151

168

PB 156

2-156

View N-N
ZX225-1102036

4-72 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Section B-B

153 561 102

P2 (P3) R1
975 975

XBtr XAtr

975

XAs XBs

975

Psp XAb2

975
(XAo) (XBo)

975 975

XAb1 XBa1

975

XBp2 (XBp1)

975
975
165 165 165
View B-B
ZX225-1102037

Shop Manual - April 2017 4-73

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Section C-C (Travel right, travel straight)

154
164
201 TRAVEL TRAVEL 201
RIGHT STRAIGHT
336 336
332 XAtr 332
335 323
321 335
320
332

332
332 MR
261
261
308
163 601

314
Pz
165
512
163 Atr 522
511 553
521

551
CP1 CMR1
561 562

165 562
163
163 Btr
CMR2

163
553

522
512

159

264 159
264
204
XBtr (PTa) 204
164
View C-C
154

ZX225-1102038

4-74 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Section D-D (Swing, travel left)

201
SWING TRAVEL LEFT 336
201
336 332
XBs XAtL
332 335
335
321
321
320
320
332
261
332
314
261

305
161

163
163 AtL

As
254 511

521
C2

551

561
BtL
251

Bs

165
Dr2

264
264
XAs XBtl
204
204
163 163
View D-D
ZX225-1102039

Shop Manual - April 2017 4-75

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

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

202 BOOM2 BOOM1

336 201
332 XAb2 XBb1 336
339 332
327 335
321
326
320
602
332
332 261
261
L L
161 158
511 Dr1
521 PbL
523

CCb CRb 552

551 561

561 513
165 511
307 521
LCb
163
Xb2
551
551 561
561
Bb
311

161 303

163
264
261 602
332 XAb1 204
BbR
320
329 158
339
332
336
202 Psp
SWING
PRIORITY
View E-E View L-L

ZX225-1102040

4-76 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Section F-F (Option, bucket)

259
164
201
201
OPTION BUCKET 336
336
(XBo) 332
332
335 335
321 321
320 320
602
332 AkR 332
261 261

604 304

163

209
971×4
165 Ak
309
163 (Ao)

163
511 511
521
521
LCo
551
551
561
561
(Bo)

Bk
163
165
971×4
209
163

264 602

604 264
(XAo) 206
204 BkR
211
164 BoR XBk
561
154 258
PCk
View F-F ZX225-1102041

Shop Manual - April 2017 4-77

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Section G-G (Arm 1, arm 2)

201
201 336
336
332
332 XBa1 XBa2
335
335
321 321
320 320
257 Dr3
AR 332
332
261
261
306
L L
158
163
165 513
162 523
152 CRa 561
165 552
162 251
152

302
511
521

551 LCAT2 256

561
551
163 561

R2 521
511

165
163

264 264
602 XAa2
XAa1
BaR 204
205
View G-G
ZX225-1102042

4-78 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Section H-H (Bypass cut 1, bypass cut 2)

612 169 162 152 158 154 164 152 162 162 152 164 154 158 152 162 164 154 169 612 162 152

PCV2 PCV1

XBp2

(XBp1)

203 333 331 372 373 337 331 262 310 165 165 310 163 262 331 337 373 372 331333 203

View H-H
ZX225-1102043

Shop Manual - April 2017 4-79

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
SPOOL ASS’Y, travel
101 BLOCK, valve A 1 308 1
straight
102 BLOCK, valve B 1 309 SPOOL, option 1
13~17 151 PLUG 3 310 SPOOL, bypass cut 2
34~39 152 PLUG 7 311 SPOOL, swing priority 1
220~250 153 PLUG 3 320 SPRING 9
69~78 154 PLUG 6 321 SPRING 8
7.4~9.8 156 PLUG, orifice 3 322 SPRING 1
7.5~10 158 PLUG 5 323 SPRING 1
10~14 159 PLUG 3 326 SPRING 1
161 O-RING 3 327 SPRING 1
162 O-RING 7 329 SPRING 1
163 O-RING 21 331 SPRING SEAT 4
164 O-RING 7 332 SPRING SEAT 22
165 O-RING 14 16~18 333 FLANGE SOCKET 2
166 O-RING 1 335 STOPPER 9
168 O-RING 3 16~18 336 FLANGE SOCKET 11
169 O-RING 2 337 STOPPER 2
201 COVER, spring 9 339 STOPPER 2
202 COVER, spring 2 372 SPRING 2
203 COVER, spring 2 373 SPRING 2
204 COVER, spool 7 511 VALVE, cone 8
205 COVER, spool 1 512 VALVE, cone 2
206 COVER, spool 1 513 VALVE, cone 2
209 FLANGE 2 514 VALVE, cone 2
210 PLATE 1 521 SPRING 10
211 PISTON 1 522 SPRING 2
49~65 251 VALVE, logic control 2 523 SPRING 2
OPTION ASS’Y, lock
9.8~14 252 2 541 BALL 1
valve
254 VALVE GP, swing logic 1 542 SPRING SEAT 1
256 VALVE GP, arm 2 logic 1 543 SPRING 1
CHECK VALVE ASS’Y,
69~78 257 1 25~29 550 PLUG 1
arm regeneration
258 PLUG 1 230~260 551 PLUG 11
259 PLUG 1 230~260 552 PLUG 2
261 O-RING 11 130~150 553 PLUG 2

4-80 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
262 O-RING 2 561 O-RING 17
264 O-RING 9 562 O-RING 2
25~34 273 SCREW, hex, S,H,C 44 69~78 601 VALVE, main relief 1
98~120 274 SCREW, hex, S,H,C 4 69~78 602 VALVE, port relief 6
301 SPOOL, travel 2 120~140 604 VALVE, port relief 2
302 SPOOL ASS’Y, arm 1 1 69~78 612 PLUG 2
303 SPOOL ASS’Y, boom 1 1 49~65 971 SCREW, hex, S,H,C 8
304 SPOOL, bucket 1 140~180 975 SCREW, hex, S,H,C 10
305 SPOOL, swing 1 977 PLATE name 1
306 SPOOL, arm 2 1 978 PIN 2
307 SPOOL, boom 2 1

Shop Manual - April 2017 4-81

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6 Hydraulic System, Part 3

4.6.1 Swing motor

L
SH PG

PB
B

IP

PA A

1
M DR

ZX215-1002081

A: Main oil port 1. Safety valve

B: Main oil port 2. Reverse prevention valve
M: Oil complement port
Specifications
PA: Pressure detection port
PB: Pressure detection port Type M5×180CHB-12A-51A/260
DB: Lubricating port Theoretical displacement 169.4 cm³/rev
PG: Brake release port Safety valve set pressure 25.5 MPa {255 Kg/cm³}
SH: Brake direction port Rated engine speed 2000 rpm
L: Oil level stick Brake release pressure 2.7 MPa {27 Kg/cm³}
IP: Gear oil feed port

4-82 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

7
6

A-A

A
8 9
5

10

11
3

12
2

13
1
ZX215-1002082

1) Spacer 6) Check valve spring 11) Plate

2) Casing 7) Check valve 12) Piston
3) Disc 8) Oil distribution plate 13) Drive shaft
4) Brake spring 9) Cylinder
5) Shell 10) Brake piston

Shop Manual - April 2017 4-83

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6.2 Swing holding brake

● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is main-
tained.

M
Pump a
1
Main valve
7
PX
PG
6

SH

ZX215-1002083

● Port SH is connected with port PX of the main valve. Once any movement other than travel
is applied on the main valve, pressure will be generated at port PX, and port PG is intercon-
nected with chamber a beneath piston 7. The pressurized oil compresses brake spring (1)
and pushes the brake piston up. Disc (5) is separated from plate (6), releasing the brake.

M
Pump a
1
Main valve
7
PX

PG
6

SH

ZX215-1002084

● Otherwise, no pressure is generated at port PX, and port PG is shut off from chamber a be-
neath piston (7). Brake piston (7) is pushed down by brake spring (1). Disc (5) and plate (6)
are pushed together, and the brake is applied.

4-84 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.3 Relief valve

Structure

● The relief valve portion consists of relief

valves (1) and (2), check valves (3) and (4).

Function

● When the machine is in the swing holding

mode, control valve (5) closes the motor
outlet circuit, but the motor rotation contin-
ues due to inertial force. The motor output,
therefore, is abnormally increased, result-
ing in motor damage.

● In order to avoid the motor damage, the

relief valve relieves the abnormally high
pressure to port (M) from the motor outlet
side (high-pressure side) of the motor.

Shop Manual - April 2017 4-85

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Operation

1. When swing begins (suppose pressur-

ized oil enters Port A) From port M
1 2
● When the swing control lever is operated
for right swing, pressurized oil from the
pump is supplied to port (A) via control
valve (5).

● The pressure on port (A) rises, the starting

torque is generated in the motor, and the
motor is activated. 4
3

● The pressurized oil from the outlet port of

the motor passes from port (B) through the C
control valve (5) and returns to the tank. A B

5
ZX215-1002085

2. When swing stops

● When the swing control lever is neutral-

From port M
ized, the supply of pressurized oil from the
1 2
pump to port (A) is cut off.

● The pressurized oil from the motor outlet

can't return to the tank since the return cir-
cuit to the tank is closed from control valve
(5). Thus, pressure at port (B) rises.

● Swing resistance is generated on the mo-

tor and hence the brake starts working. 3
4

● Pressurized oil will be relieved when the

pressure on port (B) rises to the set pres- C
sure of relief valve (2). A B

● A high braking torque is applied on the mo-

5
tor, thereby stopping the motor. ZX215-1002086

● When relief valve (2) is being actuated, the

relieved pressurized oil and the pressur-
ized oil from port (M) are fed to port (B) via
check valve (4).

● Above prevents cavitation on port (B).

4-86 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.4 Reverse prevention valve

4.6.4.1 Operation drawing

A T1

T2 B
1 2 3 4

7 6 5
Swing T
motor
B A

Swing control valve

ZX215-1002087

1) Valve body 5) Spool (B side)

2) Spool (A side) 6) Spring (B side)
3) Spring (A side) 7) Plug
4) Plug

Shop Manual - April 2017 4-87

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6.4.2 Explanatory drawing of effects

:With reversal prevention valve

:Without reversal prevention valve

Reversal pressure

Pressure MA

Containment pressure
Reversal pressure
Pressure MB

1st reversal

2nd reversal
Motor speed

Start Brake Reversal

Time
ZX215-1002088

Outline

● Inertia of the swing body, the backlash and

rigidity of the machinery system, and the A
compression of the hydraulic oil all may T
c e D4 a D3
cause the machine to shake during swing
operation. The reverse prevention valve is
designed to reduce this effect. The valve
contributes in preventing collapsing of load
when the swing is stopped and also con-
tributes in reducing cycle time (enhances
the positioning performance, enabling you
to proceed to the next work quicker than D1 d Notch D2 B b f
ever). T
ZX215-1002089

4-88 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Operation

1. When port (B) brake pressure is gener-

ated

● Pressure (MB) is conducted to chamber (d)

A
via the notch. The pressure compresses
T
spring (6) by use of the difference in areas c e D4 a D3
of circles (D1 > D2) of spool (5) and moves
spring (6) to the left side. Port (B) and
chamber (e) will be interconnected. Since
pressure (A) is lower than the set pressure
of spring (3), spool (2) does not move and
the pressurized oil is stopped by spool (2).
Thus the braking force is ensured.
D1 d Notch D2 b f
B
T
ZX215-1002090

2. When motor is stopped

● The motor rotation is reversed by the clos- A

ing pressure generated at port (B). (1st T
time: reverse rotation) Reversing pressure a 2 3
is generated on port (A). Pressure (A) is
conducted to chamber (a), and spool (2)
moves spring (3) to the right side, and A
and B is interconnected. At this time, b
is interconnected with f via the orifice on
spool (5), and reversing pressure on port A
is bypassed to port T, preventing the sec-
5 d B b f
ond reverse rotation.
T
ZX215-1002091

Shop Manual - April 2017 4-89

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6.5 Center swivel joint

Z
7 8 13 9 10
6 H
11

5 12

4 D

A
3

F1

G1 H-H H
G

D1

A1

B1
C1
Z
ZX215-1002092

1) Swing shaft 8) Plug (ZG3/4)

2) Dust seal 9) Plug (ZG1/4)
3) O-ring 10) Cover
4) Swing body 11) Spacer
5) Rotating seal φ100x5 12) Gasket
6) Gasket 13) Gasket
7) Retaining ring φ 90

4-90 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

A: From main valve BTL

B: From main valve BTR
C: From main valve ATL
D: From main valve ATR
A1: To L. travel motor port (P1)
B2: To R. travel motor port (P2)
C3: To L. travel motor port (P2)
D4: To R. travel motor port (P1)
G: To swing motor port DB
G1: From travel motor final drive assembly oil drain port (D1,D2)
F: From solenoid valve port A2
F1: To travel motor reducer Hi/Lo speed switching port (P)

Shop Manual - April 2017 4-91

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6.6 Travel motor

Type: MAG-170VP-3400E

Ps Pm1 Tin 1 Dr P1 A

Pm2 Pp 2 P2 B

ZX215-1002132

Ps: Duo speed pilot hose port A. Mounting surface with sprocket
Pm1: Pressure detection port B. Mounting surface with undercarriage
Pm2: Pressure detection port 1. Mounting hole with sprocket
Tin: Motor case inner oil port 2. Mounting hole with undercarriage
Pp: Brake release port
Dr: Oil drain port
P1: Main oil port
P2: Main oil port

4-92 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Table 1. Motor specifications

Equivalent displacement cm³/rev qxi

Large displacement q1 cm³/rev 130.4
Motor displacement q
Small displacement q2 cm³/rev 74.9
Speed reduction rate i 60
2-speed switching Lo-Hi Mpa > 6.86
Pilot pressure Hi-Lo Mpa > 1.96
Braking torque N·m 398
Operating displacement L/min 228
Operating pressure Mpa 33.34
Peak pressure Mpa within 44.1
Acting times (above 34.3Mpa and below 44.1Mpa) times < 1,200,000
Large flow rpm 1679
Motor shaft
Small flow rpm 2861
Swing speed
Large flow rpm 28
Reducer
Small flow rpm 47.7
Output torque KN·m within 37
Normal PS
Input power
Maximum PS within 210 (within 30 consecutive sec.)
Normal Mpa within 0.2
Drain pressure
Momentary maximum Mpa within 0.5 (below 0.3 MHz)
Weight kg 275

Shop Manual - April 2017 4-93

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Connected to sprocket

Mounted on the undercarriage 5 4 2-1 1-4 1-3

Piston motor shaft

1-5

1-6

1-2

1-1

2-4 2-3 2-2 2-6 2-5

ZX215-1002093

4-94 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.6.1 Operation of components

Counterbalance valve

Function

● When external load makes the rotating

speed of the piston motor faster than the
rated rotating speed of supplied delivery,
this valve controls the speed of the motor
and prevent over-speed of the motor in re-
lation with the supplied delivery.

● The counterbalance valve and the relief

valve constitute the braking circuit. The
braking circuit applies braking force onto
the rotating motor and stops the motor
gradually.

● This valve can serve as a shuttle valve

for high pressure selection to release the
brake under its own pressure.

● The structure of a standard counterbalance

valve is shown as below. The following in-
formation describes the operating principle
of a standard counterbalance valve.

Shop Manual - April 2017 4-95

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

A. Stopped state (Fig. 1)

● When the main valve is neutralized (motor pressure is generated at port P1 and port
stopped), port M1 and port M2 are shut off P2. The motor is not rotating.
by spool (1) and check valve (2) since no

8-1

8-2
Circuit B

Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1

P1 P2
6-1 6-2

7-1 7-2

5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002094

Fig. 1 Counterbalance valve layout (stopped)

4-96 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

B. When the motor is activated (Fig. 2)

● When hydraulic oil from the main pump on the inside of spring chamber (1) and
enters port P1 of the counterbalance valve, damper chamber (A1) via orifice (4-1) and
spring (3) is pushed to the left by check check valve (5-1). The force generated in
valve (2-1), opening circuit C1. The hy- this way pushes spring (7-2) on the other
draulic oil enters the piston motor via port side and moves piston (1) to the right. At
M, trying to make the motor rotating. At the this time, return oil from port M2 passes
same time, return oil from the piston motor through circuit of the notch on the periph-
enters the counterbalance via port M2, but ery of piston (1), and through port P2 when
it is stopped by check valve (2-2). The out- pressure is generated at port M2, and en-
put pressure of the main pump increases ters the tank via the main valve finally. The
as a result, and the hydraulic oil works motor is activated at this time.

8-1

8-2
Circuit B

Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1

P1 P2
6-2
6-1

7-1 7-2

5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002095

Fig. 2 Counterbalance valve when the motor is rotating

Shop Manual - April 2017 4-97

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

C. Counterbalance function (Fig. 2)

● When the engine runs at an excessively

high speed because of external force ap-
plied on it, the motor may lose control. At
this time, port P1 serves as the inlet side,
and the pressure drops. Pressure in spring
chamber 1 and damper chamber A1 also
drop. As a result, pison (1) moves to the
left under the force of spring (7-2), closing
circuit B. Circuit at the suction side is also
closed at the same time when the circuit
at return side is closed. When circuit B is
closed, pressure at port P1 rises due to
hydraulic oil from the main pump, moving
piston (10 to the right again. In this way,
when external load generates pump effect,
slight movement of piston (1) keep circuit
B open. The rotation speed of the motor
keeps in line with fuel supply of the main
pump, and the motor will not lose control
because of the vacuum in the hydraulic
system.

4-98 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

D. Braking of motor (Fig. 3)

● The counterbalance valve and the relief sure at port M2 rises and serves as the
valve forms the braking circuit. When the braking force of motor rotation. When the
main valve is neutralized position, hydrau- pressure at port M2 reaches the set pres-
lic oil from the main pump is cut off, and sure of relief valve (8), cone valve (8-1) at
pressure at port P1 and P2 is the same. port M1 overcomes the force of spring (8-
As a result, piston (1) moves to the neutral 2) and moves to the left, and hydraulic oil
position, and the opening area of circuit B flows the port M1. In this way, the impact-
decreases. At the same time, because of ing force due to inertia at port M2 is under
the inertia of external force, the motor does control, and vacuum at port M1 is avoided.
not stop rotating (pump effect), and pres-

8-1

8-2
Circuit B

Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1

P1 P2
6-1 6-2

7-1
7-2

5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002096

Fig. 3 Counterbalance valve and relief valve when the motor is braking

Shop Manual - April 2017 4-99

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E. Shuttle valve function for high pressure

selection (Fig. 4 and 5)

● The counterbalance valve can function ber E to release travel brake. In addition,
as a shuttle valve to release travel brake. piston (1) moves to neutral position, as
When hydraulic oil is fed to port P1, piston shown in fig 5 when motor stops. Circuit D
(1) moves to the right, as shown in fig. 4. is closed and drain circuit F of motor body
At this time, drain circuit F of motor body is connected. Hydraulic oil in travel brak-
is cut off, and circuit D leading to cylinder ing cylinder chamber E is conducted to the
chamber E for travel braking is connected. drain circuit of motor body, and travel brake
Hydraulic oil flows to circuit G via the ori- is applied.
fice, and enters travel brake cylinder cham-

1
Circuit D

Circuit D

Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G
Cylinder chamber E

ZX215-1002097

Fig. 4 High pressure selection function selection of high pressure

1
Circuit D

Circuit D

Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G Cylinder chamber E

ZX215-1002098

Fig. 5 High pressure selection function opening of oil drain to motor housing

4-100 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.6.2 Operation of parking brake

1) When travel begins

● As the travel lever is operated, pressurized

oil from the pump activates counterbalance
valve spool (10), opens the parking brake
circuit, and flows to chamber A of brake 10
piston (12). Pressurized oil overcomes the
force of spring (11) and pushes piston (12)
toward the left.

● Since the pushing force to plate (13) and

disc (14) disappears, plate (13) is sepa-
rated from disc (14) and the brake is re-
Travel control valve
leased.

A M
11 14 13 12 22
ZX215-1002099

2) When travel stops

● As the travel lever is placed in neutral,

counterbalance valve spool (10) returns to
the neutral position and closes the park-
ing brake circuit. The pressurized oil in
10
chamber (A) of brake piston (12) passes
through the orifice of the brake piston and
is drained to the motor case. Brake piston
(12) is pushed to the right by spring (12).
Plate (13) and disc (14) are pushed to-
gether, and the brake is applied. As brake
piston (12) returns, flow of pressurized oil
行走控制阀
is reduced with slow return valve (22). The
time delay will be set to activate the brake
only after the machine has stopped. M
A
11 14 13 12 22
ZX215-1002100

Shop Manual - April 2017 4-101

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Brake valve operation

● The brake valve consists of suction safety

valve (8A) and counterbalance valve (18). Travel control valve
Functions and operations of respective PA PB
components are described below.
8A

18

MA MB

ZX215-1002101

1) Counterbalance valve and check valve

Function

● When the machine is travels downhill, the

weight of the machine tends to make the Travel control valve
travel speed faster than the motor speed.
PA PB
If the machine travels with the engine at 8B
low speed, the motor may rotate at zero
8A
load, resulting in run away and inviting a
very dangerous situation. These valves are
used to avoid such a situation by control-
ling the machine to travel as per the engine
speed (pump delivery).

19 MA MB
Operation when pressurized oil is supplied
ZX215-1002102
● Operating the travel lever conducts the
pressurized oil from the control valve to
port (PA). The pressurized oil opens suc-
tion safety valve (8A) and then flows to
motor outlet port (MB) via motor inlet port
(MA). The motor outlet side is closed by
suction safety valve (8B) and spool (19),
so the pressure at the supply side rises.

4-102 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

● The pressurized oil on the supply side

flows to chamber (S1) via orifice (E1) and Travel control valve
orifice (E2) of the spool (19). As the pres- PA PB
sure in chamber (S1) goes above the spool
selector pressure, spool (19) is pushed
toward the right. Port (MB) and port (PB)
are connected, the motor outlet port side
opens and the motor starts rotating.
S1

19

MA MB

E1 E2
ZX215-1002103

Operation of brake during downhill travel

● If the machine goes out of control while

travelling downhill, the motor will be caused Travel control valve
to rotate without load to decrease the inlet PA PB
side oil pressure. Pressure in chamber (S1) 20
is released via orifices (E1) and (E2). As
the pressure in chamber (S1) goes below
the spool selector pressure, spool (19)
is returned to the left by spring (20) and
S1
outlet port (MB) is throttled. The pressure
at the outlet port side rises, generating ro-
tation resistance on the motor to prevent
19
the machine from losing control. On the
other hand, the spool moves to a position MA MB
where the pressure on outlet port (MB) can E1 E2
be balanced against the machine's own ZX215-1002104

weight and the inlet port pressure. Oil flow

from the outlet circuit is reduced to ensure
the travel speed corresponded to the pump
delivery.

Shop Manual - April 2017 4-103

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2) Safety valve

Function

● When the machine travel is stopped (or it

is travelling downhill), the counterbalance
valve closes the inlet and outlet circuits of
the motor. Since the motor is rotated by
inertial force, pressure in the motor outlet
port side is abnormally increased, poten-
tially resulting in damages on the motor
and piping. The safety valve releases this
abnormal pressure to the inlet port side of
the motor in order to prevent damages to
the equipment.

Operation
Travel control valve
1. When travel is stopped (or when travelling PA PB
downhill) (Right swing) 20

● Reduction of the pressure at motor inlet

(PA) decreases the pressure in chamber
(S1). When it drops beyond the spool
switching pressure, the spool is returned to S1
the left by spring (20), reducing the pres-
sure at outlet passage (B1). At this time,
the motor continues rotating due to its iner-
tial force, thus pressure on the outlet port MA MB
(MB) is increased.
A1 B1
ZX215-1002105

● When the pressure rises above the set

pressure of the suction safety valve (8A),
the poppet opens. The pressurized oil
passes through notch (A1) of spool (19)
into chamber (MA) of the circuit at the op-
posite side.

Spool MB MA

ZX215-1002107

4-104 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

2. When starting travel (or when traveling at a

constant speed) Travel control valve

PA PB 8B
● As the travel lever is operated, the pres-
surized oil from the pump moves spool (19)
toward right. The passage to the suction 8A

safety valve functions as a circuit which

passes through notch (B2) of spool (19),
producing large differential pressure. The S1
pump pressure rises, providing a large
tractional force to the valve.
19

MA MB

E1 B2
ZX215-1002106

3) Relief valve

● The structure of the relief valve is shown

in the right figure. This valve is area dif-
ference and direct flow type. It has impact
damping function during starting and brak-
ing.

ZX215-1002108

Shop Manual - April 2017 4-105

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

A. Operation principle and function

● When the main valve makes the motor

to start or brake, front pressure of cone
2-9-2 2-9-5
valve (2-9-2) rises above the set pressure
and the force of spring (2-9-5), and moves
cone valve (2-9-2) to the right and off the
valve seat. Pressurized oil in the front of
cone valve (2-9-2) is bypassed to the low
pressure side. The impact due to inertia
energy at the high pressure side is put un-
2-9-3
der control and vacuum is prevented from
ZX215-1002109
occurring at the low pressure side through
bypassing pressurized oil to the low pres-
sure side.

B. Damping function

● When the relief valve begins to function,

damping piston (2-9-9) moves to the left. 2-9-2 Area S2 2-9-5
As a result, low pressure is maintained in
spring chamber D. At this time, the loaded
area of cone valve (2-9-2) is S1, and it is
much larger than the normal set loaded
area S1-S2 of the relief valve. So, when
damping piston (2-9-9) is moving, the func-
tional pressure of relief valve is maintained
2-9-3 Area S1 2-9-9 Spring chamber D
at 1/3 of normal set pressure in order to
ZX215-1002110
absorb the impact at the high pressure
circuit side due to inertia energy. When
the movement of damping piston stops,
pressure in spring chamber D rises. Pres-
sure at both side of cone valve (2-9-2) is
the same, and the relief valve is working at
normal set pressure. In this way, the relief
valve reduces the impact during motor start
and brake by a two-stage action to provide
excellent performance.

4-106 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Pressure

Damping method Time

ZX215-1002111

Shop Manual - April 2017 4-107

Structure and Function SY215C9C5K /SY225C9C5KCrawler Hydraulic Excavator

Table 2 Repair standard of motor components

Components Check item Allowable limit Remedy

Grind sliding surface;
1. Sliding surface of the slid- Roughness 0.8a or surface rough- replace 4 cylinder block
ing shoe ness, scratch >0.02mm assembly parts if unre-
pairable
1-4-2 Plunger 2. Outside diameter of Roughness 1.2a or surface rough-
assembly plunger ness, scratch >0.02mm
3. Plunger outside diameter, Replace 4 cylinder
Clearance 0.060.
and 4-1 cylinder bore block assemblies
4. Sliding shoe ball end
Clearance 0.4.
clearance
Grind sliding surface;
1. Valve leaf and sliding sur- Roughness 0.8a or surface rough- replace 4 cylinder block
face ness, scratch >0.02mm. assembly parts if unre-
pairable
Roughness 1.6a or surface rough-
2. Shaft hole inner diameter
1-4-1 Cylinder ness, scratch >0.02mm
block 3. Shaft hole inner diameter,
4-2 piston assembly outer Clearance 0.060 Replace 4 cylinder
diameter block assembly
Roller distance below 38.749
4. Spline at shaft joint (measuring pin diameter
φ3.333(V1=2.80)); or damaged
32 Grind sliding surface
1-21 Oil distrib- Roughness 0.8a, scratch >0.02mm
1. Sliding surface or replace 22 valve
uting plate on sliding surface or burned sign
sheet if unrepairable
1-4-3 Retainer
Roughness 0.8a, scratch >0.02mm Replace retaining plate
1-4-4 Retaining 1. Sliding surface
on sliding surface or sign of burning or retaining assembly.
assembly
1-4-1 grind sliding sur-
Roughness 0.8a, abrasion on sling
1. Sliding surface face or replace 22 valve
surface or scratch >0.02mm
sheet if unrepairable
1-5 Swash Roughness 1.6a.
2. Ball hole on assembly
plate Scratch on spherical surface
steel ball portion
>0.02mm or surface roughness Replace swash plate
3. Ball hole on assembly
Ball depth 14.5
steel ball portion

4-108 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Components Check item Allowable limit Remedy

Roughness 1.6a oil seal lip sliding
1. Sliding port of oil seal
sign. Scratch >0.02mm or surface Replace swash plate
outer diameter
roughness
Roller distance below 47.380(mea-
1-3 Shaft 2. Spline of cylinder block suring pin diameter φ3.00); or dam-
aged
Replace shaft
Roller distance below 30.498 (mea-
3. Drive gear connection suring pin diameter φ3.33); or dam-
age
1. Dimension Height 38.2
1-15 Brake 2. Sliding surface Roughness 2.5a
Replace brake piston
piston Scratch 0.02mm+ or surface rough-
3. Appearance
ness
1. Dimension Thickness 3.2
1-13 Disc plate Deep scratch on sliding surface or Replace disc plate
2. Appearance
friction material peeling
1-8 Ball bear- 1. Rolling surface Peeling or fracture
ing
Abnormal rotation (noise/uneven Replace ball bearing
1-9 Ball bear- 2. Action
rotation)
ing
Grind sliding surface;
1. Sliding shoe sliding sur- Roughness 1.6a, surface rough-
replace flange plate
face ness, scratch >0.02mm
parts if unrepairable
Roughness 1.2a, surface rough-
2. Piston outer diameter
1-7 Piston as- ness, scratch >0.02mm
sembly 3. Piston outer diameter and
Roughness 0.8 a, scratch >0.02mm Replace flange plate
1-1 flange plate part inner
or surface roughness 0.040. parts
diameter
4. Ball end clearance of slid-
Roughness 0.8 a, scratch >0.02mm
ing shoe or surface roughness 1.0.
Roughness 0.8 a, scratch >0.02mm
1. Piston outer diameter
1-2-2 Piston or surface roughness.
Replace valve sheet
assembly 2. Piston outer diameter and Roughness 0.8 a, scratch >0.02mm
valve sheet inner diameter or surface roughness 0.060.

Shop Manual - April 2017 4-109

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Components Check item Allowable limit Remedy

1. Assembly 2-2 piston as- Roughness 0.8 a, scratch >0.02mm
sembly hole or surface roughness
2. Valve sheet inner diame- Roughness 0.8 a, scratch >0.02mm
ter and piston outer diameter or surface roughness 0.060
3. Assembly 2-11 sliding Roughness 0.8 a, scratch >0.02mm
1-2-1 Valve Replace valve sheet
valve spool assembly hole or surface roughness
sheet and parts
4. Sliding valve sheet inner
Roughness 0.8 a, scratch >0.02mm
diameter and valve spool
or surface roughness 0.060.
outer diameter
5. Relief valve assembly Scratch >0.02mm or surface rough-
sliding piston and valve seat ness
Roughness 0.8 a, scratch >0.02mm
1. Valve spool out diameter
or surface roughness
1-2-9 Spool as- Replace valve sheet
2. Slide valve spool outer
sembly Roughness 0.8 a, scratch >0.02mm and parts
diameter and valve sheet
or surface roughness 0.060.
inner diameter
1-2-7-9 Mov- 1. Sliding portion of valve Scratch >0.02mm or surface rough-
able piston sheet and valve seat ness Replace relief valve as-
1. Sling portion of the mov- Scratch >0.02mm or surface rough- sembly
1-2-7-1 Case
able piston (outer diameter) ness
1. Dimension Free length 61.0
1-4-7 Spring
2. Appearance Deformation and surface damage
1. Dimension Free length 39.0
1-18 Spring
2. Appearance Deformation and surface damage
1. Dimension Free length 41.5
1-20 Spring
2. Appearance Deformation and surface damage
1. Dimension Free length 48.5
1-2-4 Spring
2. Appearance Deformation and surface damage
1. Dimension Free length 28.3
1-2-10 Spring
2. Appearance Deformation and surface damage
O-ring and oil Replace o-ring and oil
When being removed
seal seal

4-110 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.7 Valve control system

7
6

1 2
4

10
3 5

5 9
6 7

11 12
8 10

13
4

11

1 12
ZX215-1002112

Shop Manual - April 2017 4-111

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Control lever position

1. Travel PPC valve (1) HOLD

2. L. travel control lever (2) Boom UP
3. R. travel control lever (3) Boom DOWN
4. Right PPC valve (4) Bucket DUMP
5. Right joystick (5) Bucket DIG
6. Accumulator (6) HOLD
7. Transition block (7) Arm IN
8. Hydraulic pump (8) Arm OUT
9. Main control valve (9) Right swing
10. Solenoid valve (10) Left swing
11. Left joystick (11) Neutral
12. Left PPC valve (12) Reverse travel
(13) Forward travel

4-112 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.8 Pilot valve

4.6.8.1 Work equipment and swing pilot valve

P3
P2
A

T
P

2
3
P

1
4

P4 P1
A

64~73.5Nm 19~22Nm

ZX215-1002113

P: From pilot pump relief valve

P1: L.H. Pilot valve: Arm OUT R.H. Pilot valve: Boom DOWN
P2: L.H. Pilot valve: Arm IN R.H. Pilot valve: Boom UP
P3: L.H. Pilot valve: Swing LEFT R.H Pilot valve: Bucket DIG
P4: L.H. Pilot valve: Swing RIGHT R.H. Pilot valve: Bucket DUMP
T: To tank

Shop Manual - April 2017 4-113

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6
7

10
2

A-A ZX215-1002114

1) Plunger 6) Nut (for lever connection)

2) Metering spring 7) Joint
3) Centering spring 8) Plate
4) Piston 9) Retainer
5) Disc 10) Valve body

4-114 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Operation

1. When in neutral

● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via orifice D
(f) in plunger (1).
f

2. Fine control (Neutral to fine control) 1 T

● When piston (4) is pushed by disc (5),

retainer (9) is pushed, plunger (1) is also P
pushed by metering spring (2), and moves
down.

● When orifice (f) is shut off from drain cham- Pilot

pump P1 P2
ber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is
led to port (A) from port (P1) via orifice (f). A M M B
Control valve
When the pressure at port (P1) becomes
higher, plunger (1) is pushed back and ZX215-1002115
orifice (f) is shut off from pump pressure
chamber (PP). At almost the same time, it
is connected to drain chamber (D) to re-
lease the pressure at port (P1). As a result,
plunger (1) moves up and down until the
force of metering spring (2) is balanced
with the pressure at port (P1).
D
● The relationship of the position of plunger
(1) and body (10) [orifice (f) is in the middle f
between drain chamber (D) and pump
pressure chamber (PP)] does not change 1 T
until retainer (9) contacts plunger (1). Me-
tering spring (2) contracts in proportion to P
the stroke of the control lever. Pressure
at port (P1) also rises in proportion to the
stroke of the control lever. In this way, the
control valve spool moves to a position Pilot
P1
pump P2
where the pressure of chamber (A) (same
as pressure at port (P1)) and the force of
the return spring of the control valve spool
are balanced. A M M B
Control valve

ZX215-1002116

Shop Manual - April 2017 4-115

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3. During fine control (When control lever

is returned)

● When disc (5) starts to return, plunger

(1) is pushed up by the force of centering
spring (3) and the pressure at port (P1). D

● Because of this, orifice (f) is connected to f

drain chamber (D), and the pressurized oil
at port (P1) is released. 1 T

● If the pressure of port (P1) is lowered ex- P

cessively, plunger (1) is pushed down by
metering spring (2).
f1
● Orifice (f) is shut off from drain chamber Pilot
(D), and it is almost simultaneously in- pump P1 P2
PP
terconnected to pump pressure chamber
(PP). Pump pressure is supplied until the
pressure at port (P1) recovers to the level
A M M B
equivalent to the lever position. Control valve

ZX215-1002117
● When the spool of the control valve re-
turns, the oil in drain chamber (D) flows in
from orifice (f) in the valve on the side that
is not working. The oil passes through port
(P2) and enters chamber (B) to replenish
the chamber with pressurized oil.

4. At full stroke D

● Disc (5) pushes down piston (4), and re- f

tainer (9) pushes down plunger (1).

● Orifice (f) is shut off from drain chamber (D), 1 T

and is interconnected to pump pressure
chamber (PP). P

● Therefore, the pilot pressure oil from

the self pressure reducing valve passes f1
through orifice (f) and flows to chamber Pilot
pump P1 P2
(A) from port (P1) to push the control valve PP
spool.

● The oil returning from chamber (B) passes

from port (P2) through orifice (f) and flows A M M B
Control valve
to drain chamber (D).
ZX215-1002118

4-116 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.8.2 Travel PPC valve

P
P

P5 A
P6
P5

P2 P1

2 1

4 3

P4 P3
ZX215-1002119

P: From pilot pump P4: R.H. forward

P1: L.H. reverse P5: Travel signal
P2: L.H. forward P6: Travel signal
P3: R.H. reverse T: To tank

Shop Manual - April 2017 4-117

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

37~30Nm
B

65~45Nm
1 8~6Nm

6
C C
7
B-B
2，4 1，3
B

13~11Nm

C-C
8~6Nm
ZX215-1002120

1) Plate 5) Centering spring

2) Body 6) Metering spring
3) Piston 7) Valve
4) Collar

4-118 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

Operation

1. When in neutral

● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the Pilot valve are
D
connected to drain chamber (D) via orifice
(f) in plunger (1). f
T
2. Fine control (Neutral to fine control) P

● When piston (4) is pushed by lever (5),

1
retainer (9) is pushed, plunger (1) is also
Pilot pump
pushed by metering spring (2), and moves P1 P2
down. When orifice (f) is shut off from drain
chamber (D), it is almost simultaneously
A B
interconnected to pump pressure chamber Control valve

(PP).
ZX215-1002121

● Pilot pressurized oil of the control pump is

led to port (A) from port (P1) via orifice (f).

● When the pressure at port (P1) becomes

higher, plunger (1) is pushed back and
orifice (f) is shut off from pump pressure
chamber (PP). At almost the same time, it
5
is connected to drain chamber (D) to re-
4
lease the pressure at port (P1).

● As a result, plunger (1) moves up and 9 D

down until the force of metering spring (2) 2
is balanced with the pressure at port (P1). f
T
● The relationship of the position of plunger P
(1) and body (10) [orifice (f) is in the middle
1
between drain chamber (D) and pump
Pilot pump PP
pressure chamber (PP)] does not change P1 P2
until retainer (9) contacts plunger (1). 10
A B
● Metering spring (2) contracts in proportion Control valve
to the stroke of the control lever. ZX215-1002122

● Pressure at port (P1) also rises in propor-

tion to the stroke of the control lever.

● In this way, the control valve spool moves

to a position where the pressure of cham-
ber (A) (same as pressure at port (P1)) and
the force of the return spring of the control
valve spool are balanced.

Shop Manual - April 2017 4-119

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3. Fine control (When control lever is

returned)

● When lever (5) starts to return, plunger

(1) is pushed up by the force of centering 5
spring (3) and pressure at port (P1).

● Because of this, orifice (f) is connected to 3 D

drain chamber (D), and the pressurized oil 2
at port (P1) is released.
f T
● If the pressure of port (P1) is lowered ex- P
cessively, plunger (1) is pushed down by f’
metering spring (2). 1
Pilot pump PP
● Orifice (f) is shut off from drain chamber (D), P1 P2
and it is almost simultaneously intercon-
nected to pump pressure chamber (PP). A Control valve B

ZX215-1002123
● Pump pressure is supplied until the pres-
sure at port (P1) recovers to the level
equivalent to the lever position.

● When the spool of the control valve re-

turns, the oil in drain chamber (D) flows in
from orifice (f) in the valve on the side that 5
is not working. The oil passes through port 4
(P2) and enters chamber (B) to replenish
9 D
the chamber with pressurized oil.

4. At full stroke f
T
P
● Lever (5) pushes down piston (4), and re- f’
tainer (9) pushes down plunger (1).
1
Pilot pump PP
● Orifice (f) is shut off from drain chamber (D), P1 P2
and is interconnected to pump pressure
chamber (PP). A Control valve B

● Therefore, the pilot pressure oil from ZX215-1002124

the self pressure reducing valve passes

through orifice (f) and flows to chamber
(A) from port (P1) to push the control valve
spool.

● The oil returning from chamber (B) passes

from port (P2) through orifice (f) and flows
to drain chamber (D).

4-120 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.9 Solenoid valve

Pilot valve lock, travel speed, bucket confluence, swing priority

P1
P2
T1

A8 A7 A6 A5 A4 A3 A2 A1

5 4 3 2 6

T2
P T1

A7 A6 A5 A4 A3 A2 A1
A8
P2 1 P2
P1

ZX225-1102044

1) Travel hi/lo speed solenoid valve T: To oil tank

2) Swing priority solenoid valve P: From accumulator and pilot pump
3) Bucket confluence solenoid valve A3 To center swivel joint port
4) Boom to arm priority solenoid valve A4 To main valve port PsP
5) Pilot lockout solenoid valve A5 To main valve port Xbp2
6) Secondary boosting solenoid valve A6 To main valve port PnA2
A7 To pilot valve block P

Shop Manual - April 2017 4-121

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6.10 Accumulator

ZX215-1002126

1) Gas plug Specifications

2) Shell
Gas capacity: 300 cc
3) Poppet
4) Holder
5) Bladder
6) Oil port

4-122 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.11 Pilot oil filter

1
K

2
型号
压力
精度
3

ZX215-1002127

Specifications

1) Name plate Max. delivery: 40 L/min

2) Head cover Filter fineness: 10 μm
3) O-ring Operating pressure: 20 Mpa
4) Seal Max. operating pressure: 40 Mpa
5) Filter Pressure loss: 0.05 Mpa
6) Case Max. allowable pressure difference: 1 Mpa
Specification of inlet/outlet port o-ring: 30×3.1

Shop Manual - April 2017 4-123

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.6.12 Pump oil pressure sensor

1 2 3

A B

ZX215-1002128

1) Pressure connector
2) Name plate
3) Connector
4) Vent hole

Function

● This sensor measures pump oil pressure

and uses it to control various machine op-
erations. When oil pressure compresses
the diaphragm, it deforms and this is de-
tected in the form of electric signals.

4-124 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Function

4.6.13 Hydraulic cylinder

Boom cylinder

5340±50N·m
2 1 544.9±5.1kgm 3

56.9±10.7N·m
267±35N·m 5.8±1.1kgm
27.2±3.6kgm
ZX215-1002129

Arm cylinder

7900±50N·m
2 1 806.1±5.1kgm 3

56.9±10.7N·m
367±35N·m
5.8±1.1kgm
37.4±3.6kgm
ZX215-1002130

Bucket cylinder

5480±50N·m
2 1 559.2±5.1kgm
3

56.9±10.7N·m
267±35N·m
5.8±1.1kgm
27.2±3.6kgm
ZX215-1002131

Shop Manual - April 2017 4-125

Structure and Function SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

100/500 hours greasing

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Standard Clearance
Cylinder
SY215CLC SY235CLC Shaft Hole clearance limit
Clearance -0.036 +0.222
between piston Boom 85 90 0.083 – 0.312 0.412 Replace
-0.090 +0.047
1
rod and bush- -0.036 +0.222 bushing
Arm 95 100 0.083 – 0.312 0.412
ing -0.090 +0.047
-0.030 +0.258
Bucket 80 90 0.078 – 0.334 0.434
-0.076 +0.048
-0.030 +0.246
Clearance Boom 80 80 0.230 – 0.322 1.0
-0.076 +0.200
between piston -0.030 +0.246
2 Arm 80 80 0.230 – 0.322 1.0
rod support pin -0.076 +0.200
and bushing -0.030 +0.246 Replace
Bucket 70 80 0.230 – 0.322 1.0
-0.076 +0.200
pin or
-0.030 +0.246
Clearance be- Boom 70 80 0.230 – 0.322 1.0 bushing
-0.076 +0.200
tween cylinder -0.030 +0.246
3 Arm 80 80 0.230 – 0.322 1.0
bottom support -0.076 +0.200
pin and bushing Bucket -0.030 +0.246
70 80 0.230 – 0.322 1.0
-0.076 +0.200

4-126 Shop Manual - April 2017

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.7 Work Equipment

4.7.1 Component dimensions
D
F
C

E
J

B A

I K
H
1

B-B

C-C
A-A
2

G-G
D-D F-F
E-E
4
5 6 3 8

H-H 7
I-I J-J K-K
ZX425-1002137

Fig. 4-135

4-124 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

SY215C9C5K
Unit：mm
Std. Tolerance Std. Clearance
No. Check item Remedy
size Pin Hole clearance limit
Clearance between the pin and bush- –0.036 +0.140 0.141 ～
1 ing connecting the boom and swing 100 1.0
platform –0.071 +0.105 0.211

Clearance between the pin and bush- –0.036 +0.174 0.140～

2 100 1.0
ing connecting the boom and arm –0.071 +0.104 0.245
Clearance between the pin and bush- –0.030 +0.335 0.305 ～
3 80 1.0
ing connecting the arm and linkage –0.071 +0.275 0.334
Replace
Clearance between the pin and bush- –0.036 +0.336 0.311 ～
4 90 1.0
ing connecting the arm and bucket –0.071 +0.275 0.407
Clearance between the pin and –0.036 +0.335 0.311 ～
5 bushing connecting the linkage and 90 1.0
bucket –0.071 +0.275 0.407

Clearance between the pin and bush- –0.036 +0.335 0.311 ～

6 90 1.0
ing connecting the linkage –0.071 +0.275 0.406
7 Bucket clearance (a) 0.5-1.0 Adjust the
8 Bucket clearance (b) 1-5 shims

Shop Manual - April 2017 4-125

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.7.2 Arm dimensions

19

11

5
C D

6
A D
A
C
12

10 14

8 7
13

16
17 15

B-B
18
A-A

1
3

4
D-D

C-C ZX425-1002138

Fig. 4-136

4-126 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Unit：mm
SY215C9C5K
No.
Std. size Tolerance
+0.1
1 φ80
0
+1.5
2 107
0
-0.3
3 310
-0.8
+0.174
4 φ90
+0.104
5 365.6 —
6 187.2 —
7 829.1 —
8 2919 —
9 2631.3 —
10 411 —
11 640 —
12 600 —
13 458 —
14 1493 —
+0.373
15 φ80
+0.273
0
16 325
-0.5
+0.1
17 φ80
0
Arm body 311 —
18 When bushing is installed 454 —
Min. 1680 —
19 Max. 2800 —

Shop Manual - April 2017 4-127

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.7.3 Bucket dimensions

16 15

14 2
1

17

10 12 11
4

13

8 9
9
5

18

WX385-1304003

Fig. 4-137

4-128 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Unit：mm
SY215C9C5K
No.
Std. size Tolerance
1 465 ±0.5
2 107° —
3 1387 —
+0.2
4 φ110
+0.1
+0.2
5 φ110
+0.1
+2
6 478
+1
+0.5
7 442
+0.2
8 520 —
9 40 —
10 89 —
11 73 —
12 227 —
13 φ170 —
14 148 —
15 186 —
16 148 —
17 125 —
18 600 —

Shop Manual - April 2017 4-129

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8 Air Conditioning System

1
2

4
5

C
C

C B 6
C

8
ZX425-1002140

Fig. 4-138

(1) Hot water piping (7) Refrigerating unit (SG443200-7194)

(2) A/C compressor (DENSO.2) (8) Air duct
(3) Refrigerant piping A. Fresh air
(4) Condenser (SG447750-A040) B. Recirculated air
(5) Reservoir (DENSO.4) C. Warm air/cool air
(6) Hot water return piping

4-130 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.8.1 Layout of A/C components

2
1
3
4

ZX425-1002141

Fig. 4-139

(1) Sunlight sensor

(2) Control panel
(3) Air conditioning unit
(4) Condenser
(5) Compressor

Shop Manual - April 2017 4-131

Structure and Functions

4.8.2 A/C control panel

1 2 3 4 5

6 7 8
ZX425-1002142

Fig. 4-140

(1) OFF switch (6) Fresh air/recirculation control

(2) Fan speed control switch (7) LCD display
(3) Temperature control switch (8) A/C power
(4) Air outlet mode switch (9) Sunlight sensor
(5) Auto mode switch

Remark:

When auto mode switch (5), fresh air/recirculation control (6) and A/C power (8) are turned on,
indicator lights above these switches will light up.

4-132 Shop Manual - April 2017

Structure and Functions

4-133
ZX425-1002143
SW
1.25R

7
FURM B G1 G2 ACC M ST
3
FL1
3 8
H
FUCD 20A FUM OFF
60A 15A 8
1.25R 5A ACC
2 13 ON
START MRF
8 8
2
CMB RLCD RLCC RLBM
15 13

Shop Manual - April 2017

13
M
RLCC RLCD RLBM
9 10

GND
REC
FFE
1

Vz
2RL 1.25RL

Pt
10 1.25L 15
16 16 19 25 24 22 26 25
1
D MR
FLZ
MCD SPCD M 200W
RLSF 40A
SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

5 2
M 11
1.256 10 2G 13 +B 16 19 25 24 26
5
80W 10 BLCM
6 16 19 22 23 1
10
5
1
SW 4 3
6 RLCH ACM
BAT BLC 2 8
12 12
1
ACC 7
28 15 14 12 13 3 16 27 4 21 20 2 24 25 9 38 26 10
7 G 12 14 17 18 20 22 21 15 23 27 28 29 30 31 32 32 34 35
D1
4.8.3 Diagram of electrical circuit

9
RCD RLCH RLCH ECC THAM THW THI THF SSD
40W
G 4 22
02 02 02 15 15 15
03 15
4 4
CMB D2 30 31 22 32 15 33 34 35 35 22

1.25B

1.25B
3
SPHL
CM

0.85B

0.50
02 02
M M M

2B
06 0.5B
2B 2B
01 02
06
03
MAM MV1 MV2

Fig. 4-141
Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Diameter/Color Diameter/Color
Wire No. Wire Color Wire No. Wire Color
Code Code
B Black 0.5VW Violet+white
Br(R) Brown 0.5YB Yellow+black
0.85W White 0.5WO White+orange
RL Red+blue 0.5PB Pink+black
G Green 0.5VR Violet+red
0.5BL Black+blue 0.5BG Black+green
0.5R Red+blue 0.5WY White+yellow
0.5Y Yellow 0.5WR White+red
0.5BR Black+red 0.5BrW Brown+white
0.5BrY Brown+yellow 0.5GO Green+orange
0.5BY Black+yellow 0.5Sb Sky blue
0.5GW Green+white 0.5OW Orange+white
0.5LO Blue+orange 1.25V Violet
0.5PG Pink+green 1.25RG Red+green
0.5RY Red+yellow 1.25RW Red+orange
0.5BW Black+white 0.85GL Green+Blue
0.5LgR Light green+red

Code Name Code Name Code Name

Condenser high speed
ACM A/C amplifier FUCD Condenser fuse RLCH
relay
BAT Battery FUM A/C main fuse RLSF Protective relay
BLC Speed regulating resistor G Alternator SSD Sunlight sensor
Condenser pressure
CMB Battery relay MAM A/M servo motor SPCD
switch
D Diode MB Blower motor SPHL Hi\Lo pressure switch
D1 Diode 1 MCD Condenser motor SW Switcher
Fresh/recirculated air Recirculated air therm-
D2 Diode 2 MRF THAM
servo motor istor
ECC Compressor clutch MV1 Air outlet servo motor THF Anti-frosting thermistor
Recirculated air therm-
FL1 Fuse MV2 FRONT outlet servo motor THI
istor
FL2 Fuse RCD Condenser resistor THW Water temp thermistor
FUBM Blower fuse RLBM Blower main relay
RLCC Compressor relay RLCD Condenser relay

4-134 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.8.4 Refrigeration principle

Refrigeration cycle diagram

Cool air Expansion valve

Lo temp\Lo press liquid (Mist)

Evaporator
Lo temp\Lo press gas

Hi temp\Hi press liquid

Cooling fan
Blower

Air in cab
Out side fresh air

Hi-temp hi-pres gas

Receiver
Lo-pres. Hi-pres.
side side

Compressor

Hot air
Lo-pressure portion Hi-pressure portion
ZX215-1002141

Fig. 4-142

Heating cycle diagram

Water tank radiator

Pump Warm air

Engine

Blower motor

Air in cab

Low temp water

High temp water ZX215-1002142

Fig. 4-143

Shop Manual - April 2017 4-135

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.5 Compressor

3 4

1 2

16

15

14

5
13

12
11 10 9 8 7
ZX425-1002146

Fig. 4-144

(1) Stator (9) Slipper

(2) Front radial bearing (10) Front cylinder block
(3) Thrust bearing (11) Piston
(4) Front radial bearing (12) Front cylinder head
(5) Rear cylinder head (13) Shaft seal
(6) Safety valve (14) Main shaft
(7) Rear cylinder block (15) Boss
(8) Swash plate (16) Rotor

4-136 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Operating principle
Compressor type: 10S15C. This compressor has 5 plungers in total with a piston at both sides
of each plunger. The rotation of the swash plate drives the pistons to move back and forth and
transforms the refrigerant sucked from the evaporator from low temperature and low pressure
gas state to high temperature and high pressure state.

Process 1 Process 2

HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe

Valve plate

Outlet valve disc

Main shaft and swash plate Intlet valve disc

Process 6 Process 3

HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe

Process 5 Process 4

HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe

ZX215-1002144

Fig. 4-145

Shop Manual - April 2017 4-137

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.6 Clutch

● The electromagnetic clutch is used to 1

transmit moment of torsion. When the en-
2
gine is operating, the compressor may not
be working. The clutch controls the opera- 3

tion of the compressor only when the air 4

conditioner is under refrigerating mode.

● Operating principle
5
When the A/C power is turned on, the
clutch coil with an electromagnet gener-
ates a magnetic field and attracts the metal 6 ZX425-1002148
piece. The stator and rotor of the clutch are
engaged and bring the main shaft of the Fig. 4-146
compressor into rotation.
(1) Rotor
(2) Stator coil
(3) Clasp
(4) Ball bearing
(5) Stator
(6) Center piece

4-138 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.8.7 Condenser

1
4
2

ZX425-1002149

Fig. 4-147

(1) Condenser core Function

(2) Bracket
● The condenser changes high-temperature,
(3) Bolt with washer high-pressure gas refrigerant (16Kg/cm²,
(4) Refrigerant inlet approx. 80 ℃ ) to high-temperature and
(5) Refrigerant outlet high-pressure liquid refrigerant (16Kg/cm²,
below approx. 60℃ ) through radiating.

Shop Manual - April 2017 4-139

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.8 Expansion valve

Operating principle
Evaporator
● Refrigerant from the reservoir spurts out
via the orifice, turns into low-temperature, 2
low-pressure liquid (mist) after expanding,
1
and enters the evaporator.

4 Compressor
Reservoir
ZX215-1002147

Fig. 4-148

(1) Spring
(2) Diaphragm
4.8.9 Evaporator (3) Probe
(4) Needle valve

Operating principle
● The evaporator is a kind of heat exchanger
that looks like a condenser. Warm air in the
cab is conducted into the evaporator via
the blower motor and undergoes heat ex-
change with the surface of the evaporator.
Heat is absorbed and warm air turns into
cool air, which flows into the cab through
the air ducts. Evaporator surface absorbs
heat → Refrigerant in the evaporator ab-
sorbs heat → Refrigerant evaporates . 2
1
Evaporated refrigerant (gas) is absorbed
by the compressor.

ZX425-1002151

Fig. 4-149

(1) Expansion valve

(2) Evaporator

4-140 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.8.10 Dehydrator

Function
● Temporary storage of refrigerant 2
1
● Dehydration of refrigerant
● Removing dust from refrigerant
● Measuring the volume of refrigerant

ZX425-1002152

Fig. 4-150

(1) Inlet
(2) Outlet
(3) Receiver/dehydrator
(4) Desiccant

Shop Manual - April 2017 4-141

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.11 Pressure switch Pressure

Function
1
● The pressure switch is installed between 7
the reservoir and the expansion valve (hi- 2
6
pressure pipe). It is a combination switch
(Hi-Lo pressure combination switch).
● When pressure is excessively high, the
compressor stops.
3
● When pressure is excessively low, the low- 5
temperature condition disappears.

ZX425-1002153

Fig. 4-151

(1) O-ring
(2) Mobile contact point
(3) Hood
(4) Plug and fixed contact
(5) Spring
(6) Chamber
(7) Diaphragm

Operating features

Features

DIFF DIFF
ON
High pressure
Above 0.02 MPa 0.59±0.2 MPa

OFF
Low pressure 0.196~0.250 MPa 2.94~3.19 MPa
0.196±0.02 MPa

ON

Medium pressure
OFF
1.23±0.1 MPa 1.52±0.08 MPa

4-142 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.8.12 Refrigerant

General property of refrigerant

● High heat absorption and easy liquefaction
● Non-flammable, nonexplosive
● Stable chemical composition
● Non-toxic
● Non-corrosive
● No hazard to clothing

Refrigerant cycle
● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor
and the condenser, which finishes a refrigerant cycle.

Compressor LO press. side (inlet): LO temp\LO press.\Gas

Compressor Pressure/Temperature: 2Kg/cm²，approx. 8℃
Evaporator
Intake→Discharge Absorb heat→Emit cold air

Compress HI press. side(outlet): HI temp\HI press.\Gas

Pressure/Temperature:16Kg/cm²，approx. 80℃

Condensor (outlet): LO temp\LO press.\Mist

Pressure/Temperature: 2Kg/cm²，approx. 0~2℃

Condensor (outlet)：HI temp\HI pressure\Liquid Expansion valve

Condensor Pressure/Tempterature：16Kg/cm²，Below 60℃
Hi pressure→Lo pressure
Via radiating: Gas refri- Hi temp→Lo temp
gerant→Liquid refrigerant
Liquid→Mist

Shop Manual - April 2017 4-143

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Refrigerant cycle principle (pressure - enthalpy diagram)

lgp
Liquefaction completed Refrigerant cyclic curve

Liquefaction starts

Throttling point Condensor

Condensing process
Liquid
Expansion throttle

Compressing
Expansion valve process Compressor

Evaporating process

Evaporator

Gas-liquid mixture Gasification completed

h=u+Apv(kJ/kg)

U-Internal energy p-Pressure V-Special volume A-Joule equivalent

ZX215-1002152

Fig. 4-152

4-144 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Feeding of refrigerant
● Filling method and volume:
(1) Refrigerant: HFC-134a;
(2) Feeding volume: 900±50 g (for refer-
ence);
(3) Feeding method: Feeding of liquid refrig-
erant from the low-pressure end is not al-
lowed. If feeding operation fails, discharge
the refrigerant that has been fed before
re-feeding.

Fig. 4-153

● Inspect the state of the refrigerant in the

A/C circulation system through the sight Sight glass
glass:
Proper filling
(1) Correct feeding: Foam is hardly observed
when the refrigerant is flowing. When en-
gine speed increases from idling to 1500 Inadequate filling
rpm, foam disappears and the refrigerant
turns clear.
(2) Over-feeding: No foam can be observed
Empty
when refrigerant is flowing.
(3) Under-feeding: Foam is always observed
when refrigerant is flowing.
ZX215-1002154

Fig. 4-154

Shop Manual - April 2017 4-145

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.12.1 Evacuation
● Reason of evacuation
No moisture shall be mixed inside the air conditioning unit. Refrigerant (R134a) is soluble in
water. Very small amount of moisture in the unit can cause the orifice of the expansion valve
to ice up, or cause the valve of the compressor to rust. To avoid such problems, moisture in
the system shall be removed before refrigerant is fed. To reduce the residual moisture in the
system to the minimum, moisture in the system can evaporate through evacuating. No better
means is available so far.

● Evacuating steps
1. Connection of manifold pressure gauge: Valve
Lo-pres.gauge
LO HI LO HI
above 750mmHg
Lo-pres.
A. Close the high-pressure valve (HI) and gauge
ON ON OFF OFF

low-pressure valve (LO) of the manifold Hi-pres. gauge

pressure gauge.
B. Connect the air hose (red, blue) to the Lo-pres. valve (ON)
Hi-pres. valve(ON)

auxiliary valve of the compressor. Green

Red D
Red hose——High pressure side (Mark
Blue
D) S

Blue hose——Low pressure side (Mark

S) Compressor
Vacuum pump (running)
● Connect the end of the air hose with a ZX215-1002155

L to the auxiliary valve of the compres- Fig. 4-155

sor. If connected inversely, the valve
will not open. Besides, do not inversely
connect the high-pressure end and the
low-pressure end.
C. Connect the middle hose (green) to the
vacuum pump.
2. Evacuating
A. Open the high-pressure valve (HI)
and low-pressure valve (LO) on the
manifold pressure gauge.
B. Turn on the vacuum pump and evacu-
ate for about 15 minutes.
C. When negative pressure reading on
the gauge (degree of vacuum) reaches
above 750 mmHg, turn off the vacuum
pump and close the Hi-pressure valve
and the Lo-pressure valve on the
gauge.

4-146 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

3. Air - proof check

Valve
A. Keep the Hi- and Lo-pressure valve Lo Hi Wait 5 min. or more Lo-press. gauge
OFF OFF
of the manifold pressure gauge under returns to 0
Lo-press. gauge
closed state for more than 5 minutes,
and make sure the pointer on the
gauge does not return to zero.
B. If the pointer returns to near zero, a Pointer returns
leakage is available somewhere. Check to 0 Tighten pipe joint

and adjust the pipe joint. Tighten the ZX215-1002156

joint and conduct another evacuating Fig. 4-156

operation until no leakage is detected.
4. Leak check
Valve
A. Connect the air hose (green) that is Lo Hi
OFF OFF
previously connected to the vacuum
pump to the fluorine cylinder.
B. Connect the other end of the hose
Vent valve
(green) to the pressure gauge. Open
Release air
the valve of the cylinder and press the Open
vent valve of the pressure gauge. (Do
not press the valve with naked hand to
avoid frostbite caused by refrigerant). Blue

Release the air in the hose with the Green

Red R134a
pressure of the refrigerant. (Release
the vent valve when you hear a To compressor Fluorine cylinder
squeezing sound). ZX215-1002157

C. Add refrigerant until pressure reading Fig. 4-157

on the Lo-pressure gauge is 1kgf/cm2.
Hi-pressure valve of the gauge is open
at this time. Close the Hi-pressure
valve when feeding is finished. Valve
Lo Hi Lo-press gauge Lo Hi
D. Use a leak detector to check if leakage OFF ON
at 1kgf/cm2
OFF OFF

is present in the cooling system. Lo-pres. gauge

reads1kgf/cm2
E. Make necessary repairs (tightening) if
leakage is observed. Lo-pres.valve (OFF) Open Hi-pres.valve
Cylinder valve (ON)
D

S
R134a
Compressor
Fluorine cylinder
ZX215-1002158

Fig. 4-158

Shop Manual - April 2017 4-147

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.12.2 Refrigerant filling operation

● When evacuation is finished, fill refrigerant into the cooling system as per the following in-
struction:

Add refrigerant kgf/cm2

Air-proofness check

Performance testing
Evacuation starts

Evacuation ends

Add refrigerant
Air leak check

Air leak check

75cm-Hg or more

More than 15 min. Wait 5 min. Pres. gauge

normal

Pres. gauge
Tighten pipe joint abnormal (1) Compressor stopped, charge at hi-press end
Check leak point (2)Compressor running, add at lo-press end

● Fill from the hi-pressure side Valve

1. Remove the air hose (green) of the Lo
OFF OFF
Hi

manifold pressure gauge from the vacuum

pump and connect it to the fluorine cylin-
der.
Vent valve
2. Open the valve of the cylinder and press
the vent valve on the pressure gauge. Use Open
Loosen
the pressure of the refrigerant to release this nut
the air in the hose.
Blue

Green
Red R134a
CAUTION
To compressor Fluorine cylinder
● Release the vent valve when you hear a ZX215-1002159

squeezing sound. Do not press the vent Fig. 4-159

valve with naked hand to avoid frost-
bite.

4-148 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

3. With the engine stopped, open the high-

pressure valve on the manifold pressure
gauge and the fluorine cylinder valve and Valve
Lo Hi A cylinder Lo Hi
fill in one and a half cylinder of fluorine OFF ON
(about 600g)
OFF OFF
(approximate 600g).
·Do not operate compressor
Lo-press. ·Do not open Lo-pressure valve

WARNING valve (OFF) Open Hi-press. valve

Fluorine cylinder
valve (ON)
● Do not run the compressor at this mo- D

ment. Once the compressor is started,

S
the refrigerant could flow back, causing R134a
the fluorine cylinder and hose to burst.
● Operating the compressor without re- ZX215-1002160
frigerant will burn the compressor. Nev-
Fig. 4-160
er run the compressor without refriger-
ant.
● Do not open the low-pressure valve on the
manifold pressure gauge (liquid compres-
sion will occur, causing damage tot he
compressor).

4. Close the high-pressure valve on manifold

pressure gauge and the fluorine cylinder
valve.

Shop Manual - April 2017 4-149

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Fill from lo-pressure side (additional filling)

1. Confirm the hi-pressure valve of the mani- Hi-press. valve (OFF) ON
Manifold pressure
fold pressure gauge is closed. gauge

2. Start the engine and open the cab door. H I

3. Turn on the air conditioner, and set
Temperature control switch to minimum. Start the engine
1300~1500rpm
4. Adjust engine speed to 1300 – 1500 rpm. ZX215-1002161

5. Open the Lo-pressure valve of the mani- Fig. 4-161

fold pressure gauge and the valve of the
fluorine cylinder, and fill refrigerant into the
reservoir until no foam is observed.

Note:
● Manifold pressure gauge reading (for ref-
erence):
● High pressure 13~17kg/cm2 (ambient tem-
perature 30℃ );
● Low pressure 1.5~2kg/cm2 (ambient tem-
perature 30℃ ).

4-150 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

6. When refrigerant filling is finished, close

the Lo-pressure valve of the manifold
Valve
pressure gauge and the valve of the Lo Hi When no foam
Lo Hi
is observed
fluorine cylinder. ON OFF OFF OFF
Lo-press. gauge
(1.5~2.5kgf/cm2) Hi-press. gauge
7. Check carefully for air leaks with a leak (13~17kgf/cm2)
detector. Lo-press. Hi-press. valve (OFF)
valve (ON) (Never open it)
Fluorine cylinder
valve (ON)
WARNING

● Never open the Hi-pressure valve of the

manifold pressure gauge. If it is opened, Compressor
Fluorine cylinder
high-pressure gas will counterflow and (never placed upside down) running

cause the air hoses and the fluorine ZX215-1002162

cylinder to explode, resulting in serious Fig. 4-162
injury.
● Do not position the fluorine cylinder
upside down (when engine is operating
and filling in progress). If the cylinder is
placed upside down, liquid refrigerant
will be sucked directly into the com-
pressor and cause liquid compression,
resulting in damage to the compressor
valve and the gaskets. Place the cylin-
der vertically and fill gas refrigerant.

8. When ambient temperature is low

When refrigerant filling can not be per- Valve
formed due to low ambient temperature, Lo Hi When no foam Lo Hi
ON OFF is seen OFF OFF
place the cylinder in water of less than
40 ℃ to increase the pressure of the
refrigerant inside the cylinder. Lo-pressure
valve (ON) Hi-pressure valve
9. When ambient temperature is high (OFF)
Cylinder valve
When ambient temperature is very high, (ON)

cool the compressor with an electrical

fan.
Compressor
Water less than 40°C running
(Do not use hot water)
ZX215-1002163

Fig. 4-163

Shop Manual - April 2017 4-151

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Replace the fluorine cylinder

When the refrigerant in a cylinder is used Handle

up, replace the cylinder as per the follow-

ing instruction:
1. Close the Hi- and Lo-pressure valves of Air hose connector
the manifold pressure gauge.
Needle valve
2. Raise the needle and disc plate of the
cylinder and remove the empty cylinder. Gasket

3. Install a new cylinder onto the cylinder Disc plate

valve.
Refrigerant
4. Release the air in the hose as per the fol- cylinder

lowing instruction: ZX215-1002164

A. Tighten the valve of the fluorine cylin- Fig. 4-164

der, and then, loosen it a bit.
B. Open the Lo-pressure valve of the
manifold pressure gauge a bit. Valve
Lo Hi
C. Press the vent valve and allow a little Loose OFF
refrigerant to come out. Immediately Close the Lo-pressure valve
once you hear the hissing sound
close the valve of the cylinder and the
Lo-pressure valve of the manifold pres-
sure gauge.
● Do not press the vent valve with naked Loosen the valve a bit
Lo-pressure
hand to avoid frostbite by refrigerant. valve

5. Turn the handle of the cylinder valve to Green

pierce the cylinder and continue filling Blue

operation. Red
R-134a

To compressor Refrigerant cylinder

ZX215-1002165

Fig. 4-165

4-152 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.8.12.3 Troubleshooting with manifold pressure gauge

After the engine has been preheated, read the pressure value on the gauge under the following
conditions:
1. Temperature at air inlet: 30 – 35℃
2. Engine speed: 1500 rpm
3. Fan speed: High
4. Temperature control: Minimum.
5. Air mode: Recirculation

● Refrigerating system under normal condition

Gauge reading:
Lo-pressure end 0.15~0.25 Mpa (1.5~2.5 Kg/cm²)
Hi-pressure end 1.37~1.57 Mpa (14~16 Kg/cm²)

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa

R134a

ZX425-1002171

Fig. 4-166

Shop Manual - April 2017 4-153

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Moisture in the refrigerating system

Fault: Intermittent refrigeration to non-refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
8 3
0
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

ZX425-1002172

Fig. 4-167

Symptom Cause Analysis Remedy

● Over-saturation of dehy- ● Replace receiver/de-

● When the system is ● Moisture in the system
drator. hydrator
operating, pressure at ices up at the expansion
● Moisture in the system ● Remove the moisture
the Lo-pressure end valve causing temporary
ices up at the expansion in the system through
unstable (sometimes stop of circulation. When
valve and hinders the constant pumping.
vacuum, sometimes ice melts, the system
circulation of the refrig- ● Add proper volume of
normal) becomes normal again.
erating system. new refrigerant.

4-154 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

● Insufficient refrigeration
Fault: Insufficient refrigeration.

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

ZX425-1002173

Fig. 4-168

Symptom Cause Analysis Remedy

● Check for air leakage with a leak
● Pressure at both Hi- and detector. Make necessary repairs.
● Air leaks ● Insufficient refrig-
Ho-pressure ends very low ● Add proper amount of refrigerant.
somewhere in erant in the sys-
● Foam is continuously ob- ● When connected with the gauge,
the refrigerat- tem
served via the sight glass if the reading is near zero, set the
ing system ● Leak of refrigerant
● Insufficient refrigeration. system under vacuum state after
inspection and repair.

Shop Manual - April 2017 4-155

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Defective refrigerant circulation

Fault: insufficient refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

ZX425-1002174

Fig. 4-169

Symptom Cause Analysis Remedy

● Pressure at both Hi-
and Lo-pressure sides
● Contaminant in the res-
very low ● Blocked reservoir ● Replace reservoir
ervoir hinders the flow of
● Frosting on the piping
refrigerant.
between parts and
reservoir

4-156 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

● Refrigerant not circulating

Fault: Non-refrigeration (intermittent refrigeration)

04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

ZX425-1002175

Fig. 4-170

Symptom Cause Analysis Remedy

● Check the expansion valve

● Vacuum at Lo-pres- and ERP.
sure side; pressure ● Moisture or contaminant ● Blow the contaminant in the
at Hi-pressure side in the refrigerant hinders expansion valve or replace
extremely low the flow of refrigerant. ● Refrigerant not the expansion valve if nec-
● Frosting or conden- ● Air leak at the thermal circulating essary.
sation on the pipes pipe of the expansion ● Replace the receiver
around the expansion valve hinders the flow of ● Release internal air and add
valve or receiver/de- refrigerant. refrigerant. If air leaks from
hydrator thermal pipe, replace expan-
sion valve.

Shop Manual - April 2017 4-157

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Over-filling of refrigerant or insufficient refrigeration of condenser

Fault: Insufficient refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa

ZX425-1002176

Fig. 4-171

Symptom Cause Analysis Remedy

● Excessive refrigerant in ● Clean the condenser
● Pressure at both Hi-
● Over-filling of refriger- system → Over-filling of ● Check the working
and Lo-pressure sides
ant in the system. Re- refrigerant condition of fan motor
very high
frigerating performance ● Insufficient refrigeration ● If the two above items
● No foam can be ob-
inadequate. of condenser → Ra- are normal, check the
served via the sight
● Insufficient refrigeration diator fins of condenser volume of refrigerant.
glass even when
of condenser plugged or failure of fan Add refrigerant as
engine speed drops.
motor required.

4-158 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

● Air present in refrigerating system

Fault: Poor refrigeration

If refrigerant is added with no evacuation operation performed, the following gauge reading
will appear:

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

ZX425-1002177

Fig. 4-172

Symptom Cause Analysis Remedy

● Pressure at both Hi- and
Lo-pressure ends very ● Check if compressor
high ● Air enters the refrigerant oil is contaminated or
● Air enters the refrig-
● Lo-pressure piping feeling system inadequate.
erating system
hot ● Insufficient evacuation ● Evacuate and add
● Foam is observed through new refrigerant.
the sight glass

Shop Manual - April 2017 4-159

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Improper installation of expansion valve/thermal pipe defect (wide opening)

Fault: insufficient refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa

ZX425-1002178

Fig. 4-173

Symptom Cause Analysis Remedy

● Pressure at both Hi- ● Check the installation of ther-

● Improper installation of ● Excessive re-
and Lo-pressure ends mal piping
thermal pipe/defective frigerant in Lo-
very high ● If thermal piping is normal,
thermal pipe (exces- pressure piping
● Frosting or condensa- check the expansion valve.
sively wide opening) ● Expansion valve
tion on Lo-pressure Replace expansion valve if
opening too wide
piping found defective.

4-160 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

● Compressing error
Fault: No refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25

7
1 5
01 07 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 - 01 35
MPa MPa

ZX425-1002179

Fig. 4-174

Symptom Cause Analysis Remedy

● Pressure at Lo-pressure ● Compressing fault;

side very high ● Compressor internal ● Leaking or damaged ● Repair or replace
● Pressure at Hi-pressure leakage valve, or missing parts compressor
side very low

Shop Manual - April 2017 4-161

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.8.13 Compressor oil

Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing compo-
nents, inadequate lubrication will result. Add compressor oil according to the chart below:

ND8# (10P, 10PA, 10S series compressor)

Compressor oil grade
ND9# (TV series compressor)

CAUTION

● Add oil into a new compressor according to the required volume of the system. When
the compressor is to be replaced, discharge the surplus oil in it.
● Filling of improper amount of compressor oil: Over-filling of compressor oil will reduce
the refrigerating capacity. Short of compressor oil in the system will lead to an abnor-
mal compressor.
● Keep the pipe connectors and O-ring seals free from contamination when disassem-
bling the compressor.

4-162 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.9 Engine Control

4 5

ZX425-1002180

Fig. 4-175

(1) Battery relay Outline

(2) Battery ● Start and stop the engine only with the
(3) Start switch engine start switch (3).
(4) Fuel control dial
● The controller (8) receives the signal from
(5) Start motor
the fuel control dial (4) and send the object
(6) Controller speed to engine controller through can bus
(7) Fuel injection pump the governor lever angle of fuel injection
(8) Controller pump (7) and control the engine speed.
● When engine start switch (3) is turned to
the OFF position, the engine controller
(6) closes the injection nozzle of the fuel
injection pump to cut off the engine fuel
supply. Then, the engine stops.

Shop Manual - April 2017 4-163

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.9.1 System operation

Engine start
● When the start switch is turned to the
START position and the pilot switch is
locked, the starting signal is sent to the
start motor. Then, the start motor starts the
engine.
● When it happens, the engine controller de-
tects the signal voltage sent from the fuel
control dial and sets the engine speed to
the speed set by the fuel control dial.
Fig. 4-176

Engine speed control

● The fuel control dial sends to the controller
a signal voltage corresponding to its
angle. According to the signal voltage,
the controller sends speed signal to
ECM controller in order to control the
fuel injection pump, hence controlling the
engine speed.

Fig. 4-177

Engine shutdown
● When the start switch is turned to the
STOP position, then sends stop signal to
ECM controller in order to control the fuel
injection pump stop working.

WX500-16061212

Fig. 4-178

4-164 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.9.2 System components

4.9.2.1 Fuel control dial

140°
9×10°
1
Level 1
Level 10

2 25°

Left limit Right limit

3

6 Yellow
1 5V

2 Blue
VR

2
1 3
Red
3 0V

ZX215-1002180

Fig. 4-179

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

Shop Manual - April 2017 4-165

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Function
● Turning of the fuel control dial changes
the resistance of the sliding rheostat inside
（%）
the dial and the voltage signal collected by 100
the controller. The controller calculates the

Dial angle
collected signals and sends speed signal
to ECM controller and controls the injection
of the fuel pump so that the engine can run
at an optimal speed..
● When throttle voltage is beyond the area,
0 0.25 1.72 4.49 4.75 5（V）
the controller sends out alarm code and Voltage (V)
the engine runs at low idle. The area under
the sloping line is the abnormality detection ZX425-1002185

area. Fig. 4-180

Note:
The leftmost position is 0%; and the rightmost
position is 100%.

4.9.2.2 Engine control unit (ECU)

Diagram and description of ECU terminal block

WX485-15111602

Fig. 4-181

4-166 Shop Manual - April 2017

SY215C9CK/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

283H I/O
DSPpin PIN Type
Name Signal name
AI_V_1 ADCINA0(DSP1) 43 Rear pump pressure sensor AI_V
AI_V_2 ADCINA1(DSP1) 24 Boom RAISE pressure sensor AI_V
AI_V_3 ADCINA2(DSP1) 22 Boom LOWER pressure sensor AI_V
AI_V_4 ADCINA3(DSP1) 41 Bucket CURL pressure sensor AI_V
AI_V_5 ADCINA4(DSP1) 23 Bucket DUMP pressure sensor AI_V
AI_V_6 ADCINA5(DSP1) 42 Arm IN pressure sensor AI_V
AI_V_7 ADCINA6(DSP1) 62 Arm OUT pressure sensor AI_V
AI_V_8 ADCINA7(DSP1) 61 Swing pressure sensor AI_V
AI_V_9 ADCINB0(DSP1) 39 Front pump pressure sensor AI_V
2AI_V_1 2ADCINA0(DSP2) 40 R. travel pressure sensor 2AI_V
2AI_V_2 2ADCINA1(DSP2) 21 L. travel pressure sensor 2AI_V
2AI_V_3 2ADCINA2(DSP2) 38 shear O/C 2AI_V
2AI_V_4 2ADCINA3(DSP2) 20 Fuel dial signal 2AI_V
2AI_V_5 2ADCINA4(DSP2) 19 Oil temperature sensor signal 2AI_V
AI_R_1 ADCINB1(DSP1) 80 Fuel level sensor AI_R
AI_R_2 2ADCINA5(DSP2) 79 \\ 2AI_R
PWM_1 PWM1A(DSP1) 104 Boom priority PWM
PWM_2 PWM2A(DSP1) 103 Front pump solenoid valve PWM
PWM_3 PWM3A(DSP1) 111 Rear pump solenoid valve PWM
PWM_4 PWM4A(DSP1) 112 Bucket confl uence solenoid valve PWM
PWM_5 GPIO34(DSP1) 109 swing priority PWM
PWM_6 GPIO37(DSP1) 110 \ PWM
PWM_7 2PWM1A(DSP2) 107 \ 2PWM
PWM_8 2PWM2A(DSP2) 108 \ 2PWM
PWM_9 2PWM3A(DSP2) 98 shear Open 2PWM
PWM_10 2PWM4A(DSP2) 106 shear Close 2PWM
PWM_11 2PWM5A(DSP2) 100 \ 2PWM
PWM_12 2PWM6A(DSP2) 99 \ 2PWM
PWM_13 2GPIO34(DSP2) 64 \ 2PWM
PWM_14 2GPIO37(DSP2) 63 \ 2PWM
PWM_15 2GPIO48(DSP2) 44 \ 2PWM
PWM_16 2GPIO49(DSP2) 45 \ 2PWM
DI_H_1 GPIO24(DSP1) 29 Start DI_H
DI_H_2 GPIO25(DSP1) 10 stop DI_H
DI_H_3 2GPIO24(DSP2) 30 \ 2DI_H
DI_H_4 2GPIO25(DSP2) 11 \ 2DI_H
DI_L_1 GPIO50(DSP1) 50 Pilot Valve DI_L
DI_L_2 GPIO51(DSP1) 51 Fuel dial signal DI_L
DI_L_3 GPIO52(DSP1) 52 manual regeneration and diagnose DI_L
DI_L_4 GPIO53(DSP1) 7 air cleaner block alarm DI_L
DI_L_5 GPIO64(DSP1) 27 \ DI_L
DI_L_6 GPIO65(DSP1) 8 \ DI_L
DI_L_7 2GPIO50(DSP2) 25 \ 2DI_L
DI_L_8 2GPIO51(DSP2) 6 \ 2DI_L

Shop Manual - June 2016 4-167

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

DI_L_9 2GPIO52(DSP2) 26 HYD SHEAR R SWING SIGNAL 2DI_L

DI_L_10 2GPIO53(DSP2) 69 HYD SHEAR L SWING SIGNAL 2DI_L
DI_L_11 2GPIO64(DSP2) 70 \ 2DI_L
DI_L_12 2GPIO65(DSP2) 71 \ 2DI_L
DO_1 GPIO40(DSP1) 88 start ouput DO
DO_2 GPIO41(DSP1) 89 delay DO
DO_3 GPIO42(DSP1) 97 BOOSTING DO
BOOM PRIORITY
DO_4 GPIO43(DSP1) 96 DO
PROPORTIONAL-2
DO_5 GPIO48(DSP1) 86 \ DO
DO_6 GPIO49(DSP1) 87 \ DO
DO_7 2GPIO40(DSP2) 84 Travel speed switching solenoid 2DO
DO_8 2GPIO41(DSP2) 85 Travel Alarm 2DO
DO_9 2GPIO42(DSP2) 91 HYD SHEAR Swing L SOL VALVE 2DO
DO_10 2GPIO43(DSP2) 90 HYD SHEAR Swing R SOL VALVE 2DO
DO_11 2GPIO44(DSP2) 82 \ 2DO
DO_12 2GPIO45(DSP2) 83 \ 2DO
RX232A SCIRXDB(DSP1) 15 \
TX232A SCITXDB(DSP1) 34 \
2RX232B 2SCIRXDB(DSP2) 16 \
2TX232B 2SCITXDB(DSP2) 35 \
RS (DSP1) 32 \
2RS (DSP2) 13 \

4-168 Shop Manual - June 2016

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Shop Manual - June 2016 4-169

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10 Electrical Control System

4.10.1 Control function

● See “Troubleshooting” for more infor-

mation on self-diagnostic function.

4-170 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.2 Diagram of machine control system

WX500-160601201

Fig. 4-182

Shop Manual - April 2017 4-171

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Engine electronic control device

3 Right travel pressure sensor
4 Left travel pressure sensor
5 Boom-up pressure sensor
6 Boom-down pressure sensor
PPC
7 Arm-in pressure sensor
valve
8 Arm-out pressure sensor

9 Bucket-dig pressure sensor

10 Bucket-dump pressure sensor

Work equipment rotating device

11 Swing pressure sensor

Frong pump oil feed device

PPC basic pressure

12
13
14
15
16
17
Boom priority Boom 2 spare Boom priority Travel Pilot
for bucket confluence solenoid for swing speed sw
proportional cut proportional solenoid solenoid
solenoid solenoid valve solenoid valve valve
valve valve valve

18
Port for each action control valve
pump 2
1 proportional valve
Main valve

Trave motor
Servo
Pilot pump

Trave motor
Main
pump Cooling Rear pump oil feed Swing motor
pump device
Work equipment rotating device

Servo Cooling fan

motor

pump 2
1
proportional valve

19 WX500-16061202

Fig. 4-183

Note: TThe above diagram is a schematic drawing of electrical control. For more information on
the hydraulic circuit, see the description in Hydraulic Part.

4-172 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.3 Engine-pump combination control

Diagram of control function

Fig. 4-184

Note: The above diagram is a schematic drawing of electrical control. For more information on
the hydraulic circuit, see the description in Hydraulic Part.

Shop Manual - April 2017 4-173

Structure and Functions SY215C9C5K /SY225C9C5KCrawler Hydraulic Excavator

Function
● This function allows operator to change the engine torque and the pump absorption torque
according to the kind of job that the machine is to be engaged.
● Pump controller controls the pump so that the pump is able to absorb all torques at engine
output point. These torques are determined by the pump absorption torque specification, fuel
control dial setting and real engine speed under each mode.

4-174 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

ESS Control

Function
● Changing of the engine speed due to load change controls the pump power, and engine
output can be used more efficiently. (This function can also prevent the engine from losing
control when the machine is operating under harsh conditions (eg. high - altitude area).

Operation
● The engine control panel controls the target operating speed of the engine.
● The engine controller collects the actual speed signal from the speed sensor, and preform a
loop control with the target operating speed. Then, the controller involves the output of loop
control with the calculation of the solenoid valve control signal, and sends the fi nal regulating
current signal to the pump proportional solenoid valve.
● The solenoid valve controls pump flow by feeding pilot oil to the pump regulator according to
the signal sent from the controller.

Shop Manual - April 2017 4-175

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.4 Valve control function

Bucket confluence

WX500-160612004

Fig. 4-185
● The relief pressure is 34.3Mpa (350 kg/
Function
cm2) under normal working condition.
● In order to make the machine applicable
under high load, a two-level relief function
is adopted to enhance its digging power.

4-176 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.5 Travel control function

Travel speed control

Main valve

Pressure sensor Pressure sensor

Engine

Main pump Adjuster

Adjuster

Speed
sensor Servo

ESU
High-speed travel
solenoid valve
Proportional Proportional
valve valve
Fuel control dial
Hi
(Engine speed signal)
(Throttle control signal)

Lo (Control signal)
(Control signal)

(Control signal)

Controller Monitor
(CAN bus)
Travel pressure signal

WX385-1304008

Fig. 4-186

Function ● High/Low Travel speeds are shown below.

● The monitor control panel is used to
change travel motor displacement, hence Reducer High speed Low speed
the control of travel speed. In this way,
MAG-170VP-3400E 5.5km/h 3.2km/h
the travel performance can match certain
working environment and work category.

Shop Manual - April 2017 4-177

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.6 Low engine oil pressure alarm and protection

Fig. 4-187

Function
● The controller collects signal from oil pressure sensor. If the oil pressure is too low with the
engine running at a speed of more than 600 rpm, alarm information will be generated and sent
to the monitor. The monitor receives the alarm information and lights up the alert indicator.
● As the monitor alarms, the controller will force the engine to run at low idle in order to protect
the engine.

4-178 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.7 High engine coolant temperature alarm and protection

Fig. 4-188

Function
● The controller collects signal from water temperature sensor. If coolant temperature is too
high (exceeding 103 ℃ ), alarm information will be generated and sent to the monitor. The
monitor receives the alarm signal and lights up the alert indicator.
● As the monitor alarms, the controller will force the engine to run at low idle in order to protect
the engine.

Shop Manual - April 2017 4-179

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.8 Engine preheating control

WX500-160612007
Fig. 4-189

Function
● When the engine is started, engine control unit (ECU) will detect coolant temperature and de-
termine whether the engine is to be preheated.
● When ECU determines that preheating is necessary, it will send preheating control signal to
close the preheat relay. The engine preheating plug will be energized and activated.

4-180 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.9 Engine starting and energizing delay control

WX500-160612008

Fig. 4-190

Function
● When the start switch is turned to the START position, the controller closes K-3 relay
after detecting that the hydraulic lockout control in the safe position. After the start relay is
energized, the start motor will bring the flywheel into rotation. The engine is then started.
● When the start switch is turned to the OFF position, ECM of the engine is de-energized, the
engine shutdown device shuts off fuel supply of the engine, and the controller sends an eight-
second high level signal to close K-12 shutdown relay after detecting that the wiring 13# has
been de-energized. The whole vehicle will be powered off after eight (8) seconds.

Shop Manual - April 2017 4-181

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.10 System parts and components

4.10.10.1 Pump pressure sensor

Sumitomo connector Body O-ring seal Pressure connector

Connection graph

Terminal Signal name

Z
A Power（+5V）

B GND
B
A C Output
C

Z direction ZX215-100117

Fig. 4-191

Operation (V)
● The relationship between the pressure ap- 5
plied to sensors (P) and output voltage (E) 4. 5
Sensor output voltage (E)

4
is shown in the figure on the right.
3

1
0. 5
(MPa)
0 10 20 30 40 50
Oil pressrue (P)
ZX425-1002203

Fig. 4-192

4-182 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.10.2 Pilot pressure sensor

Sumitomo connector Body O-ring seal Pressure connector

Connection graph

Terminal Signal name

Z
A Power（+5V）

B GND
B
A C Output
C

Z direction ZX215-100117

Fig. 4-193

Operation
(V)
● The relationship between the pressure ap- 5
plied to sensors (P) and output voltage (E) 4. 5
Sensor output voltage (E)

is shown in the figure on the right. 4

1
0. 5
(MPa)
0 1 2 3 4 5
Oil pressrue (P)
ZX425-1002205

Fig. 4-194

Shop Manual - April 2017 4-183

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.10.3 Engine speed sensor

2 1
ZX425-1002206

Fig. 4-195

Function
NOTICE
● The engine revolution sensor is installed to
the ring gear of the engine flywheel. It elec- ● If the engine speed sensor is not tight-
trically calculates the number of the gear ened to the specified torque, the sensor
teeth which pass in front of it and transmits may send out no signals. Tighten the
the result to the engine controller. engine speed sensor to the specified
torque.
Operation
● Measure the resistance between terminal
1 and terminal 2 when using it.

Standard value at 25℃ 2.3±0.2kΩ

● If the measured value exceeds the stan-

dard value, replace the sensor.

4-184 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.10.4 Coolant temperature sensor

1 2

WX385-1304001

Fig. 4-196

(1) 1. Sensor
(2) 2. Connector

Function Specifications
● The output resistance of the engine cool- 50℃ 80Ω (Ref.)
ant temperature sensor changes with the
60℃ 56.3Ω
coolant temperature. The controller collects
and processes coolant temperature signals Standard 80℃ 29.5±10Ω
and works out the coolant temperature. value 100℃ 16.5Ω
106℃ 14.3±0.5Ω
120℃ 10Ω(Ref.)

Shop Manual - April 2017 4-185

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.10.10.5 Fuel level sensor

1 2 3 4

ZX425-1002241

Fig. 4-197

(1) Float
(2) Lever
(3) Housing
(4) Connector

4-186 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.10.10.6 Oil pressure switch

1 2 3

Load

Pressure
Circuit diagram

ZX425-1002208

Fig. 4-198

(1) 1. O-ring
(2) 2. Sensor
(3) 3. Connector

Function Specifications
● The oil pressure switch is installed on the ● Type of contact: Normally close contact
outlet circuit of the oil filter. It detects oil
● Operating pressure: 1.9 kgf
pressure and transmit the signal to the
controller.

Shop Manual - April 2017 4-187

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11 Monitor System

Monitor-Controller

CAN signal

Controller

Each sensor

Power source

Battery
Fig. 4-199

ZX335-1002073

● The machine condition is monitored by the sensors mounted on different locations of the ma-
chine. The controller processes the signals and transmits the signals to the monitor display,
informing the operator of the machine condition.
● The monitor panel also contains mode selector, functional keys and machine operation con-
trol outputs.
● Information on the monitor display includes primarily:
1. Alert information in case of machine failure
2. Operating condition (coolant temperature, hydraulic oil temperature, fuel level, etc. )

4-188 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.1 Monitor

WX500-160612009

Fig. 4-200
Input and output signals
No. Signal Name I/O
Outline 1 CAN low
● The monitor is used to display monitoring 2 CAN high
information and select a working mode. 3 CAM -

● The monitor has a CPU (Central Process- 7 Digital reset

ing Unit) which processes, displays, and 9 Camera power (24V)
outputs information. 12 CAM +
17 GPS power
● The monitor uses a LCD (Liquid Crystal
Display). 24 Ground
25 Display power (24V)
29 Display protection Input
33 Ground
34 Display power (24V)
Note:
● The LCD may have black spots (which do not light up) or bright spots (which stay on). Prod-
ucts having 10 or less black or bright spots conform to the product specification; such condi-
tion is quite normal.
● Continuous operation of the monitor may cause the LCD to display bright blue spots on a
black background; it is quite normal.
● When the monitor is turned on, blinking strips may appear on the LCD. This is normal.

Shop Manual - April 2017 4-189

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.2 Monitor panel

NOTICE

● Stop operation immediately when the

alert indicator is on. Check and repair
related parts.
● The monitor does not display all work-
ing conditions of the machine.
● Do not solely depend on what is dis-
played on the monitor when maintain-
ing and checking the machine.

The monitor panel performs the functions of

monitoring and displaying, selecting a working
mode, and switching on/off an electrical ele-
ment.
XP235-13001

Overview Fig. 4-201

The monitor consists of three parts:
A: SANY log display
B: LCD display
C: Operation keys

SANY log display

display SANY log

When the excavator starter switch to “on”
position，the display is supplied by the battery
and enter into the interface..

XP235-13002

Fig. 4-202

4-190 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

Default display
When the excavator start switch is turned to
the on position, the monitor is energized by the
battery and initializes. A fully displayed screen
is as shown in the right figure, where in,
1. System time
2. Working mode (Divided by engine speed
level)
3. GPS information
4. Engine speed level (According to the throttle
knob position)
5. Operation time
6. Fuel level gauge 17
WX485-15111901
7. Lock indicator (Lock countdown reminder)
8. Maintenance indicator and time Fig. 4-203
9. Fuel instaneous flow
10. Operate time of this time
11. Coolant temperature gauge
12. Malfunction alert and signal indicators
13. Video page
14. Auto deceleration
15. High/low travel speed
16. Icon for entering Failure Information
17. Icon for entering System Information

Shop Manual - April 2017 4-191

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Operation keys
The operation keys include five function keys.
Function keys
The function keys include F1, F2, F3, F4 and F5, as show by the figure. Function of each key is
defined by the icon above it.
● A different icon defines different function of a key.
● When no icon is shown, the corresponding key is undefined.

Key Icon Function Range of display

F1 Elect item on upper/ ——

lower side
F2 Auto idle/non-idle shift Idle/non-idle

High/low travel speed shift High/low

F3 Enter a selected ——
item/Set up an item
Change the value ——
F4
Enter the video Page ——

View system information ——

F5
Back to previous page ——

Enter an option/setup

4-192 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3 Monitor operation

4.11.3.1 Default page

The Default page is the normal operation
display of the monitor.

Operation
1. Enter the Video Page
If the machine is equipped with a camera,
press F1 enter the Video Page.
2. Auto-idle and Non auto-idle mode
Press F2 to switch between auto-idle and
Non auto-idle mode.
When the icon above F2 shows , press
AUTO

n/min

the key to disable auto idle. When the icon

shows , press the key to enable auto
Fig. 4-204
n/min

idle.
NOTE: Auto-idle mode is the default mode
after the machine is powered on.
● Auto idle is on as default. When all controls
are in neutral position, engine speed will
drop by 100 rpm after 0.2 second and then
enter auto idle after another 3 seconds
(as the controller automatically changes
engine speed to idling) in order to save fuel
and reduce noise.
● In auto idle, if the controller detects any
maneuver or gear position change, engine
speed will rise to corresponding level.

Shop Manual - April 2017 4-193

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3. High and low travel speed

Press F3 to switch between high and low
travel speed.
When the icon above F3 shows , press
the key to select high travel speed. When
the icon shows , press the key to select
low travel speed.
NOTE: Default travel speed is Low after the
machine is powered on.
4. Failure Information
When the alert indicator is on, failure code
appears on bottom of monitor screen.
Above the key F4 you will see a red .
Press this key to view failure Information.
5. Main menu (5)
Press F5 view system information.
NOTE: Password is required to access system
information. You may contact local Sany
distributor to get the password.

4-194 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.3 Main Menu

Press F5 on the default page of monitor to

enter Main Menu. This page contains a list of

system functions. You can select an item and
enter corresponding page.
Operation

● F1 Selection function
● F2 -
● F3 Confirmation
● F4 Access System Setting page
● F5 Return to the default page

CB2016042501

Fig. 4-206

4.11.3.2 Main Menu Password entry to

system information
Choose“Running Iinformation”on the“Main
Menu”, Press F3 to call the password entry
to system information (After power-on, you
only should enter the correct passwords to
access at the first time).
Operation

● F1 Increase or decrease the number at the

cursor.
● F2 Move the cursor to the left or to the
right.
● F3 Confirmation
● F4 Access System Lockout page CB2016042502

● F5 Return to the default page

Fig. 4-205

Shop Manual - April 2017 4-195

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.3.4 System Lockout

Operation

● F1 Increase or decrease the number at the

cursor.
● F2 Move the cursor to the left or to the
right.
● F3 Confirmation
● F4 -
● F5 Return to the default page

CB2016042503

Fig. 4-207

4.11.3.5 Engine & Throttle Signals

Select Running Information on the Main Menu
page to access Engine & Throttle Signals at
first.
Operation

● F1 Enter Input & Output Switch Signals

query.
● F2 Enter Pilot Pressure Signals.

CB2016042504

Fig. 4-208

4-196 Shop Manual - April 2016

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.6 Pilot Pressure Signals

Press F2 on the Engine & Throttle Signals

page or press F1 on the Main & Cooling Pump

Signals page to access Pilot Pressure Signals.
This page displays real-time pilot pressure
signals collected by the controller.
Operation

● F1 Enter Engine & Throttle Signals.

● F2 Enter Main & Cooling Pump Signals.

CB2016042505

Fig. 4-209

4.11.3.7 Main & Cooling Pump Signals

Press F2 on the Engine & Throttle Signals

page or press F1 on the Input & Output Switch

Signals page to access Main & Cooling Pump
Signals.
Operation

● F1 Enter Pilot Pressure Signals.

● F2 Enter Input & Output Switch Signals.

CB2016042506

Fig. 4-210

Shop Manual - April 2017 4-197

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.3.8 Input & Output Switch Signals

Press F2 on the Main & Cooling Pump Signals
page or press F1 on the Engine & Throttle

Signals page to access Input & Output Switch

Signals.
Operation

● F1 Enter Main & Cooling Pump Signals.

● F2 Enter Engine & Throttle Signals.

CB2016042507

Fig. 4-211

4.11.3.9 Failure information

Select Failure Information on the Main Menu to
enter and check failure code and information.
Operation

● F1 Return to the previous page.

● F2 -
● F3 -
● F4 -
● F5 Return to Main Menu page

CB2016042508

Fig. 4-212

4-198 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.10 GPS Information

Select GPS Information on the Main Menu to
check GPS information.
Operation

● F1 -
● F2 -
● F3 -
● F4 -
● F5 Return to Main Menu page

CB2016042509

Fig. 4-213

4.11.3.11 Language Selection

Select Language Selection on the Main Menu
to enter Language Setting page, the currently
available languages are Chinse and English.
Operation

● F1 -
● F2 Chinse
● F3 English
● F4 -
● F5 Return to Main Menu page

CB2016042510

Fig. 4-214

Shop Manual - April 2017 4-199

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.3.12 System Time Calibration

Select System Clock on the Main Menu to
enter System Time Calibration page.
Operation

● F1 Increase or decrease the number at the

cursor.
● F2 Move the cursor to the left or to the
right
● F3 Confirmation
● F4 -
● F5 Return to Main Menu page
NOTE: System clock can only be set up once
after the system is powered on. When the
machine is powered on and the F1 key is CB2016042511
pressed, you will only see the prompt of setup
result. Fig. 4-215

4.11.3.13 Maintenance Information

Select Maintenance Information on the
Main Menu to enter Maintenance Info.
page. Maintenance Information includes
maintenance items of every 50 & 250 & 500 &
1000 & 2000 service hours.
NOTE: Just enter operation when maintenance
is reminded.
Operation

● F1 -
● F2 -
● F3 Enter maintenance code confirmation
● F4 Pause and open of maintenance items
cycle play CB2016042512

● F5 Return to Main Menu page

Fig. 4-216

4-200 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.14 Maintenance Confirmation

Press F3 on the Main Menu to access
Maintain Password page and input password
to confirm maintenance.
Operation

● F1 Increase or decrease the number at the

cursor
● F2 Move the cursor to the left or to the
right
● F3 Confirme maintenance
● F4 -
● F5 Return to Main Menu page

CB2016042513

Fig. 4-217

4.11.3.15 System Setting

Press F4 on the Main Menu to access System
Setting page, Password is required to access
Operation Time Calibration. For method of
entering the password see Password Entry to
System Information.
Operation

● F1 Selection
● F2 -
● F3 Confirme maintenance
● F4 -
● F5 Return to Main Menu page

CB2016042514

Shop Manual - April 2017 4-201

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.3.16 Machine Configuration Setting

Select Machine Configuration on the
System Setting page to check the machine
configuration information.

● F1 -
● F2 -
● F3 -
● F4 -
● F5 Return to Main Menu page

CB2016042515

Fig. 4-218

4.11.3.17 Operation Time Calibration

Press Operating Hours on the System Setting
page to calibrate operating time. Password is
required to access Operation Time Calibration.
For method of entering the password see
Password Entry to System Information.

● F1 Increase or decrease the number at the

cursor
● F2 Move the cursor to the left or to the
right
● F3 Confirmation
● F4 -
● F5 Return to System Setting page

CB2016042516

Fig. 4-219

4-202 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.18 Machine Configuration Setup

Select Machine Demarcration on the
System Setting page to calibrate machine
configuration information. Password is
required to access Machine Configuration
Setting. For method of entering the password
see Password Entry to System Information.
Operation

● F1 Change Machine S/N

● F2 Change engine model
● F3 Confirm and Return to System Setting

page
● F4 Change model of the hydraulic system
● F5 Change controller model CB2016042603

Fig. 4-220

Shop Manual - April 2017 4-203

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.3.19 Alarm Content Setting

Select Alarm Contet on the System Setting
page to acess Alarm Content Setting page.
Operation

● F1 Select setting item

● F2 -
● F3 Confirm setting item
● F4 -
● F5 Return to System Setting page

CB2016042517

Fig. 4-221
4.11.3.20 Screen Backlight Adjust
Select Screen Backlight on the System Setting
page to acess Alarm Content Adjust page.
Operation

● F1 Enhance the backlight

● F2 Dim the backlight
● F3 Confirmation
● F4 -
● F5 Return to System Setting page

CB2016042518

Fig. 4-222

4-204 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.21 Running Correct Setting

System set the second level password to
enter.
Operation

● F1 Select setting item

● F2 Increase the number at the cursor
● F3 Decrease the number at the cursor
● F4 Confirmation
● F5 Return to System Setting page

CB2016042519

Fig. 4-223

4.11.3.22 Engine Information

Display history fail and work times of engine.
Operation

● F1 Display history fail and work times

● F2 Enter the history fails query page
● F3 Confirm sending request
● F4 Enter the engine other information
page
● F5 Return to System Setting page

CB2016042520

Fig. 4-224

Shop Manual - April 2017 4-205

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4.11.3.23 Engine Failure Information

Display engine history fails.
Operation

● F1 Enter the next page

● F2 -
● F3 -
● F4 -
● F5 Return to Engine Information page

CB2016042521

Fig. 4-225

4.11.3.24 Engine other information

Display engine related information.
Operation

● F1 Enter basic engine information-4 page

● F2 Enter basic engine information-2 page
● F3 -
● F4 -
● F5 Return to Engine Information page

CB2016042522

Fig. 4-226

4-206 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

4.11.3.25 Daily maintenance information

It pop up automatically when stars at first time
every day.
Operation

● F1 -
● F2 -
● F3 -
● F4 -
● F5 Return to Engine Information page

CB2016042523

Fig. 4-227

4.11.3.26 System lockout information

The excavator enters level system lockout
when receive lockout singals. Lockout singals
include two kinds system status of level 1 and
level 2.
Operation

● F1 -
● F2 -
● F3 -
● F4 -
● F5 Enter system unlock page

CB2016042524

Fig. 4-228

Shop Manual - April 2017 4-207

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4-208 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Structure and Functions

E
G
PA
K
AN
BL

Shop Manual - April 2017 4-209

Structure and Functions SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

4-210 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Standard Values

Standard Values
5 Standard Values
5.1 Standard Values for Chassis-Related Parts ............................................................ 5-3

Shop Manual - April 2017 5-1

Standard Values SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

5-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Standard Values

5 STANDARD VALUES

5.1 Standard Values of Chassis-related Parts

Std. value for Permis-

Categ. Item Measurement condition Unit
new machine sible value
● Engine coolant temperature: Within
operational range
● Hydraulic oil temperature: Within
Engine Speed

2 pumps at relief operational range rpm 2,000±50 2,000±50

● Engine running at high idle
● Heavy-load operating mode (H)
● Arm-in relief condition
Speed when auto ● Engine running at high idle
deceleration is oper- ● Auto idling switch on rpm 1,200±50 1,200±50
ated ● All control levers neutral
UP mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve
DOWN mm 9.5 ± 0.5 9.5 ± 0.5
Spool Stroke

IN mm 11.5 ± 0.5 11.5 ± 0.5

Arm control valve
● Engine stopped OUT mm 9.5 ± 0.5 9.5 ± 0.5
Bucket control valve ● See Control valve. DIG/DUMP mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve Travel (L&R) mm 9.5 ± 0.5 9.5 ± 0.5
Forward &
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
Boom control lever mm 80 ± 10 80 ± 10
● Engine stopped
Arm control lever mm 80 ± 10 80 ± 10
● Control lever grip at center
Bucket control lever mm 80 ± 10 80 ± 10
● Max. reading at stroke end (except
Control Lever stroke

Swing control lever mm 80 ± 10 80 ± 10

lever play in NEUTRAL position)
Travel control lever mm 115 ± 12 115 ± 12
● Engine stopped Work Equip-
mm Max. 15 Max. 20
● Slightly push the ment
control lever. Stop
Play of control lever pushing when re-
sistance is felt. Stroke mm Max. 20 Max. 25
● Max. reading at
stroke end.

Shop Manual - April 2017 5-3

Standard Values SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Std. value for Permis-

Categ. Item Measurement condition Unit
new machine sible value
Boom control Max. 19.6 Max. 24.5
Operating Force of Control Lever/

lever {Max. 2.0} {Max. 2.5}

Arm control Max. 19.6 Max. 24.5
lever ● Hydraulic oil temp: Within operational {Max. 2.0} {Max. 2.5}
Bucket con- range Max. 15.6 Max. 21.6
trol lever ● Engine running at high idle N {Max. 1.6} {Max. 2.2}
Pedal

Swing control ● Control lever grip at center {kgf} Max. 15.6 Max. 21.6
lever ● Pedal at tip {Max. 1.6} {Max. 2.2}
Travel control Max. 30.4 Max. 39.2
● Max. reading at stroke end
lever {Max. 3.1} {Max. 4.0}
Travel control Max. 93.1 Max. 107.8
pedal {Max. 9.5} {Max. 11}
● Hydraulic oil temp: Within operational
range
Unloaded ● Engine running at high idle
0 – 1.0 0 – 2.0
pressure ● Working mode: H
● All control levers in neutral position
● Hydraulic pump output pressure
Boom relief ● Hydraulic oil temp: Within operational 34.3 ± 1.0 33.3 ~ 35.3
range {350 ± 10} {340 ~ 360}
● Operate corresponding control lever 34.8 ± 1.0 33.3 ~ 36.8
Arm relief
after engine runs at high idling speed. {355 ± 10} {340 ~ 375}
● Working mode: H
Hydraulic Pressure

34.8 ± 1.0 33.3 ~ 36.8

Bucket relief ● Hydraulic pump output pressure with {355 ± 10} {340 ~ 375}
all measurement circuits relieved MPa
● Hydraulic oil temp: Within operational 25.5 ± 1.0 24.5 ~ 27.5
Swing relief {kg/cm²}
range {261 ± 10} {250 ~280}
● Operate corresponding control lever
after the engine runs at high idling
speed. 33.4 ± 1.0 32.4 ~ 34.4
Travel relief
● Working mode: H {342±10} {330 ~ 351}
● Hydraulic pump output pressure with
all measurement circuits relieved
● Hydraulic oil temp: Within operational
range
Control circuit
● Engine running at high idle 3.9 ± 0.2 3.7 ~ 4.1
source pres-
● Self pressure reducing valve output {40 ± 2} {37 ~ 41}
sure
pressure with all control levers in
NEUTRAL position

5-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Standard Values

Std. value for Permis-

Categ. Item Measurement condition Unit
new machine sible value
● Hydraulic oil temp: Within operational range
● Engine running at high idle
Swing
● Working mode: H Deg. Max. 100 Max. 130
brake
● Swing circle misalignment amount when stopping mm (—) (—)
angle
after one turn
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range 90° sec. 3.1 ± 0.3 Max. 3.7
Time ● Engine running at high idle
taken ● Working mode: H
to start ● Time required for passing points 90°and 180° sec. 4.4 ± 0.4 Max. 5.5
swing 180° from starting point
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range
● Engine running at high idle
Swing

Time
● Working mode: H
taken to sec. 28 ± 3.5 Max. 34
● Time required for 5 turns after making initial 1
swing
turn
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range
● Engine stopped
● Keeping the upper structure transverse on a
Hydraulic
grade of 15°. For more information see Swing 2. mm 0 0
drift
● Notching a mating mark on inner and outer races
of the swing circle
● Mating mark misalignment amount during 5 min.
● Hydraulic oil temp: Within operational range
Motor ● Engine running at high idle ml/
Max. 5 Max. 10
leakage ● Swing lockout switch: ON min
● Leakage amount for 1 minute during swing relief
● Hydraulic oil temp: Within operational range Lo 51.3 ± 5.1 46.2 - 60.4
● Engine running at high idle
Travel
● Working mode: H
Travel

speed
● Time required for track shoes to make 5 sec.
(unload- Hi 28.0 ± 1.4 26.6 - 31.4
turns after making one initial idle turn
ed)
● For more information on measuring posture
see Travel 1.

Shop Manual - April 2017 5-5

Standard Values SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Std. value for Permis-

Cat. Item Measurement Condition Unit
new machine sible value

● Hydraulic oil temp: Within operational range

Travel speed

● Engine running at high idle Lo 20 ± 2.5 17.5~22.5

(Actual run)

● Working mode: H
sec.
● Level ground
● Time required for traveling 10m after 10m trial run
Hi 13 ± 2.5 11.5~15.5
● For measuring posture see Swing 2.

● Hydraulic oil temp: Within operational range

● Engine running at high idle
● Working mode: H
Deviation

● Travel Speed: Low

mm Max. 800 Max. 900
● Hard level ground
● Amount of deviation (χ) while traveling 20m after initial
Travel

10m trial run

● For measuring posture see Travel 2/3.
● Hydraulic oil temp: Within operational range
Hydraulic drift

● Engine stopped
● Park the machine on a grade of 12°, with the sprocket
mm 0 0
in the downhill direction
● Measure the sliding distance for 5 minutes
● For measuring posture see Travel 4.
● Hydraulic oil temp: Within operational range
travel motor
Leakage of

● Engine running at high idle

● Traveling with the sprocket locked mm 13.6 27.2
● Oil leakage amount for one minute with traveling in re-
lief condition
Bucket

● Hydraulic oil temp: Within operational range

tips

mm Max. 600 Max. 900

● Flat and level ground
● Bucket full of earth or with rated load (0.8m³: 1,440 kg)
● Boom horizontal, arm fully retracted and bucket cylin-
cylinder
Arm cylin- Boom

der fully extended mm Max. 20 Max. 27

Work Equipment

● Engine stopped
Hydraulic drift

● Work equipment control lever in neutral position

● Measure total amount of falling for 15 min. by measur-
der

mm Max. 20 Max. 20
ing the falling every 5 min. immediately after initial set-
ting
● Bucket tip lower distance
Bucket cylinder

● Boom cylinder: Cylinder retracting distance

● Arm cylinder: Cylinder extending distance mm Max. 35 Max. 40
● Bucket cylinder: Cylinder retracting distance
● For measuring posture see Work Equipment 1.

5-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Standard Values

Std. value for Permis-

Categ. Item Measurement condition Unit
new machine sible value
● Hydraulic oil temp: Within operation-
al range
● Engine running at high idle
Boom

● Working mode: H
UP sec. 3.6 ± 0.4 Max. 4.8
● Time required for the bucket to raise
from the ground to its stroke end
● For measuring posture see Work
Equipment 2.
● Hydraulic oil temp: Within operation- IN sec. 2.6 ± 0.4 Max. 3.3
al range
Work Equipment Speed

● Engine running at high idle

Work Equipment

● Working mode: H
Arm

● Time required from dumping stroke OUT sec. 2.3± 0.3 Max. 2.8
end to digging stroke end
● For measuring posture see Work
Equipment 3.

● Hydraulic oil temp: Within operation- DIG sec. 2.3 ± 0.4 Max. 2.8
al range
● Engine running at high idle
Bucket

● Working mode: H
● Time required from dumping stroke
DUMP sec. 1.6 ± 0.3 Max. 1.9
end to digging stroke end
● For measuring posture see Work
Equipment 4.

Shop Manual - April 2017 5-7

Standard Values SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Std. value for Judgement

Cat. Item Measurement condition Unit
new machine criteria

● Hydraulic oil temp: Within operational range

● Engine running at low idle
● Working mode: H
● Time required from maneuvering the joystick
Boom

to the moment that the bucket reaches the sec. Max. 1.0 Max. 1.2
ground and begins to push the machine up-
ward, within 50mm off the ground
● For measuring posture see Work Equipment
5.

● Hydraulic oil temp: Within operational range

● Engine running at low idle
Time Delay

● Working mode: H
● Average time required for operating the con-
Arm

sec. Max. 2.0 Max. 2.8

trol lever back and forth till the arm starts to
Work Equipment

move
● For measuring posture see Work Equipment
6.

● Hydraulic oil temp: Within operational range

● Engine running at low idle
● Working mode: H
Bucket

● Average time required for operating the con-

sec. Max. 1.0 Max. 3.6
trol lever back and forth till the arm starts to
move
● For measuring posture see Work Equipment
7.
Cylinders

5 20
Internal Leakage

● Hydraulic oil temp: Within operational range

● Engine running at high idle ml/
Central Swivel

● Leakage amount for one minute with cylinder min

Joint

or travel measured at relief condition 10 50

work equipment and travel
Performance in Combined

simultaneous operation of
Amount of deviation in

● Hydraulic oil temp: Within operational range

● Engine running at high idle
Operations

● Working mode: H
● Travel Speed: Low mm Max. 200 Max. 220
● Amount of deviation measured for 20 m after
traveling about 10 m on a hard level ground
● For measuring posture see Travel 2.

5-8 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Standard Values

Machine postures for measuring (For all models)

Control value: Spool stroke Travel 1: Travel speed (without load)

ZX215-1003002 ZX215-1003005

Swing 1: Swing brake angle, time taken to Travel 2: Travel speed (actual run), Travel de-
start swing, time taken to swing viation

45°

ZX215-1003003 ZX215-1003006

Swing 2: Hydraulic drift of swing Travel 3: Travel deviation

15° x

10m

Sprocket ZX215-1003007

ZX215-1003004

Shop Manual - April 2017 5-9

Standard Values SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Travel 4: Hydraulic drift of Travel Work equipment 3: Arm speed

12°

ZX215-1003008 ZX215-1003011

Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed

equipment

ZX215-1003009 ZX215-1003012

Work equipment 2: Boom speed Work equipment 5: Boom delay

ZX215-1003010 ZX215-1003013

5-10 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Standard Values

Work equipment 6: Arm delay Work equipment 7: Bucket delay

ZX215-1003014 ZX215-1003015

Shop Manual - April 2017 5-11

Standard Values SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

5-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

Testing and Adjusting

6 Testing and Adjusting
6.1 Exhaust Gas Color - Test ......................................................................................... 6-3
6.2 Valve Clearance - Adjust.......................................................................................... 6-5
6.3 Compression Force - Test........................................................................................ 6-8
6.4 Fuel Injection Timing - Test and Adjust .................................................................. 6-10
6.5 Engine Oil Pressure - Test ......................................................................................6-11
6.6 Engine Speed Sensor - Adjust ............................................................................... 6-12
6.7 A/C Compressor Belt Tension - Check and Adjust................................................. 6-13
6.8 Swing Bearing Clearance - Check ......................................................................... 6-14
6.9 Track Tensioning device - Check and Adjust ......................................................... 6-16
6.10 Oil in hydraulic circuits - Test and Adjust ............................................................. 6-18
6.11 Control Oil Circuit Pressure - Check and Adjust .................................................. 6-22
6.12 Solenoid Valve Output Pressure - Test ................................................................ 6-23
6.13 Pilot Valve Output Pressure - Test ....................................................................... 6-25
6.14 Work Equipment and Swing PPC Valves - Adjust ............................................... 6-26
6.15 Hydraulic Drift of Work Equipment - Test ............................................................. 6-27
6.16 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-29
6.17 Oil Leakage Amount - Test................................................................................... 6-30
6.18 Air in Each Component - Purge ........................................................................... 6-34
6.19 Sensors - Test ...................................................................................................... 6-36
6.19.1 Coolant temperature sensor ...................................................................... 6-36
6.19.2 Engine speed sensor ................................................................................. 6-36
6.19.3 Pressure sensor ......................................................................................... 6-37
6.19.4 Fuel level sensor ....................................................................................... 6-37

Shop Manual - April 2017 6-1

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6 TESTING AND ADJUSTING

6.1 Exhaust Gas Color - Test

Testing tools

ID Model Part Name

1 YDJ-2006 Smoke meter
2 SV-2TY Opacimeter

CAUTION

● Hot part can cause burns. Do not

touch any hot parts when you install or
remove a testing tool.

1. Testing with smoke meter

A. Put the filter paper in the smoke meter.
B. Insert the waste gas intake pipe into
the exhaust pipe.
C. S t a r t t h e e n g i n e a n d k e e p t h e
engine running until engine coolant
temperature is within the operational
range.
D. W h e n e n g i n e s p e e d i n c r e a s e s
suddenly or is kept at high idle, direct
ZX425-1004002
exhaust gas through smoke meter to
the filter paper. Fig. 6-1

E. Remove the filter paper from the smoke

meter. Read the smoke value through
the apparatus provided.
F. Remove the testing tools after testing.
Make sure the machine goes back to
its normal state.

Shop Manual - April 2017 6-3

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2. Measuring with opacimeter

A. Mount the opacimeter onto the exhaust
pipe by clamping it to the pipe outlet.

ZX425-1004003

Fig. 6-2

B. Open the opacimeter and preheat it for

about 15 minutes.
C. S t a r t t h e e n g i n e a n d k e e p t h e
engine running until engine coolant
temperature is within the operational
range.
D. W h e n e n g i n e s p e e d i n c r e a s e s
suddenly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.
E. R e m o v e t h e t e s t i n g t o o l s a f t e r ZX425-1004004

measuring. Make sure the machine Fig. 6-3

goes back to its normal state.

6-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.2 Valve Clearance - Adjust

Service standard (unit: mm)

Correction
Location Service Item Standard Value Limits
Method
Intake 0.4 — Adjust
— Valve clearance (engine cold)
Exhaust 0.4 — Adjust

Special tool

Location Tool name and shape Part number Application

Flat-head screwdriver

— MH060008 Adjusting valve clearance

Check and adjust the valve clearance in cold

state according the to the following method:

Checking
1. Remove the rocker arm cover.
2. Turn the No.1 piston or the No.6 piston to
the top dead center(TDC) of compression
stroke by following the procedure below.
● Turn the engine until the TDC line on
the crankshaft pulley is in line with the Aligning point

timing pointer.
● Turn the No.1 piston or the No.6 piston
to the TDC of compression stroke.

Note: When the rocker arm at the intake side

and rocker arm at the exhaust side cannot be
turned by hands, it is indicated that the piston
has reached the TDC of compression stroke.
Turning the engine by one more turn, the TDC
of compression stroke of No.1 piston and No.6 Fig. 6-4
piston swaps.

Shop Manual - April 2017 6-5

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3. When the No.1 piston is at the TDC, adjust

the valve clearance in a sequence marked
with a black dot ( ● ).

Cylinder 1 2 3 4 5 6
Exhaust ● ○ ● ○ ● ○
Intake ● ● ○ ● ○ ○

A. When a feeler gauge is used for such

measurement, resistance to a moving
feeler gauge in the clearance should be
felt.
B. If the feeler gauge moves easily in the
clearance, it is impossible to obtain
accurate result.
4. If the measured value is out of specifica-
tion, readjustment shall be performed
according to the following method.
ZX335-1004008

Fig. 6-5

Adjusting
Adjusting screw
1. In adjustment of valve clearance, loosen
the locknut before adjusting the adjusting
Locknut
screw. A standard clearance is achieved
when resistance to the feeler gauge is felt
when pulling it out from the clearance.

Valve clearance ZX425-1004008

Fig. 6-6

6-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

2. After adjustment, hold the adjusting screw

with a screwdriver to prevent it from turn- setscrew
ing, and tighten the locknut.
Locknut: 21-30 N.m{2.1- 3.1 kgf.m}

3. Go on with the next step until all valve

clearances marked with a black dot ( ● )
have been adjusted
4. Recheck the clearances with the feeler
gauge. Readjustment should be made if
deviation from the standard valve is found. Overarm
WX500-16061321
5. When the engine is carried in vehicle,
Fig. 6-7
using to turn the adjusting screw will
make the job easy.

Shop Manual - April 2017 6-7

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.3 Compression Force - Test

Service Standard
Correction
Location Service Item Standard Value Limits
Methods
Each cylinder (at 200 3.0MPa {30.6kgf/cm2 }
2.5MPa {25.5kgf/cm 2 } Test
Compression rpm)
—
force Differential pressure
— 390 kPa {4kgf/cm2 以下} Test
between cylinders

Special Tool

Symbol Tool Name and Shape Part Number Application

5-85317-001-0 (JKM- Measuring compression

1015) force

Pressure gauge connector

1. Reduction of compression force can be an

indication for engine overhaul.
2. Check the compression force regularly
and pay attention to its variation from time
to time. Understanding the variation of
compression force is helpful for trouble-
shooting. In addition, in a new vehicle or
when new parts are installed for replace-
ment, the pressure may be higher due to
running-in of the piston ring, valve seat, Pressure gauge connector
ZX335-1004010
etc. The pressure will become normal as
the parts wear. Fig. 6-8
3. Before testing, make sure that the engine
oil, start motor and battery are in normal
condition.
4. The vehicle is to meet the following condi-
tions.
A. Preheat the engine until engine coolant
temperature reaches 75~85℃ .
B. Switch off all lamps and auxiliary devices.

C. Place the gear lever in a neutral posi-tion.

6-8 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

5. Remove the entire fuel injector.

6. Cover the fuel injector mounting opening
with a rag.
7. Activate the start motor in order to run the
engine. Check the cloth if it is stuck with
foreign substances.
8. According to the substances (engine oil
and/or coolant) adhering to the cloth, the
WARNING
following factors might be involved.
● When coolant and/or engine oil is found
A. When engine oil is found, it might be attached to the rag, running the engine
improper sealing caused by piston ring. may cause the hot coolant and engine
Check the piston ring. oil to squirt out through the mounting
B. When engine oil and coolant are found, hole of the fuel injector. This is very
it might be cracking of cylinder. Replace dangerous. Never touch or look into the
the crankcase. fuel injector mounting hole when the
engine is running.
9. Mount the gasket and to the fuel injec-
tor mounting hole and fix them with the
injector cap. Install the compression force
gauge.
10. Start the engine and measure the com-
pression force of each cylinder. Calculate
the differential pressure between the
cylinders.
11. When the compression force and the
differential pressure between cylinders
deviate from their limits, inject a small
amount of engine oil through the fuel
injector mounting hole, and measure the
compression force again.
● If the compression force is higher, it is
probably due to worn or damaged piston
ring or cylinder inner surface.
● If the compression force is still low, it is
probably due to stuck valve or improper
seating, or improperly mounted gasket
of cylinder head.

Shop Manual - April 2017 6-9

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.4 Fuel Injection Timing - Test and Adjust

Service standard

Location Service Item Standard Value Limits Correction Method

Fuel injection timing
— 0° — Adjust
(BTDC)

T Tightening torque Unit: N·m (kgf·m)

Symbol Parts Tightened Tightening Torque Remark

-- Timing adjusting bolt 31 (3.2) —

Testing

1. Reverse the crankshaft once to make

it to 90 degrees before top dead center
position. Rotate the crankshaft forward to
make flywheel engraved lines P-P align
with timing pointer. Therefore, check the
No. 1 cylinder to make sure it in the vicinity
of compression top dead center.

WX-16031402

Fig. 6-9

2. If the groove is inconsistent, loosen the two

coupling bolts. Rotate the coupling to make
fuel supply pump align with the coupling-
side groove, and then tighten coupling.
1） Coupling bolts
2）Coupling-side groove
3） Pump-side groove
4） Bolt with pin
Tightening torque:
WX-16031404
Common fuel tank side：54N.m{5.5kgf.m}
Fig. 6-10
Supply pump side: 44N.m{4.5kgf.m}

6-10 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.5 Engine Oil Pressure - Test

Service Standard
Correction
Location Service Item Standard Value Limits
Method
Engine oil pressure at Max. speed, 540kPa｛6kgf/ 49kPa
— Adjust
70~90℃ unloaded cm2｝ (0.5kgf/cm2)

T Tightening torque Unit: N·m (kgf·m)

Location Part Tightened Tightening Torque Remark
1 Engine oil pressure switch 18｛1.8｝ Check when engine is cold.
2 sleeve

1. Remove the engine oil pressure sense (1).

2. Mount the adaptor (2) to where the engine
oil pressure switch has been removed.
Mount an engine oil pressure gauge to the 1
adaptor.
3. P r e h e a t t h e e n g i n e u n t i l e n g i n e o i l
temperature reaches 70-90℃ .
4. Measure respectively the unloaded engine
oil pressure at minimum speed and
maximum speed. If the measured value is
WX-16031403
lower than the specified standard value,
check the entire lubrication system. Fig. 6-11

5. R e i n s t a l l p r e s s u r e s e n s e ( 1 ) a f t e r
measurement. Tighten the pressure
sense(1) to the specific torque.

NOTICE

● The engine must be cold when installing 2

PT1/8
the pressure switch (1).

ZX425-1004017

Fig. 6-12

Shop Manual - April 2017 6-11

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.6 Engine Speed Sensor - Adjust

★ Disconnect accumulator ground wire、
connector for transitional harness of crank
shaft location sensor. And then remove
crank shaft location sensor.

★ Remove the engine speed sensor (1)

before adjusting. Check for presence of
metal chips and for damaged top. Restore
the sensor.
1
WX-16031405

1. Screw on the sensor (1) until its end

contacts with the flywheel housing (2). Fig. 6-13
2. Tighten the sensor (1) with the nut.
Nut: 10N•m {1.0kgfm}
3. Install crank shaft location sensor and
accumulator ground wire.
4. Make sure that the engine speed is
displayed correctly on the monitor after
adjustmen

6-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.7 A/C Compressor Belt Tension - Check and Adjust

Checking
Press the intermediate point of the belt be- Compressor pulley
tween the drive pulley and the compressor
belt pulley with a finger force of about 58.8 A
N(6kgf), and measure deflection (A) of the
belt, which shall be 5~8 mm (0.20 in~0.31in).

Adjusting
★ If the belt deflection is abnormal, adjust it
according to the following procedure. Drive pulley

ZX425-1004019
1. Loosen the bolts (1) and (2).
Fig. 6-14
2. Move the compressor (3) and the bracket
(4) together to adjust belt tension.
3. After positioning the compressor (3),
tighten the bolts (1) and (2).
4. Recheck belt tension after adjustment.

Reference 1
Use a tensiometer to check the compressor
belt tension. 2

New Belt Used Belt 3

637±108 N 441±88.2 N
{65±11 kgf} {45±9 kgf} ZXT425-1004002

Fig. 6-15
Note:
● Check each belt for damage. Check the
V-groove and the V-belt for wear. In addi-
tion, it is especially important to keep the
V-belt free from friction with bottom of the
V-groove.
● Contact local Sany dealer and replace the
belt in case of the following conditions.
● The fan belt has been stretched and
little margin is left for adjustment.
● Cuts or cracks are found in the belt.
● Abnormal sliding or noise.
● When a new belt is mounted, readjust the
belt tension after one hour operation.
Shop Manual - April 2017 6-13
Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.8 Swing Bearing Clearance - Check

Measuring tool

Symbol Part Number Part Name

H 60033930 Dial gauge

★ Follow the steps below when you are

checking the clearance of swing bearing.

CAUTION

● Park your machine on a level ground.

Lower the work equipment to the
ground.
● Do not put your hands or feet under the
undercarriage during testing.
H

1. Fix the dial gauge (H) to the track frame

and make the pointer point the lower end
of the outer race. ZX425-1004020

Fig. 6-16

2. Place the work equipment to the maximum

reach position. Raise the bucket to a
height that the bucket tips and the swing
frame bottom are on the same level.
★ At the moment, the front of upper struc-
ture lowers while the rear rises.

ZX425-1004021

Fig. 6-17

6-14 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

3. Reset the dial gauge (H) to zero.

4. Set the arm almost perpendicular to the
ground and lower the boom until the front
track shoe tilts.

150～200mm
★ At the moment, the front of upper struc-
ture rises while the rear lowers.
5. Read the dial gauge (H).
★ The value indicated by the dial gauge
(H) is the clearance of the bearing.
★ For more information on standard val- ZX425-1004022
ues see “Swing bearing” on page 4-12.
Fig. 6-18
6. Restore the machine to the condition of
step 2. Check the dial gauge (H) to see if it
reads zero.
★ Repeat step 3 through step 5 if the dial
gauge (H) reads a value other than
zero.

Shop Manual - April 2017 6-15

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.9 Track Tensioning device - Check and Adjust

Checking
1. Move your machine forward at a distance
3 2
that is equal to the length of track on the
ground. Keep running the engine at low a
idle. Park your machine slowly.
2. Place a straight edge on top of the track
grousers between the idler (1) and the
front carrier roller (2).
★ A straight edge of angle steel is recom- 1
mended for this purpose as angle steel
bends little. In addition, an L-shaped beam ZX425-1004023

has good performance against bending. Fig. 6-19

3. Measure the maximum clearance (a)
between the upper surface of track and the
bottom of straight edge.
● Max. clearance (a): 10~30 mm(0.4~1.2 in)

Adjusting
★ If the track tension is incorrect, adjustment
is to be made in the following way.
1
1. Decreasing the tension
A. Loosen the valve (1) to discharge
grease. Tighten the valve after dis-
charging. 2

WARNING
ZX425-1004024
● Never loosen the valve more than one
Fig. 6-20
turn. If it is loosened too much, the
highly-pressurized grease behind the
valve can cause it to eject.

B. Recheck the track tension as per the

above method after adjustment.
2. Increasing the tension
A. Add grease through the grease fitting
(2) with a grease gun.
B. Recheck the track tension as per the
above method after adjustment.

6-16 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

★ Add grease until the gap (b) between

the idler guide and the track frame end
becomes zero. If the tension is till low, it
indicates that the pins and bushings are
seriously worn. Replace the pins and bush-
ings, or remove a track shoe.

ZX425-1004025

Fig. 6-21

Shop Manual - April 2017 6-17

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.10 Oil in hydraulic circuits - Test and Adjust

Testing and adjusting tools

ID Part Number Part Name

60038932 Hydraulic Tester
—
B210770000084 Adaptor

★ The hydraulic pressure in work equipment,

swing and travel (hydraulic pump output
pressure) circuits can be viewed on the
monitor.

Testing
1. Preparatory work before measuring

Lower the work equipment to the ground

and stop the engine. After the engine is
stopped, operate the control levers for sev-
eral times in order to release the remaining
pressure in hydraulic circuits. Open the
butterfly nut on the breather valve. Press
the relief button to release pressure in the
hydraulic tank.

A. Remove the plug (1) and plug (2) for

testing the hydraulic pressure.
● Plug (1): For oil circuit of back hydrau-
lic pump
2 1
● Plug (2): For oil circuit of front hydrau-
lic pump
Fig. 6-22
B. Install the priming adaptor and connect
it to the hydraulic tester.
★ Use an oil pressure gauge with a ca-
pacity of 40 MPa {408 kg/cm2}.
C. Start the engine and keep it running
until the hydraulic pressure rises to a
point within the operational range.

6-18 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

2. Testing the unloading pressure

A. Start the engine.
B. Test the hydraulic pressure when the engine is running at high idle and all control levers
are in neutral position.
★ The hydraulic pressure indicated is the pressure when the unloading valve unloads.
3. Testing the relief pressure of work equipment
A. Start the engine and move the cylinder to be measured to its stroke end.
B. Test the hydraulic pressure when the engine is running at high idle and the cylinder is in
relief condition.
★ The hydraulic pressure indicated is the pressure when the main relief valve is in relief con-
dition.
4. Testing the swing relief pressure
A. Start the engine. Reach out the work equipment as far as possible. Lower the work equip-
ment on the ground in order to restrict swinging.
B. Test the hydraulic pressure when the engine is running at high idle and the swing circuit is
in relief condition.
★ The hydraulic pressure indicated is the pressure when the swing motor relief valve is in re-
lief condition.
★ The relief pressure of swing motor is lower than the main relief pressure.

5. Testing the relief pressure of travel circuit

A. Start the engine and lock the travel
mechanism.
Place pin (1) between the sprocket and
the track frame in order to block the
travel mechanism.
B. Test the hydraulic pressure when the
1
engine is running at high idle and the
travel circuit is in relief condition.
★ The hydraulic pressure indicated is
ZXT215-1004004
the pressure when the main relief
Fig. 6-23
valve is in relief condition. When the
travel circuit is in relief condition, the
pressure indicated is always the pres-
sure at high relief.

Shop Manual - April 2017 6-19

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Adjusting
★ The boom unloading valve and safety
valve are not adjustable.
1. Adjusting the main relief pressure (at the
high pressure setting side) 3
★ If the high relief pressure in work equip-
ment and travel circuits is abnormal, adjust
the high pressure setting side of the main
relief valve (3) according to the following
procedure.
A. Disconnect the pilot hose.
B. Loosen the locknut (4). Turn the adjust-
ing screw (5) to adjust the pressure. Fig. 6-24

★ The pressure increases as the retainer

is turned right.
The pressure decreases as the retainer
is turned left.
★ Each turn of the retainer approximates:
12.5 MPa {128 kg/cm2}
Locknut: 53.5±4.9N·m
C. Check the pressure again after adjust -
ment. Test the pressure according to
the procedure described above.
★ Connect the pilot hose before testing
Fig. 6-25
the pressure.
★ Adjustment of the high pressure setting
side will affect the low pressure setting
side. The low pressure setting side is,
therefore, to be adjusted too. 8
2. Adjusting the swing relief pressure 7
★ If the swing relief pressure is abnormal, 6
adjust the swing motor relief valve (6) ac-
cording to the following procedure.

Fig. 6-26

6-20 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

A. Loosen the locknut (7). Turn the adjust-

ing screw (8) to adjust the pressure. 7

★ The pressure increases as the retainer

is turned right. The pressure decreases
as the retainer is turned left.
★ Each turn of the retainer approximates:
6.71 MPa { 68.4 kg/cm2}
Locknut:
78-103 Nm{8.0-10.5 kgm} 8

B. Check the pressure again after adjust- ZX425-1004031

ment. Test the pressure according to Fig. 6-27
the procedure described above.

Shop Manual - April 2017 6-21

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.11 Control Oil Circuit Pressure - Check and Adjust

Checking and adjusting tools

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

6.11.1 Testing
Lower the work equipment to the ground and
1
stop the engine. After the engine is stopped,
operate the control levers for several times
in order to release the remaining pressure in
hydraulic circuits. Open the butterfly nut on 2
the breather valve. Press the relief button to
release pressure in the hydraulic tank.
Fig. 6-28
1. Remove the plug (1) for testing the
hydraulic pressure.
2. Install the priming adaptor and connect it
to the hydraulic tester.
3 2
★ Use an oil pressure gauge with a capacity
of 6 MPa {60 kg/cm2}
3. Start the engine and keep it running until
the hydraulic pressure rises to the opera-
tional range.
4. Test the oil pressure with the engine run-
ning at high idle and all control levers in
neutral position. Fig. 6-29

6.11.2 adjusting
1. If the oil pressure measured is lower than3.5 MPa {36 kgf/cm²}, loosen the locknut (2) and
screw screw in the stud (3). Observe pressure change on the gauge at the same time.
Tighten the nut (2) when desired pressure is reached.

2. Remove all measuring tools after testing. Make sure that the machine returns to its normal
condition.

6-22 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.12 Solenoid Valve Output Pressure - Test

Testing tools

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

★ Make sure that the initial pressure of con-

trol oil circuit is normal before testing the
output pressure of solenoid valve.

● Lower the work equipment to the ground

and stop the engine. After the engine is
stopped, operate the control levers for sev-
eral times in order to release the remaining 1
pressure in hydraulic circuits. Open the
butterfly nut on the breather valve. Press 2
the relief button to release pressure in the 3
hydraulic tank.
4
1. Disconnect the hose of solenoid valve in
5
order to test the pressure at the outlet.

No. Solenoid valves to be tested 6

1 Hi/Lo travel speed valve

7
2 Power Boost valve
3 option valve
8
4 Swing priority valve
5 Bypass Cut valve
6 Arm Regeneration valve
7 Pilot Locking Solenoid valve
8 option valve Fig. 6-30

2. Install a tee to location (A) on each sole-noid valve and connect the hose.
3. Mount the adaptor onto the tee and connect it to the hydraulic tester.
2
★ Use a hydraulic tester with a capacity of 6 MPa {61 kg/cm } .
4. Start the engine and keep it running until the hydraulic oil temperature rises to the
operational range.

Shop Manual - April 2017 6-23

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

5. Run the engine at full speed. Operate

the control levers to open or close each
solenoid valve, and measure the pressure.
★ The function of each solenoid valve can be
checked through the monitor's monitoring
function. (This is a special function of the
monitor.)

Table 1: Travel high speed

Solenoid Valve Output Pressure

OFF (de-energized) 0{0}
ON (energized) 3.9~4.1MPa{39~41kgf/cm2}

Ta b l e 2 : Swing priority valve

Solenoid valve Output pressure

OFF (de-energized) 0{0}
ON (energized) 3.9~4.1MPa{30~39kgf/cm2}

Table 3:PPC lock solenoid valve

Functional state Function
Lock OFF
Hyd lockout control
Unlock ON

6. Remove all measuring tools after measure-

ment. Make sure that the machine returns
to its normal condition.

6-24 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.13 Pilot Valve Output Pressure - Test

Testing tools

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

★ Make sure that the initial pressure of con-

trol oil circuit is normal before testing the
output pressure of pilot valve.

1. Remove the pilot oil pressure switch.

Oil circuit Oil circuit
No. No.
tested tested 2 1
5 4 3
1 Boom DOWN 7 Left swing 6
8 7
2 Bucket DIG 8 Arm IN 10 9

3 Bucket DUMP 9 Arm OUT

4 Boom Up 10 Right swing
5 Left travel
Fig. 6-31
6 Right travel

2. Install the adaptor and connect it to the

hydraulic tester.
★ Use a hydraulic tester with a capacity of 6
MPa{61 kg/cm2}.
3. Start the engine and keep it running until
the hydraulic oil temperature rises to the
operational range.
4. Measure the output pressure when the en-
gine is running at high idle and all control Control lever Hydraulic pressure
levers of the tested circuit are in neutral Neutral position 0{0}
position. Close to the average initial pres-
★ When the measured output pressure reads Full stroke sure of oil control circuit
(See Table of Standard Values)
the following values, the pilot valve is nor-
mal.
5. Remove all the tools after testing. Make
sure that the machine returns to its normal
condition.

Shop Manual - April 2017 6-25

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.14 Work Equipment and Swing PPC Valves - Adjust

★ If the play of work equipment or swing 2

control lever is too big, adjustment can be
made through the following steps.
3
1. Remove the work equipment and swing
pilot valve assembly.
2. Remove the bellows (1). 1

3. Loosen the locknut (2). Screw on the disc

(3) until it contacts with the four heads of
4
plunger (4).
★ Do not move the plunger.
4. When the disc (3) is fixed, tighten the
locknut (2) to the specified torque.
Locknut: 98~127 Nm {10~13 kgm}
5. Restore the bellows (1).
ZX425-1004035
6. Restore the work equipment and swing Fig. 6-32
pilot valve assembly.

6-26 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.15 Hydraulic Drift of Work Equipment - Test

★ If hydraulic drift occurs to the work equip-

ment (cylinder), check it according to the
following procedure. It is to determine
whether the failure is caused by cylinder
seal or control valve.
1. Check the boom and bucket cylinders.
A. Park your machine in an attitude as
shown in the illustration on the right,
and stop the engine.
★ Load the bucket fully with soil or apply
rated load to the bucket.
B. Operate the control levers in order to
keep the boom in the UP position and
the bucket in the DIG position.
● If the lowering speed increases, it is failure ZX425-1004036
of the cylinder seal.
Fig. 6-33
● If nothing changes, it is failure of the con-
trol valve.
★ Operate the control levers with engine
start switch in the ON position.
★ If the pressure in accumulator drops,
charge the accumulator again by run-
ning the engine for about 10 seconds.
2. Check the arm cylinder.
A. Park your machine in an attitude as
shown in the illustration on the right.
The distance between the arm cylinder
and the digging stroke end is 100 mm.
Stop the engine.
B. Operate the control levers in order to
place the arm in the digging position.
● If the lowering speed increases, it is failure
of the cylinder seal.
ZX425-1004037
● If nothing changes, it is failure of the con-
trol valve. Fig. 6-34

★ Operate the control levers with engine

start switch in the ON position.
★ If the pressure in accumulator drops,

Shop Manual - April 2017 6-27

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

charge the accumulator again by running the engine for about 10 seconds.
[Ref.] If the hydraulic drift is caused by failure of the cylinder seal, the reason for increase of low-
ering speed during the above operation is described below:
A. If the machine is set in the above position (where the holding pressure is applied to the head
end), the oil leaks from the head end to the rod end. The pressure in the rod end is increased
as a result.
B. As the pressure in the rod end decreases, the pressure in the head end increases in order to
keep it balanced. This process is repeated until balance is reached at a certain level depend-
ing on the amount of leakage.
C. When the pressure is balanced, the lowering speed decreases. If the control levers are oper-
ated according to the above procedure, the oil circuit in the rod end opens to the drain circuit
(while the head end is closed by a check valve), and the oil flows to the drain circuit from the
rod end. As a result, the lowering speed increases.
3. Check the pilot valve.
Test the hydraulic drift respectively while the accumulator is pressurized and the hydraulic
lockout control in the LOCK/FREE position.
★ Operate the control levers with engine start switch in the ON position.
★ If the pressure in accumulator drops, charge the accumulator again by running the engine
for about 10 seconds.
★ If there is a difference in hydraulic drift between the LOCK position and the FREE position,
it is the failure (internal fault) of the pilot valve.

6-28 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

6.16 Remaining Pressure in Hydraulic Lines - Relieve

Before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor
and the control valve, perform the following steps in order to release the remaining pressure from
the hydraulic circuit.
★ Even if there is no pressure remaining in the swing motor line and the travel motor line, they
will be influenced by the internal pressure of hydraulic tank. The breather valve must therefore
be opened to release pressure prior to operation.
1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button
to release the pressure in hydraulic tank.
2. Turn the engine start switch to the ON position and operate the control levers for several
times.
★ The pilot lock valve must be energized. Operate the control levers with the engine start
switch in the ON position.
★ Operate the control levers 2 or 3 times to release the pressure in the accumulator.
3. Start the engine and keep the engine running at low idle for about 10 seconds in order to
increase the pressure in accumulator. And then stop the engine.
4. Repeat the above step 2 through step 3 several times.

Shop Manual - April 2017 6-29

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.17 Oil Leakage Amount - Test

1. Testing the oil leakage amount of boom

cylinder
A. Start the engine and keep the engine
running until the hydraulic oil tempera-
ture reaches the operational range. And
then fully extend the boom cylinder.
Release the pressure remaining in the
circuits. “Air in Each Component - 1
Purge” on page 6-29.
B. Disconnect the hose (1) on the cylinder
rod end and plug the hose opening.
Take care not to disconnect the hose Fig. 6-35
on the cylinder head end.
C. Start the engine and apply relief pres-
sure to the head end of the cylinder
while the engine is running at high idle.
D. Hold this state for 30 seconds and then
test the amount of oil leakage for one
minute.
E. Make sure that the machine returns to
its normal condition after testing.

2
2. Testing the oil leakage amount of arm
cylinder
A. Start the engine and keep the engine
running until the hydraulic oil tem-
perature reaches a point within the
operational range. Fully extend the arm
cylinder.
Release the pressure remaining in the
circuits. “Remaining Pressure in Hy-
draulic Lines - Relieve” on page 6-29.
B. Disconnect the hose (2) on the cylinder WX485-15112320
head end and blind the hose end with a Fig. 6-36
cap.
Take care not to disconnect the hose
on the cylinder head end.

6-30 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

C. Start the engine and apply relief pres-

sure to the head end of the cylinder
while the engine is running at high idle.
D. Hold this state for 30 seconds. Test the
amount of oil leakage for one minute.
E. Make sure that the machine returns to
its normal condition after testing.

3. Testing the oil leakage amount of bucket

cylinder
A. Start the engine and keep the engine
running until the hydraulic oil tempera-
ture reaches the operational range.
Fully extend the bucket cylinder.
Release the pressure remaining in the
circuits. “Remaining Pressure in Hy-
draulic Lines - Relieve” on page 6-29.
3
B. Disconnect the hose (3) on the cylinder
rod end and blind the hose end with a
cap.
Take care not to disconnect the hose
ZX425-1004040
on the cylinder head end.
Fig. 6-37
C. Start the engine and apply relief pres-
sure to the head end of the cylinder
while the engine is running at high idle.
D. Hold this condition for 30 seconds and
them test the amount of oil leakage for
one minute.
E. Make sure that the machine returns to
its normal condition after testing.

Shop Manual - April 2017 6-31

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Testing the oil leakage amount of swing

motor
A. Fully extend the work equipment. Lower
the bucket on the ground and raise the
machine slightly. Stop the engine.
B. Disconnect the drain hoses (4) and (5).
Blind the hose ends with caps.
4
C. Start the engine and apply relief pres-
5
sure to the head end of the cylinder
while the engine is running at high idle.
Measure the amount of oil leakage
under this condition.
★ Hold the condition described in step 3)
Fig. 6-38
for 30 seconds. Measure the amount
of oil leakage for one minute.
★ After the first testing, turn the upper
structure 180 ° and measure the
leakage again in the same way.
D. Make sure that the machine returns to
its normal condition after testing.

5. Testing the oil leakage amount of the travel

motor
A. Remove the cover of the travel motor.
B. Start the engine and lock the travel.
Insert the pin (1) between the sprocket
and the track frame in order to prevent
traveling.
1
C. Disconnect the drain hose (6) of the
travel motor. Blind the hose end with a
cap.
ZXT215-1004004
D. Start the engine and apply relief pres- Fig. 6-39
sure to the head end of the cylinder
while the engine is running at high idle.
Measure the amount of oil leakage
under this condition.
During testing, misoperation of the con-
trol levers can cause serious accidents.
Make sure that all signals are correct.

6-32 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

★ Hold the condition described in step 4) 6 6

for 30 seconds. Test the amount of oil
leakage for one minute.
★ Rotate the motor slightly. Swap the
positions of the oil distributor and the
cylinder and of the cylinder and piston.
Repeat the testing several times.
E. Make sure that the machine returns to
its normal condition after testing.

Fig. 6-40

Shop Manual - April 2017 6-33

Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6.18 Air in Each Component - Purge

Purging Steps
Item to Be Purged
1 2 3 4 5 6
Job Description Hydraulic Engine Oil Cylin- Swing Travel Operation
Pump Starting der Motor Motor Starting
● Changing the hydraulic oil
○ ○ ○ ○ ○ ○
● Cleaning the filter element
(Note) (Note)
● Replacing the return filter element ○ ○
● Repairing/replacing the hydraulic
pump ○ ○ ○ ○
● Disassembling the suction hose
● Repairing/replacing the control valve ○ ○ ○
● Replacing the oil cylinder
○ ○ ○
● Disassembling the cylinder piping
● Replacing the swing motor
○ ○ ○
● Disassembling the swing motor
● Replacing the travel motor
○ ○ ○
● Disassembling the travel motor

Note: Purge air from the swing motor and travel motor only when the oil in the motor cases is
drained.

1. Purging air from hydraulic pump 6

A. Loosen the air bleeder (1) and check

that oil oozes out through the air
bleeder.
B. Tighten the air bleeder (1) if oil is seen.
Bleeder: 7.8~9.8 Nm{0.8~1.0 kgm}

★ Engine starting precautions

Run the engine at low idle for 10 min-
utes after purging the air according to
the above procedure.
Fig. 6-41

6-34 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Testing and Adjusting

2. Purging air from hydraulic cylinder

A. Start the engine and keep the engine running at low idle for 5 minutes.
B. Raise or lower the boom 4 or 5 times with the engine running at low idle.
★ Be careful not to apply relief pressure. Stop the piston when the piston rod is about 100
mm ahead its stroke end.
C. Repeat step 2) with the engine running at high idle.
D. While running the engine at low idle, move the piston rod to the stroke end and apply relief
pressure.
E. Purge the air from the arm cylinder and bucket cylinder by performing step 2) through step
4).
★ When a new cylinder is installed for replacement, purge the air from the new cylinder be-
fore mounting it to the work equipment. Especially the boom cylinder, once mounted to
the work equipment, its piston rod is unable to reach its stroke end in lowering operation.
Therefore, the air must be purged from the boom cylinder before it is mounted to the work
equipment.

3. Purging air from swing motor

A. Start the engine and run the engine at
low idle.
B. Purge the air from the swing motor by
turning the upper structure slowly.
4. Purging air from travel motor
A. Start the engine and run the engine at low idle.
B. Loosen the bleeder plug (1) and make sure that oil oozes through the plug.
C. If you are sure of the leak, tighten the plug (1).

27.5~35.3 Nm {2.8~ 3.6 kgm}

Shop Manual - April 2017 6-35

 SY385/465H Crawler Hydraulic Excavator
Testing and Adjusting Testing
SY215C9C5K/SY225C9C5K and Hydraulic
Crawler AdjustingExcavator

6.19 Sensors
6.19 Sensor - -Test
Test
6.19.1 Coolant temperature sensor
6.19.1 Checking water temperature 1
sensors

● Put the sensor into a container filled with

organic oil. Body

● Heat the oil to specified level and stir the

oil at the same time.
● Check the resistance value between termi-
nal 1 and body.

50°C 867.2Ω ZX425-1006263

60°C 586.5Ω Fig. 6-42

Standard 80°C 322.2Ω
values 100°C 188.4Ω
106°C 168.4Ω
120°C 116.3Ω

● If measured value exceeds the standard

value given, replace the sensor.

6.19.2 Engine
Checking engine
speed speed sensor
sensor

● Check the resistance between terminals 1

and 2.

Standard value at 25°C 2.3±0.2kΩ

● If measured value exceeds the standard

value given, replace the sensor.

2 1
NOTICE
ZX425-1006264

● If engine speed sensor is not tightened Fig. 6-43

enough, it probably cause sensor out-
put signal failure. The engine speed
sensor must be tightened to specified
torque.

6-36 Shop
Shop Manual Manual
- April 2017 - September 2013 6-39
Testing and Adjusting Crawler Hydraulic Excavator
SY215C9C5K/SY225C9C5K Testing
SY385/465H Crawler and Adjusting
Hydraulic Excavator

6.19.3 Pressure
Checkingsensor
pressure sensor Pressure
Connector Body connector

● Input voltage: 4.75 - 5.25 VDC

● Output voltage: 0.5 - 4.5
● Range of testing pressure: 0-50 Bar

Terminal B

Terminal A Terminal C

WX385-1306002

Fig. 6-44

6.19.4 Fuel level fuel

Checking sensor
level sensor

● Swing the oat up and down to check the Float

angle of rotation of effective radius, which
should be 105°.
Lever
● Swing the oat up and down to check the
vertical distance between the upper posi-
tion and lower position of the float, which
should be 500 mm. Terminal R
Housing
● Move the oat to top end. Use a multime-
ter to check the resistance between sen- Connector
sor terminal R and ground. The resistance
value (Ru) should be not more than 9.6 Ω. ZX425-1006266

● Move the float to the lower end. Check the Fig. 6-45
resistance between sensor terminal R and
ground. The resistance value (Rd) should
be not lower than 86 Ω.

6-40 Shop ManualShop Manual 2013

- September - April 2017 6-37
Testing and Adjusting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

6-38 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Troubleshooting
7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5
7.2 Troubleshooting Types and Steps ........................................................................... 7-6
7.2.1 Troubleshooting types .................................................................................... 7-6
7.2.2 Troubleshooting steps .................................................................................... 7-6
7.3 Connectors .............................................................................................................. 7-8
7.3.1 List of connectors ........................................................................................... 7-8
7.3.2 Connector locations ..................................................................................... 7-12
7.3.3 SWP connectors .......................................................................................... 7-14
7.3.4 A/AMP connectors ....................................................................................... 7-15
7.3.5 DT connectors.............................................................................................. 7-15
7.4 Troubleshooting with an Event Code ..................................................................... 7-17
7.5 Troubleshooting the Electrical System (E-Mode)................................................... 7-31
7.6 Troubleshooting the Hydraulic and Mechanical System (H-Mode) ........................ 7-51

Shop Manual - April 2017 7-1

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

7 TROUBLESHOOTING

WARNING

● Stop the machine on a level ground, and check that lock pins, blocks, and parking
brake are effective.
● When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
● If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
● When disconnecting wiring, always disconnect the negative (–) terminal of the battery
first.
● When removing the plug or cap from a location which is under pressure from oil, water,
or air, always release the internal pressure fi rst. When installing measuring equipment,
be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the fault, to carry out repairs swiftly,
and to prevent reoccurrence of the fault.
When carrying out troubleshooting, important point is to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form
some idea of possible causes of the fault that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If compo-
nents are disassembled immediately any fault occurs:
● Parts that have no connection with the fault or other unnecessary parts will be disassembled.
● It will become impossible to find the cause of the fault.
It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fi xed procedure.
2. Points to ask user or operator:
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the fault occurred?
C. Did the fault occur suddenly, or were there problems with the machine condition before
this?
D. Under what conditions did the fault occur?
E. Had any repairs been carried out before the fault? When were these repairs carried out?

Shop Manual - April 2017 7-3

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

F. Has the same kind of fault occurred before?

3. Check before troubleshooting
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered
to be necessary.
4. Confirming fault
Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a
problem with the method of operation, etc.
When operating the machine to reenact the troubleshooting symptoms, do not carry out any
investigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes
of fault, then use the troubleshooting flowchart to locate the position of the fault exactly.
● The basic procedure for troubleshooting is as follows.
A. Start from the simple points.
B. Start from the most likely points.
C. Investigate other related parts or information.
6. Measures to remove root cause of fault
Even if the fault is repaired, if the root cause of the fault is not repaired, the same fault will oc-
cur again. To prevent this, always investigate why the problem occurred. Then, remove the
root cause.

7-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

7.1 Checks before Troubleshooting

Item Criterion Remedy

1. Check fuel level and type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level Add oil
Lubricating oil, coolant

—
4. Check hydraulic oil strainer — Clean, drain
5. Check swing drive oil level — Add oil
6. Check engine oil level (in oil pan) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
—
mechanical Electrical equipment

1. Check for looseness, corrosion of battery terminal and

Tighten or replace
wiring
2. Check for looseness, corrosion of alternator terminal —
Tighten or replace
and wiring
3. Check for looseness, corrosion of start motor terminal — Tighten or replace
and wiring

1. Check for abnormal noise and smell Repair

equipment

—
Hydraulic,

2. Check for oil leakage — Repair

3. Bleeding air — Bleed air
1. Check battery voltage (with engine stopped) 20-30V Replace
2. Check electrolyte level — Add or replace
Electrics, electrical equipment

3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clips and hanging wiring — Repair
5. Check for wet wires (esp. wet connectors or terminals) — Disconnect con-
nector and dry
6. Check for blown or corroded fuses
7. Check alternator voltage (with engine speed at middle
or higher) — Replace
8. Check operating sound of battery relay (when start After running for Replace
switch is turned ON or OFF) several minutes:
27.5~ 29.5V
Replace
—

Shop Manual - April 2017 7-5

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7.2 Troubleshooting Types and Steps

7.2.1 Troubleshooting types

Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechani-
Code display
cal system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems

7.2.2 Troubleshooting steps

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding
troubleshooting No. and proceed to the explanations for diagnosis.
Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes
and work out the corresponding methods.
1. Read related technical manuals in detail. Have a knowledge of related system, principle of
operation, and structure, function and technical specification of parts.
2. Ask operator
Before checking, ask related person, i.e. the operator for all information about the failure.
A. Current working condition of machine (Whether machine is operated properly).
B. When troubles are found and what kind of operation does machine perform at that time?
C. Development of troubles (Whether troubles are becoming severer or occur for the first
time.)
D. What kind of trouble did machine have before? For example, which parts have been
repaired or replaced?
E. What has been done after troubles take place and how about the reaction?
F. Will the trouble reoccur? Does the trouble occur regularly?
3. Check before starting
Before starting troubleshooting, check the operator's records on operation, maintenance and
service of the machine. Understand whether related personnel has done wrong in operation,
maintenance and service. Check for wrong operation and maintenance at the same time.
Check each part of the machine for abnormalities, such as insufficiency or leakage of oil or
water, looseness and disconnection of pipe line and circuit, and breakage, etc.
Meanwhile, check the electrical system. For example, check the voltage of battery; check for
loose or burnt posts of the power lines; check for blown fuses. Use a multimeter to check the
fuse.

7-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

4. Operate machine by yourself (trial run)

Confirming that the third item above is normal, run startup check on the machine in order to
determine the cause of failure. If the failure cannot be determined, turn off the engine and get
more information from the operator.
5. Perform troubleshooting
Conduct deep analysis and determine the cause of trouble according to the symptoms of the
machine and the information displayed on the monitor.

Remark:
● Never disconnect harness and hydraulic lines when the engine is running. Oil and water un-
der high pressure and high temperature may squirt and cause personal injuries. Shut off then
engine when disconnecting the harness and hydraulic lines.
● Failure codes may not indicate machine trouble. Temporary electrical failure can occur in con-
troller memory, such as low battery output voltage, or open circuit in switch or sensor. There-
fore, make repeated trials to erase the accumulated failure codes from the controller memory
and confirm whether the failure codes are displayed after repeated trials. That is to say, "reoc-
currence" of this trouble is possible.

6. Find out possible causes

Before making a conclusion, check the most possible causes again and try to determine the root
causes of troubles. Make a feasible repair scheme according to your conclusion.

Shop Manual - April 2017 7-7

 Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7.3 Connectors
7.3.1 List of connectors

Connector No Category Number of Pins Component Name

CN-110F Connector 9 to exterior diagnose intrusment
CN-415F Connector 12 to body harness CN-415F
CN-112F Connector 12 to body harness CN-412M
CN-114F Connector 12 to body harness CN-414M
CN-115F Connector 2 to body harness CN-115M
CN-486M Connector 12 to screen harness CN-7-111F
CN-1-110M Connector 6 To Wiper Controller
PF021-00000 Terminal 20 to fuse box
T103 Terminal 1 GND
T104 Terminal 1 GND
CN-466M Connector 6 to 12V covertor
CN-101M Connector 2 Intermediate connector282080-1
CN-102F Connector 2 Intermediate connector282104-1
CN-113M Connector 8 Cab left harnessCN-1-150F
CN-009M Connector 4 Cab left harnessCN-1-009F
CN-114F Connector 8 to air condition
CN-134F Connector 12 Control Switch Harness CN-314M
CN-134M Connector 6 to left right joystick
CN-104M Terminal 1 to body GND
CN-133M Connector 12 Control Switch Harness CN-313F
CN-102M Connector 7 to radio
CN-101F Connector 2 to pilot switch
CN-128M Connector 6 to left left joystick
CN-301M Connector 6 to start switch
CN-302F Connector 3 To Throttle knob
CN-303M Connector 8 to work lamp
CN-304M Connector 8 To Wiper Controller button
CN-305M Connector 8 To Washer Switch
CN-306M Connector 8 to cab lamp
CN-313F Connector 12 to cab harness CN-133M
CN-314M Connector 12 to cab harness CN-134F
CN-105M Connector 2 to boom right lamp
CN-104M Connector 2 to boom left lamp

7-8 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Connector No Category Number of Pins Component Name

CN-415M Connector 2 to driver’s harness CN-115F
CN-415F Connector 12 to driver’s harness CN-115M
CN-412M Connector 12 to driver’s harness CN-115M
CN-414M Connector 12 to driver’s harness CN-114F
CN-410M Connector 9 to driver’s harness CN-110F
CN-503F Connector 14 to exterior diagnose intrusment
CN-417M Connector 9 to ECM diagnose intrusment
CN-484M Connector 3 to driver’s harness CN-7-112F
CN-306F Connector 2 to Seat belt
CN-306M Connector 2 to Seat heat
CN-487F Connector 40 to Controller connector Ａ2
CN-488F Connector 81 to Controller connector Ａ1
T-406 Terminal Glow relay coil
T-407 Terminal Glow relay coil
T-408 Terminal Glow relay contact
T-409 Terminal Glow relay contact
CN-490 Connector 12 To GPS
CN-404M Connector 2 To flat lamp
F-401 Connector 1 To horn
F-402 Connector 1 To horn
CN-504F Connector 4 To DEF Quality sensor
CN-447M Connector 2 To terminal resistance
CN-405F Connector 1 To fuel level sensor
CN-406M Connector 2 To working light
CN-211M Connector 2 To washing motor
CN-423F Connector 3 To swing pressure sensor
CN-422F Connector 3 To arm dumping pressure sensor
CN-428F Connector 3 To arm dig pressure sensor
CN-421F Connector 3 Right travel pressure sensor
CN-420F Connector 3 Left travel pressure sensor
CN-426F Connector 3 Boom up pressure sensor
CN-424F Connector 3 Bucket dig pressure sensor
CN-427F Connector 3 Bucket dumping pressure sensor

Shop Manual - April 2017 7-9

 Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Connector No Category Number of Pins Component Name

CN-425F Connector 3 Boom down pressure sensor
CN-431F Connector 2 High speed travel valve
CN-432F Connector 2 Relief boost solen0id
CN-433F Connector 2 Boom priority-1 electromagnetic valve
CN-434F Connector 2 Swing priority electromagnetic valve
CN-435F Connector 2 Boom priority-2 electromagnetic valve
CN-436F Connector 2 Boom priority-2 electromagnetic valve
CN-437F Connector 2 Pilot electromagnetic valve
CN-445f Connector 96 to ECM
CN-510F Connector 24 De engine
CN-450M Connector 3 Liquid leveel sensor
CN-511F Connector 4 Doc Temp
CN-514F Connector 4 SCR Temp
CN-502F Connector 12 DEF SUPPLY MOUDLE
CN-440M Connector 2 Hydraulic temperature sensor
CN-503F Connector 8 water in fuel
CN-115F Connector 2 to walking alarm
CN-501F Connector 4 Coolent flow valve
CN-446F Connector 3 Front pump pressure sensor

7-10 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Shop Manual - April 2017 7-11

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7.3.2 Connector locations

CN-501F

CN-219F

WX201606140001

Fig. 7-1

7-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

CN-161M

CN-162M

CN-163M

CN-164M

CN-109M

CN-166M

CN-101M

CN-104M

WX201606140002

Fig. 7-2

Shop Manual - April 2017 7-13

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7.3.3 SWP connectors

Male (plug) Female (socket)

7222-7414-40 7123-7414-40 (1 pin)

7222-1424-40 7123-1424-40 (2 pins)

7222-7464-40 7123-7464-40 (6 pins)

7222-7484-40 7123-7484-40 (8 pins)

7222-7564-40 7123-7564-40 (16 pins)

7-14 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

7.3.4 A/AMP connectors

Male (plug) Female (socket)

Part number: 282104-1 Part number: 282080-1 (2 pins)

282105-1 282087-1 (2 pins)

174354-2 174352-2 (3 pins)

7.3.5 DT connectors

Shell (plug) Shell (socket)

A B B A

ZX425-1005023 ZX425-1005024

DT06-2S DT04-2P

Shop Manual - April 2017 7-15

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

A
A B B

C C

DT06-3S DT04-3P (3 pins)

1 6 6 1

2 5 5 2

3 4 4 3

DT06-6S DT04-6P (6 pins)

8 5 8
5

1 4 4 1

DT06-8S DT04-8P (8 pins)

12 7 7 12

1 6 6 1

DT06-12S DT04-12P (12 pins)

7-16 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

7.4 Troubleshooting with an Event Code

Information contained in troubleshooting table ............................................................. 7-21

01 HCU system failure.................................................................................................. 7-22
02 TRU communication controller system failure ......................................................... 7-23
03 Engine oil pressure low ........................................................................................... 7-24
04 Fuel level low ........................................................................................................... 7-25
05 Coolant temperature high ........................................................................................ 7-26
06 Air cleaner plugged .................................................................................................. 7-27
08 Engine speed high ................................................................................................... 7-28
09 Power supply voltage abnormal .............................................................................. 7-29
10 Auto deceleration/acceleration control failure .......................................................... 7-30

Shop Manual - April 2017 7-17

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Information contained in troubleshooting table

Failure code Code Failure The monitor displays failure information

Displayed on monitor P805/ description corresponding tot he code.
Failure alarm condition Motor common error ；Inspect Task pause

Controller reaction Alarm output

Machine symptom ——

Causes Engine running in an unusual status

Possible causes and standard value under

please connect the dignose nstrument to plunge for

1 Engine error error captured plunge in the cab
normal condition

2 ，

Related circuit diagram

This is part of the circuit diagram which shows the portion where the failure occurred.

7-18 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Failure code E102 Controller inside temp. abnormal

Failure code Code

Failure description motor serious error
Displayed on monitor P806/
Failure alarm condition There are some serious fault in engine
Controller reaction Alarm output
Machine symptom Keep on running

there are something wrong in the system,for:

Causes
aftertreatment electric system .
Possible causes and standard value

please connect the dignose nstrument to plunge for

1 Engine error
under normal condition

error captured plunge in the cab

Shop Manual - April 2017 7-19

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Failure code E103 Sensor power abnormal

Failure code Code Failure

Double loop pilot pressure errorl
Displayed on monitor H210/ description
Failure alarm condition
Controller reaction Alarm output
Machine symptom Keep on running
Possible causes and standard value under

Causes

1
normal condition

7-20 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Failure code E104 Memory failure

Failure code Code Failure

DEF alarm level1
Displayed on monitor P803/ description
Failure alarm condition GPS lock memory failure
Controller reaction Alarm output
Machine symptom Keep on running
Possible causes and standard value under

Causes

1
normal condition

Shop Manual - April 2017 7-21

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Failure code P804 DEF failure

Failure code Code Failure

DEF alarm level2
Displayed on monitor P804/ description

Failure alarm condition

Controller reaction

Machine symptom

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1
normal condition

7-22 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Failure code P303 Coolent level overlow

Failure code Code Failure

Coolent level overlow
Displayed on monitor P303/ description
Failure alarm condition Coolent level overlow
Controller reaction Alarm output
Machine symptom Normal action is slow.

Standard value in normal condition Reference value in

Causes
Possible causes and standard value under

troubleshooting

1 Coolent level overlow Please add antifreeze

normal condition

Shop Manual - June 2016 7-23

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Failure code P301 Water temp high

Failure code Code Failure

water temp over high
Displayed on monitor P301/ description
Failure alarm condition The water temperature higher than 95 ℃
Controller reaction Alarm output
Machine symptom ——.

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1 Thermostat is not open Check that the thermostat is open.

normal condition

2 Fan belt loose Check whether the fan belt tension

3 Fan fault Check the cooling fan for damage

4 A lack of coolant Check whether the lack of coolant

7-24 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Failure code H402 Hyd oil temp. high

Failure code Code Failure
Hyd oil temp. high
Displayed on monitor H402/ description
Failure alarm condition The hydraulic oil temperature higher than 90℃
Controller reaction Alarm output
Machine symptom Normal action is slow.

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1 Thermostat is not open Check that the thermostat is open.

normal condition

2 Fan belt loose Check whether the fan belt tension

3 Fan fault Check the cooling fan for damage

4 A lack of coolant Check whether the lack of coolant

Shop Manual - April 2017 7-25

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Failure code P101 Engine oil pressure low

Failure code Code Failure

Engine oil pressure low
Displayed on monitor P101/ description
Failure alarm condition The ECM send low oil pressure alarm signal
Controller reaction Alarm output. Engine is forced to run at low idle.
Machine symptom Engine speed decreases to low idle.

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1 Lack of oil Stop engine, check the gngine oil level.

normal condition

7-26 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Failure code P301 Coolant temp. high

Failure code Code Failure

Coolant temp. high
Displayed on monitor P301/ description
Failure alarm condition Coolant temperature greater than 105℃ .
Controller reaction Alarm output, Engine speed forced to reduce to idle
Machine symptom Engine speed reduce to idle

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1 Thermostat is not open Check that the thermostat is open.

normal condition

2 Fan belt loose Check whether the fan belt tension

3 Fan fault Check the cooling fan for damage

4 A lack of coolant Check whether the lack of coolant

Shop Manual - April 2017 7-27

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Failure code P401 Fuel level low

Failure code Code Failure

Fuel level low
Displayed on monitor P401/ description
Failure alarm condition Fuel level less than 10% and the delay time for 10 sec.
Controller reaction Alarm output
Machine symptom ——

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1 Fuel level less than 10% Please add fuel.

normal condition

7-28 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Failure code P501 Air filter blockage

Failure code Code Failure

Air filter blockage
Displayed on monitor P501/ description
Failure alarm condition Blocked air filter pressure switch is closed, lead to report to the alarm
Controller reaction Alarm output
Machine symptom ——

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting

1 Air filter blockage Check the air filter to remove dust, clean filter strainer
normal condition

Shop Manual - April 2017 7-29

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Failure code P601 Water separator abnormal

Failure code Code Failure

Water separator abnormal
Displayed on monitor P601/ description
Failure alarm condition RAM/EEPROM failure；Inspect Task pause
Controller reaction Alarm output
Machine symptom The oil-water separator water level to exceed warnning line

Standard value in normal condition Reference value in

Possible causes and standard value under

Causes
troubleshooting
oil-water separator water level is
1 Open the oil-water separator drain switch, draining water
too high
normal condition

7-30 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

7.5 Troubleshooting the Electrical System (E-Mode)

Table of fuse box connections ...................................................................................... 7-32

Information contained in troubleshooting table ............................................................. 7-33
E-1 Engine does not start ............................................................................................. 7-34
E-2 Engine runs rough.................................................................................................. 7-36
E-3 Engine does not stop ............................................................................................. 7-37
E-4 Auto deceleration fails ............................................................................................ 7-38
E-5 Preheating function fails......................................................................................... 7-39
E-6 All equipment do not work ...................................................................................... 7-40
E-7 Boom-up operation slow and weak ........................................................................ 7-41
E-8 Arm operation slow and weak ................................................................................ 7-42
E-9 Bucket operation slow and weak ........................................................................... 7-43
E-10 Travel operation slow and weak........................................................................... 7-44
E-11 Monitor blank........................................................................................................ 7-45
E-12 Monitor displays nothing ...................................................................................... 7-46
E-13 Double speed travel fails...................................................................................... 7-47
E-14 Engine coolant temperature reading incorrect ..................................................... 7-48
E-15 Fuel level reading incorrect .................................................................................. 7-49
E-16 Wiper does not work ............................................................................................ 7-50

Shop Manual - April 2017 7-31

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Information contained in troubleshooting table

Failure information Machine symptom

Related information Failure occurred and troubleshooting information

Standard value in normal condition

Causes
Possible causes and standard value under normal condition

Reference value in troubleshooting

< Contents>
● A standard value under normal condition can be
used to judge a possible cause.
● A reference value can be used to approve/disap-
The possible causes of failure prove the above judgement.
are to be discussed. (Instead < Failure of wiring harness>
1 of priority, the sequential num- ● Open circuit
bers are just used for easy Improper contact with connector or open circuit of
identification.) wiring harness
● Faulty grounding
A non-grounding wire is grounded.
● Short circuit
A wire has mistaken contact with a 24 V electric
circuit.

Shop Manual - April 2017 7-33

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-1 Engine does not start

Failure information Engine misfires (engine does not crank).

Related information

Standard value in normal condition

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF position before troubleshooting. Keep
Lower power the switch in the OFF position while troubleshooting is performed.
1
of battery
Battery voltage Volts ≥ 24V
★ Turn the engine start switch to the OFF position before troubleshoot-
Internal failure ing. Keep the switch in the OFF position while troubleshooting is per-
2 of engine start formed.
switch OFF: Between lines 22# and 11# Resistance ≥ 1M
ON: Between lines 22# and 11# value ≤1 Ω
Possible causes and standard value under normal condition

★ Turn the engine start switch to the OFF position before troubleshooting. Keep
the switch in the OFF position while troubleshooting is performed.
Failure of pilot Hydraulic lockout control FREE: Between lines
3 ≤ 1M Ω
switch 105 # and 0# Resistance
Hydraulic lockout control LOCKED: Between value
≥1 Ω
lines 105 # and 0#
★ Turn the engine start switch to the OFF position. Keep the engine running dur-
ing troubleshooting. (If all power supplies, grounding, generated signals and
engine inputs, except engine output, are normal, it should be the failure of en-
Failure of start gine start motor.)
4
motor Engine start motor Start switch Volts
Power supply: terminal B and ground 20—30V
Start
Between engine input S and ground 20—30V
★ Turn the engine start switch to the OFF position before troubleshooting. Keep
the switch in the OFF position while troubleshooting is performed.
Between start switch line 22# and start motor
≤1 Ω
Open circuit of terminal B
5
wiring harness Between start switch line 11# and start relay ter- Resistance
≤1 Ω
minal SW value
Between start relay terminal L and safety relay
≤1 Ω
terminal S
Failure of fuse Between battery terminal "+" (line 20#) and con- Resistance
6 trol dial line 22#. ≤1 Ω
F1 value
Short circuit of ★ Turn the engine start switch to the OFF position before troubleshooting. Keep
wiring harness the switch in the OFF position while troubleshooting is performed.
7
(grounding Between start relay terminal SW and ground Resistance ≥1M Ω
failure) Between engine input s and ground value ≥1M Ω
★ Turn the engine start switch to the OFF position before troubleshooting. Turn
Internal failure the switch to the ON position and keep it in the ON position while troubleshoot-
8 ing is performed.
of alternator
Between engine terminal P and ground Volts ≤ 1V

7-34 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Shop Manual - April 2017 7-35

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-2 Engine runs rough

Failure information Engine runs rough.

Related information Engine speed reading is displayed on the monitor.

Standard value in normal condition

Causes
Possible causes and standard value under nor-

Reference value in troubleshooting

★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
Open circuit of
1
wiring harness Unplug the controller connector and check Resistance
the resistance between controller pins 38 2.3±0.2 K Ω
value
and 19.
mal condition

★ Turn the engine start switch to the OFF position before troubleshooting.
Internal failure Keep the switch in the OFF position while troubleshooting is performed.
2
of sensor Unplug the connector and check the resis- Resistance
2.3±0.2 K Ω
tance between CN-448M A and B. value
★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit of Keep the switch in the OFF position while troubleshooting is performed.
3
wiring harness
Between CN-448M A and ground Resistance value ≥ 1M Ω
Internal failure No troubleshooting can be done since it is an internal failure. (If a failure is not
4
of controller caused by the above factors, it should be the failure of controller.)
5

Controller
CN-448M
（S-2） Speed sensor

Speed sensor 38 A Signal

input signal

GND 19 B GND

Operator station Chassis harness

ZX425-1005041

Fig. 7-4

7-36 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-3 Engine does not stop

Failure information Engine does not stop.

The engine shuts down without power-cut delay when engine
Related information
start switch is turned to the OFF position.

Standard value in normal condition

Possible causes and standard value under normal

Causes
Reference value in troubleshooting
Failure of ba- The battery is good if a click of battery relay contact can be heard when the
1
ttery relay engine start switch is operated. The start switch is turned ON-START-ON.
★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit Keep the switch in the OFF position while troubleshooting is performed.
2 (breakdown) of
Resistance
condition

flywheel diode Between battery relay lines 20# and 21# ≥ 1M Ω

value

Internal failure No troubleshooting can be done since it is an internal failure. (If a failure is not
3
of controller caused by the above factors, it should be the failure of controller or program.)

K-1
Battery relay

20 21
B1 B2

D-2
- + - + 15

BAT-1 Battery
ZX425-1005042

Fig. 7-5

Shop Manual - April 2017 7-37

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-4 Auto deceleration fails

Failure information Engine fails to run at auto deceleration.

Under the mode of auto deceleration, engine speed does
Related information
not drop when the joystick is in the neutral position.

Standard value in normal condition

Causes
Possible causes and standard value under

Reference value in troubleshooting

★ Turn the engine start switch to the OFF position before trouble-
shooting. Restart the engine and keep the engine running while
troubleshooting is performed.
Pressure signal is sent with
1 Sensor failure
normal condition

the control lever in neutral 0 KG

Pressure
position.
value
Pressure signal is sent with
0 ～ 37 KG
the control lever operated.
2 Failure of pressure switch Check the state of pressure switch.
● No troubleshooting can be done since it is an internal failure.
3 Controller failure (If a failure is not caused by the above factors, it should be the
failure of controller or program.)
4
5

7-38 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-5 Preheating function fails

Failure information Engine preheating function fails.

Related information

Standard value in normal condition

Possible causes and standard value under normal condition

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF position before troubleshooting.
Failure of preheat Keep the switch in the OFF position while troubleshooting is performed.
1
fuse
Resistance
Between line 21# and preheat relay pin (contact) 3# ≤1 Ω
value
Failure of preheat When the preheating function is activated, the preheat relay is normal if a
2
relay click of preheat relay is heard. The preheat switch is turned OFF-ON-OFF.
★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
Failure of preheat
3 Between lines 16# and 17#, with preheat switch off ≥ 1M Ω
switch
Resistance
value
Between lines 16# and 17#, with preheat switch on ≤1 Ω

★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit of lead Keep the switch in the OFF position while troubleshooting is performed.
4
(grounded)
Resistance Ω
Between preheat relay pin (contact) 3# and ground ≥ 1M
value
5

Battery S0 TERMINAL
HEAT
B BR ACC R1 R2 C

F1 20A OFF

0 20 Start switch ON
START
22 13
- + - +

Preheat relay switch

Battery relay
F15 10A 1 2 3 45

1 2 3 45
21
45
1 2
75
3 45
21 95
Preheat relay
F13 160A
1 2 3 45
21
21
1 2 3 45
1 2 3 45
95 0 16 17 GR-1 GLOW PLUG

Preheater
Chassis harness Operator station Chassis harness

ZX425-1005044

Fig. 7-6

Shop Manual - April 2017 7-39

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-6 All equipment do not work

Failure information No operation can be made after the machine is started.

Related information

Standard value in normal condition

Possible causes and standard value under nor-

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF position before troubleshooting.
Restart the engine and keep the engine running while troubleshooting is
performed.
Failure of safety Lockout con- Resistance
1 Item checked
lockout switch trol value
mal condition

LOCK ≤1 Ω
Between lines 105# and 41#
FREE ≥ 1M Ω
★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit of Keep the switch in the OFF position while troubleshooting is performed.
2
lead (grounded) Resistance
Between 105# and ground ≥ 1M Ω
value
★ Turn the engine start switch to the OFF position before troubleshooting.
Failure of internal
Keep the switch in the OFF position while troubleshooting is performed.
3 coil (pilot lockout
Resistance
solenoid valve) Between 1 and 2 of solenoid valve About 34 Ω
value

Lockout relay Start switch

TERMINAL B BR ACC R1 R2 C
HEAT
OFF
ON
START
1 2 3 45 11
Pilot switch
1 2 3 45

0 105 41 11 12

B L SW S
24V

0
E

Start relay
ZX425-1005045

Fig. 7-7

7-40 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-7 Boom-up operation slow and weak

Boom motion is slow and weak during operation of

Failure information
machine.
Pressure signal reads on the monitor during boom
Related information
operation.

Standard value in normal condition

Causes
Possible causes and standard
value under normal condition

Reference value in troubleshooting

★ Turn the engine start switch to the OFF position before troubleshooting.
Restart the engine and keep the engine running while troubleshooting
1 Sensor failure is performed.
Pilot pressure is 0 kg when the joystick is in neutral position.
Pilot pressure is 0-37 kg when the joystick is in operated.
Engine speed ab- Check engine speed and the ampere of proportional solenoid valve. Cali-
2
normal brate engine speed if it is too low.
No troubleshooting can be done since it is an internal failure. (If a failure
3 Controller failure
is not caused by the above factors, it should be the failure of controller.)

Controller
CN-400F Boom-up
CN-127F pressure sensor
206
70 1 Signal
Monitor

(CNA bus) 73 0 2 GND

WX385-1307008

Fig. 7-8

Shop Manual - April 2017 7-41

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-8 Arm operation slow and weak

Failure information Arm motion is slow and weak during operation of machine.
Related information Pressure signal reads on the monitor during arm operation.

Standard value in normal condition

Causes
Possible causes and standard

Reference value in troubleshooting

value under normal condition

★ Turn the engine start switch to the OFF position before troubleshooting.
Restart the engine and keep the engine running while troubleshooting
is performed.
1 Sensor failure
Pilot pressure is 0 kg when the joystick is in neutral position.
Pilot pressure is 0-37 kg when the joystick is in operated.
Engine speed ab- Check engine speed and the ampere of proportional solenoid valve. Cali-
2
normal brate engine speed if it is too low.
No troubleshooting can be done since it is an internal failure. (If a failure
3 Controller failure
is not caused by the above factors, it should be the failure of controller.)

Controller
CN-400F
Arm-in
CN-123F pressure sensor
202
52 1 Signal
Monitor
(CNA bus) 54 0 2 GND

WX385-1307009

Fig. 7-9

7-42 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-9 Bucket operation slow and weak

Bucket motion is slow and weak during operation of ma-

Failure information
chine.
Pressure signal reads on the monitor during bucket opera-
Related information
tion.

Standard value in normal condition

Causes
Possible causes and standard

Reference value in troubleshooting

value under normal condition

★ Turn the engine start switch to the OFF position before troubleshooting.
Restart the engine and keep the engine running while troubleshooting
is performed.
1 Sensor failure
Pilot pressure is 0 kg when the joystick is in neutral position.
Pilot pressure is 0-37 kg when the joystick is in operated.
Engine speed ab- Check the engine speed and the ampere of proportional solenoid valve.
2
normal Calibrate engine speed if it is too low.
No troubleshooting can be done since it is an internal failure. (If a failure
3 Controller failure
is not caused by the above factors, it should be the failure of controller.)

Controller
CN-400F
Bucket-dig
CN-125F pressure sensor
204
50 1 Signal
Monitor
(CNA bus) 54 0 2 GND

WX385-1307010

Fig. 7-10

Shop Manual - April 2017 7-43

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-10 Travel operation slow and weak

Travel motion is slow and weak during operation of ma-

Failure information
chine.
Pilot pressure signal reads on the monitor during travel
Related information
operation.

Standard value in normal condition

Causes
Possible causes and standard value

Reference value in troubleshooting

★ Turn the engine start switch to the OFF position before troubleshooting.
Restart the engine and keep the engine running while troubleshooting is
under normal condition

performed.
1 Sensor failure
Pilot pressure is 0 kg when the joystick is in neutral position.

Pilot pressure is 0-37 kg when the joystick is in operated.

Engine speed Check the engine speed and the ampere of proportional solenoid valve. Cali-
2
abnormal brate engine speed if it is too low.

Failure of con- No troubleshooting can be done since it is an internal failure. (If a failure is not
3
troller caused by the above factors, it should be the failure of controller.)

Left travel
CN-120F pressure sensor
200
1 Signal

Controller
0 2 GND
CN-400F

49 Right travel
CN-121F pressure sensor

201
Monitor 67 1 Signal
(CAN总线）

54 0 2 GND

WX385-1307011

Fig. 7-11

7-44 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-11 Monitor blank

Failure information Monitor is blank when the excavator is powered on.

Related information

Standard value in normal condition

Causes
Reference value in troubleshooting
Possible causes and standard value under normal condition

★ Turn the engine start switch to the OFF position before troubleshooting. Turn
the switch to the ON position and keep it in the ON position while troubleshoot-
Failure of ing is performed.
1
fuse
Between line 21# and ground About 24V
Volts
Between line 29# and ground About 24V
★ Turn the engine start switch to the OFF position before troubleshooting. Keep
the switch in the OFF position while troubleshooting is performed.
Breakage of Between CN-400F pin 60, DT06-3S pin A and
2
lead ≤1 Ω
CN-401F 77 Resistance
Between CN-400F pin 78, DT06-3S pin B and value
≤1 Ω
CN-401F 58
★ Turn the engine start switch to the OFF position before troubleshooting. Keep
the switch in the OFF position while troubleshooting is performed.
Short circuit
3
of lead Between CN-400F pin 60 and CN-401F pin 58 ≥ 1M Ω
Resistance
Between CN-400F pin 78, DT06-3S pin A and CN- value Ω
≥ 1M
401F 77
Monitor No troubleshooting can be done since it is an internal failure. (If a failure is not
4
failure caused by the above factors, it should be the failure of monitor.)

CAN+ CAN-

To SECD-5I7D
A B
CN-400F DT 06-3S
CN-405F
DT04-3P 120 ohms
CAN+
60 A

CAN-
78 B

CN-401F

CAN+
77

CAN-
58
WX385-1307012

Shop Manual - April 2017 7-45

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-12 Monitor displays nothing

When the machine is powered on, the monitor illumi-

Failure information
nates but displays nothing.
Related information

Standard value in normal condition

Causes
Reference value in troubleshooting
Possible causes and standard value under normal condition

★ Turn the engine start switch to the OFF position before troubleshooting.
Failure of resis- Keep the switch in the OFF position while troubleshooting is performed.
1
tance Resistance
Between 1 and 2 of M09 120 Ω
value
★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
Between CN-400F pin 60, DT06-3S pin A Ω
2 Breakage of lead ≤1
and CN-401F 77 Resistance
Between CN-400F pin 78, DT06-3S pin B value
≤1 Ω
and CN-401F 58
★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
Short circuit of Between CN-400F pin 60 and CN-401F pin Ω
3 ≥ 1M
lead 58 Resistance
Between CN-400F pin 78, DT06-3S pin A and value
≥ 1M Ω
CN-401F 77
No troubleshooting can be done since it is an internal failure. (If a failure is
Failure of moni-
4 not caused by the above factors, it should be the failure of monitor or con-
tor or controller
troller.)

CAN+ CAN-

To SECD-5I7D
A B
CN-400F DT 06-3S
CN-405F
DT04-3P 120 ohms
CAN+
60 A

CAN-
78 B

CN-401F

CAN+
77

CAN-
58
WX385-1307012

Fig. 7-12

7-46 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-13 Double speed travel fails

Machine always travels at low speed during opera-

Failure information
tion. High speed travel fails.
High/Low travel speed shifts by pressing the Hi/Lo
Related information
travel button on the monitor.

Standard value in normal condition

Causes
Possible causes and standard value under normal

Reference value in troubleshooting

Failure of ★ Turn the engine start switch to the OFF position before troubleshooting. Keep
double- the switch in the OFF position while troubleshooting is performed.
1 speed travel
Resistance
solenoid Between CN451F 607 and 0 About 34 Ω
valve value
★ Turn the engine start switch to the OFF position before troubleshooting. Keep
condition

the switch in the OFF position while troubleshooting is performed.

Breakage of Between CN451F 609 and controller SEHC-281A- Ω
2 ≤1
lead J2 signal collecting port pin 82 Resistance
Between CN451F 0 and controller SEHC-281A-J2 value
≤1 Ω
signal collecting port pin 114
★ Turn the engine start switch to the OFF position before troubleshooting. Keep
the switch in the OFF position while troubleshooting is performed.
3 Short circuit
Resistance Ω
of lead Between CN451F 607 and ground ≥ 1M
value
4

Controller
Hi-speed
CN-451F travel valve
607
Position signal 82 A Hi-speed
collecting port travel signal

0
GND 114 B GND

Operator station Chassis harness

WX385-1307013

Fig. 7-13

Shop Manual - April 2017 7-47

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-14 Engine coolant temperature reading incorrect

Engine coolant temperature sensor is unable to correctly reflect

Failure information
current temperature.
Related information Coolant temperature reads on the monitor.

Standard value in normal condition

Causes
Possible causes and standard value under normal condition

Reference value in troubleshooting

Standard reference values of engine coolant temperature sensor are shown
below.
50℃ 80Ω
Failure of coolant 60℃ 56.3 Ω
1 temperature sen- Ω
80℃ 29.5
sor
100℃ 16.5 Ω
106℃ 14.3 Ω
120℃ 10 Ω
★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
2 Breakage of lead
Resistance
Between line 510# and controller pin 30 ≤1 Ω
value
★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit of Keep the switch in the OFF position while troubleshooting is performed.
3
lead (grounded) Resistance
Between line 510# and ground ≥ 1M Ω
value

Controller

F-407

Temperature signal 510

33 A
collecting port
0
1 B

Operator station Chassis harness

WX385-1307014

Fig. 7-14

7-48 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

E-15 Fuel level reading incorrect

Engine fuel level sensor is unable to correctly reflect

Failure information
current fuel level.
Related information Fuel level reads on the monitor.

Standard value in normal condition

Causes
Possible causes and standard value under normal

Reference value in troubleshooting

★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
Fuel level sen- Resistance
1 Pin Fuel level
sor failure value
Full (upper limit) About 10 Ω
Between line 509# and ground
85-95 Ω
condition

Empty (lower limit)

★ Turn the engine start switch to the OFF position before troubleshooting.
Breakage of Keep the switch in the OFF position while troubleshooting is performed.
2
lead Resistance Ω
Between line 509# and controller pin 11 ≤1
value
★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit of Keep the switch in the OFF position while troubleshooting is performed.
3
lead (grounded) Resistance Ω
Between line 509# and ground ≥ 1M
value

Controller
Fuel
CN-413M level sensor
509
Position signal 11 Fuel level
collecting port Signal

0
GND GND

Operator station Chassis harness

WX385-1307015

Fig. 7-15

Shop Manual - April 2017 7-49

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E-16 Wiper does not work

Failure information Wiper operation fails.

Related information

Standard value in normal condition

Possible causes and standard value under normal con-

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF position before troubleshooting.
Internal failure Keep the switch in the OFF position while troubleshooting is performed.
1
of wiper motor Resistance
Between wiper line 25# and ground >10
value
★ Turn the engine start switch to the OFF position before troubleshooting.
Keep the switch in the OFF position while troubleshooting is performed.
Breakage of Between F6 25 and CN-107M 2 ≤1 Ω
dition

2
lead Resistance
Between wiper switch line 35L# and CN-107M 5 ≤1 Ω
value
Between wiper switch line 35H# and CN-107M 4 ≤1 Ω
★ Turn the engine start switch to the OFF position before troubleshooting.
Short circuit Keep the switch in the OFF position while troubleshooting is performed.
3 oflead (groun-
Between the harness connecting F6 25 with CN- Resistance
ded) ≥ 1M Ω
107M 2 and the ground value

CN-114M
S-5
Washer motor
M-1
21 F6-5A 25 37

CN-107M
S-3 Wiper motor

M-2
36

35H M
35L

0
Control switch Operator station

ZX425-1005052

Fig. 7-16

7-50 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

7.6 Troubleshooting the Hydraulic and Mechanical System (H-Mode)

A Schematic of hydraulic and mechanical systems ...................................................... 7-52

Information contained in troubleshooting table ............................................................. 7-53
H-1 Work equipment speed slow, or swing and travel speeds slow ............................ 7-54
H-2 Engine speed drops sharply or engine stalls ........................................................ 7-55
H-3 Work equipment, swing, and travel systems do not work ..................................... 7-56
H-4 Abnormal noise in hydraulic pump ........................................................................ 7-57
H-5 Auto deceleration not functioning.......................................................................... 7-58
H-6 Boom speed slow ................................................................................................. 7-59
H-7 Arm speed slow .................................................................................................... 7-60
H-8 Bucket speed slow ................................................................................................ 7-61
H-9 Work equipment cylinder fails in separate operation ........................................... 7-62
H-10 Work equipment cylinder drifts excessively ........................................................ 7-63
H-11 Work equipment moves sluggishly .................................................................... 7-66
H-12 Other work equipment moves while single oil circuit is relieved ......................... 7-66
H-13 Travel speed drops considerably during swing-plus-travel operation ................. 7-67
H-14 Machine deviates during travel ........................................................................... 7-68
H-15 Travel speed is low ............................................................................................. 7-70
H-16 Machine is not steered well or steering power is low.......................................... 7-71
H-17 Travel speed cannot be changed........................................................................ 7-72
H-18 Travel system fails (only at one side).................................................................. 7-73
H-19 Swing operation fails........................................................................................... 7-74
H-20 Swing acceleration poor or swing speed low ...................................................... 7-76
H-21 Excessive swing distance upon swing stoppage ................................................ 7-78
H-22 large shock is produced when upper structure stops swinging .......................... 7-79
H-23 High abnormal noise upon swing stoppage ........................................................ 7-80
H-24 Excessive swing drift .......................................................................................... 7-81

Shop Manual - April 2017 7-51

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

A Schematic of hydraulic system and mechanical system

PILOT VALVE - L PILOT VALVE - TRAVEL PILOT VALVE - R

ARM SWING TRAVEL TRAVEL

BOOM BUCKET
(LEFT) (RIGHT)

LOWER
RAISE
RIGHT

BWD
OUT

DUMP
BWD

FWD
LEFT

CURL
FWD
IN

LOCK
(PILOT VALVE )

16
BOOM PRIORITY

1 2 3 4 15
5 6 7 8 9 10 11 12 BUCKET CONFLUENCE
14
SWING PRIORITY
13
VARIABLE SPEED
(TRAVEL)
ACCUMULATOR

1
2

19 20

17 18

REGULATOR REGULATOR

SERVO SERVO
MECHANISM MECHANISM

P1 P2
M
FRONT REAR

ZX225-1105039

Shop Manual - April 2017 7-89

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● The system schematic is a simplified hydraulic circuit schematic, which can be used as a ref-
erence to the hydraulic system and the mechanical system.

Sa: SAFETY VALVE

Su: SUCTION VALVE
S&S: SAFETY&SUCTION

1 BACKUP VALVE
CONFLUENCE
BUCKET
CONFLUENCE 15
ARM HOLD

1 S&S ARM VALVE

S&S 2
VALVE

REG. VALVE
1 ARM 2 VALVE
2
14
BUCKET
CYLINDER

BUCKET S&S BUCKET 12 S&S BACKUP

S&S
10 11 VALVE S&S VALVE
BACKUP ACTUATOR
CYLINDER
9
BOOM HOLD
VALVE

ANTISWING ANTISWING
BOOM 9 S&S
BOOM
S&S 10
BOOM 2
9

Su
VALVE
VALVE

CYLINDER SWING

Sa
MOTOR

Su
VALVE
13
5 Su L. TRAVEL
VALVE
Su 6 3 SWING
VALVE 4

13
BALANCE VALVE
Sa

MECHANISM
SERVO

BALANCE VALVE
R. TRAVEL
STRT. TRAVEL 7 Su VALVE Su 8
Sa
VALVE
Sa

MECHANISM
SERVO
Sa

TRAVEL
MOTOR (L)
TRAVEL
MOTOR (R)
1
2
3

ZX225-1105040

7-90 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Information contained in troubleshooting table

● The following information is contained in the troubleshooting table and related electric circuit
diagrams. Fully understand these information before carrying out troubleshooting.

Trouble Trouble which occurs on the machine

Related information Information related to detected trouble or troubleshooting

Cause Standard value in normal state/References for troubleshooting

Possible causes and standard value in normal state

3 Possible causes of < Description >

trouble (Given numbers ● Standard value in normal state, which is used to judge possible
4 are reference numbers, causes that might be OK or N/G.
which do not indicate
priority) ● A reference value is used to determine OK or N/G.

Shop Manual - April 2017 7-91

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-1 Work equipment speed slow, or swing and travel speeds slow
● Work equipment speed is slow or the travel and swing speeds
Trouble
are slow.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is running at

Possible causes and standard value in normal state

high idle.
Defective
adjustment or Control levers Main relief pressure
1 malfunction
33~34.3 MPa
of main relief Arm in
{337~350 kg/cm²}
valve
If normal pressure cannot be restored after adjustment, it is possible the fail-
ure of main relief valve or internal defect. Check the valve directly.
★ Stop the engine. Perform troubleshooting while the engine is running at
Malfunction high idle.
2 of pilot relief Control levers Pilot control pressure
valve 3.9~4.1 MPa
All levers in "NEUTRAL"
{40~42 kg/cm²}
Malfunction of
3 The regulator possibly fails. Check the servo mechanism of the regulator.
regulator
Malfunction of If the trouble is caused by other factors, it might be the main pump that has
4
main pump performance deterioration, malfunction or internal defect.

7-92 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-2 Engine speed drops sharply or engine stalls

Trouble ● Engine speed drops sharply or engine stalls.

Related information ● Information concerned
Possible causes and standard value in normal

Standard value in normal state/Refer-

Cause
ences for troubleshooting
1 Failure of injection pump Injection pump may be defective. Check it directly.

2 Malfunction of regulator Regulator may have malfunction. Check its servo mechanism.
Clogging of oil filter ele-
3 Oil filter element may be clogged. Check the element directly.
state

ment
Carbon buildup at fuel
4 Carbon built up at fuel injection nozzle. Check it directly.
injection nozzle
5 Clogging of air cleaner Air cleaner may be clogged. Check it directly.

6 Abnormal wear of engine Engine may be worn abnormally. Check it directly.

7 Failure of oil pump Oil pump may be defective. Check it directly.

Shop Manual - April 2017 7-93

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-3 Work equipment, swing, and travel systems do not work

Trouble ● Whole work equipment, swing, and travel systems do not work.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Possible causes and standard value in normal state

Malfunction of pilot Pilot lockout control lever Pilot relief pressure

1 LOCKED 0 {0}
relief solenoid valve
3.9~4.1 MPa
FREE
{40~42 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Failure of relief valve Control lever Pilot relief pressure
2
(pilot pump)
3.9~4.1 MPa
All levers in "NEUTRAL"
{40~42 kg/cm²}
The main pump may have malfunction or internal defect. Check it by
Failure of hydraulic following method.
3
pump ● Remove the oil pressure measurement plug and start the engine. If
oil flows out of the opening, the piston pump is in good condition.
Internal failure of the coupling can stop rotation of the pump shaft.
Check the coupling.
4 Failure of coupling
● Loosen the oil delivery line of the pilot pump. If no oil is seen, it is
probably the failure of coupling.

7-94 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-4 Abnormal noise in hydraulic pump

Trouble ● Abnormal noise is produced from the hydraulic pump

Related information ―
Possible causes and standard value in normal

Cause Standard value in normal state/References for troubleshooting

Low level of
1 Make a visual check.
hydraulic oil
Inferior hydrau-
2 Hydraulic oil probably contains air. Make a visual check.
lic oil
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that
state

3 vent on top of causes negative pressure in the hydraulic tank. Press the release button of
hydraulic tank the breather valve to eliminate air. Check again if the noise disappears.
Clogging of
It is probably the clogging of hydraulic tank strainer that causes negative
4 hydraulic tank
pressure in the oil suction line. Make a visual check.
strainer
Failure of main
5 The main pump may have internal defect. Check the main pump.
pump

Shop Manual - April 2017 7-95

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-5 Auto idle not functioning

Trouble ● Auto-deceleration is not functioning.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in normal state

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is running at high
idle.
Malfunction Control levers Pilot valve output pressure
1 "NEUTRAL" 0 {0}
of sensor
3.5~4.1MPa
Operation
{36~42 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is running at high
idle.
Malfunction Control levers Pilot valve output pressure
2 "NEUTRAL" 0 {0}
of pilot valve
3.5~4.1MPa
Operation
{36~42 kg/cm²}
Failure of
3 Controller may be defective. Check it directly.
controller

7-96 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-6 Boom-raise speed or power is low

Trouble ● The boom moves slowly.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Malfunction of right Boom control lever Pilot valve output pressure
1 pilot valve (boom "NEUTRAL" 0 {0}
circuit)
Boom RAISE ≥3.5MPa
Boom LOWER {36 kg/cm²}
Possible causes and standard value in normal state

★ Stop the engine. Perform troubleshooting while the engine is running

Failure of pressure
2 at high idle.
sensor
Check the pressure sensor by replacing it with a new one.
Malfunction of boom
3 Spool of boom control valve may have malfunction. Check it directly.
control valve (spool)
Malfunction of boom
Retaining valve of boom control valve may have malfunction. Check the
4 control valve (re-
valve directly.
taining valve)
Malfunction or de-
fective seal of boom
The relief valve and makeup valve in boom control valve may have mal-
5 control valve
function or defective seal. Check the valves directly.
(Relief valve and
makeup valve)
★ Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cylin-
Failure of boom
6 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more
information on the measuring procedure, see "Work Equipment Hydrau-
lic Drift - Test" on page 6-27.

Shop Manual - April 2017 7-97

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-7 Arm speed or power is low

Trouble ● The arm moves slowly.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Arm control lever Pilot valve output pressure
Malfunction of left pilot
1 "NEUTRAL" 0 {0}
valve (arm circuit)
Possible causes and standard value in normal state

≥3.5MPa
Arm IN or Arm OUT
{36 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is
2 Failure of pressure sensor running at high idle.
Check the pressure sensor by replacing it with a new one.
Malfunction of arm control
3 Spool of arm control valve may have malfunction. Check it directly.
valve (spool)
Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
4
valve (regeneration valve) Check it directly.
Malfunction or defective
seal of arm control valve The relief valve or makeup valve inside the arm control valve may
5
(Relief valve and makeup have malfunction or defective seal. Check the valves directly.
valve)
★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Cut off the oil passage to the high-pressure side of the cylinder.
Disconnect the cylinder from the main valve. Measure the displace-
6 Failure of arm cylinder
ment of piston for 15 minutes after the cylinder becomes stable. If
the measured value is greater than 10 mm, it is deemed that cyl-
inder has a defective seal. For more information on the measuring
procedure, see "Work Equipment Hydraulic Drift - Test" on page 6-27.

7-98 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-8 Bucket speed or power is low

Trouble ● The bucket moves slowly.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Malfunction of right Bucket control lever Pilot valve output pressure
1 pilot valve (bucket "NEUTRAL" 0 {0}
circuit)
≥3.5MPa
Possible causes and standard value in normal state

Bucket CURL or Bucket DUMP

{36 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is running
Failure of pressure
2 at high idle.
sensor
Check the pressure sensor by replacing it with a new one.
Malfunction of
3 bucket control valve Spool of bucket control valve may have malfunction. Check it directly.
(spool)
Malfunction or
defective seal of
Relief valve and makeup valve in bucket control valve may have mal-
4 bucket control valve
function or defective seal. Check the valves directly.
(relief valve and
makeup valve)
★ Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cylin-
Failure of bucket
5 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more
information on the measuring procedure, see "Work Equipment Hydrau-
lic Drift - Test" on page 6-27.

Shop Manual - April 2017 7-99

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-9 Work equipment cylinders no response in separate operation

● Boom cylinder gives no response in separate operation.

Trouble ● Arm cylinder gives no response in separate operation.
● Bucket cylinder gives no response in separate operation.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in normal

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Work equipment control lever Pilot valve output pressure
1 Malfunction of pilot valve "NEUTRAL" 0 {0}
≥3.5MPa
state

DIG or DUMP
{36 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is
Failure of pressure sen-
2 running at high idle.
sor
Check the pressure sensor by replacing it with a new one.

Malfunction of control
3 Spool of control valve may have malfunction. Check it directly.
valve (spool)

7-100 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-10 Work equipment drifts excessively

Trouble (1) ● The boom drifts at excessive speed.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

Possible causes and standard value in normal state

★ Stop the engine. Perform troubleshooting while the engine is

running at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the
oil passage to the high-pressure side of the cylinder. Disconnect the
1 Failure of boom cylinder cylinder from the main valve. Measure the displacement of piston
for 15 minutes after the cylinder becomes stable. If the measured
value is greater than 10 mm, it is deemed that cylinder has a defec-
tive seal. For more information on the measuring procedure, see
"Work Equipment Hydraulic Drift - Test" on page 6-27.
Failure of boom retain- Boom retaining valve or pilot valve may be worn or sluggish. Check
2
ing valve the valves.
Malfunction or defective
seal of boom control The relief valve and the makeup valve in the boom control valve
3
valve (relief valve and may have a defective seal. Check the seals.
makeup valve)
Failure of boom valve
4 Spool of boom valve may be worn excessively. Check the spool.
spool

Shop Manual - April 2017 7-101

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Trouble (2) ● The arm drifts excessively.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

Possible causes and standard value in normal state

★ Stop the engine. Perform troubleshooting while the engine is running at

high idle.
Cut off the oil passage to the high-pressure side of the cylinder. Disconnect
Failure of arm the cylinder from the main valve. Measure the displacement of piston for 15
1
cylinder minutes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more infor-
mation on the measuring procedure, see "Work Equipment Hydraulic Drift -
Test" on page 6-27.
Malfunction or Relief valve or makeup valve of the arm control valve may be defective.
defective seal of Check the valves directly.
2 arm control valve ★ The performance of seal can be judged by replacing it with another
(relief valve and relief valve or makeup valve. (Do not replace it with the boom-down
makeup valve) relief valve or makeup valve as their pressures are set differently.)
Failure of arm Arm retaining valve or pilot valve may be worn or sluggish. Check the
3
retaining valve valves.
Failure of arm
4 Arm valve (spool) may be worn excessively. Check it directly.
valve (spool)

Trouble (3) ● The bucket drifts excessively.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in nor-

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is running
Failure of bucket at high idle.
1 Bucket control lever Leakage from bucket cylinder
cylinder
Bucket-in relief 20 ml/min
mal state

Seal of relief valve or makeup valve of bucket control valve may be defec-
Defective seal
tive. Check it directly.
of bucket control
2 ★ The performance of seal can be judged by replacing it with another
valve (relief valve
relief valve or makeup valve. (Do not replace it with the boom-down
and makeup valve)
relief valve or makeup valve as their pressures are set differently.)
Defective seal
3 of bucket control Seal of bucket control valve spool may be defective. Check it directly.
valve (spool)

7-102 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-11 Work equipment moves sluggishly

Trouble ● Work equipment moves sluggishly.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in

Cause Standard value in normal state/References for troubleshooting

Malfunction of arm
1 Regeneration valve of arm may have malfunction. Check it directly.
regeneration valve
normal state

Relief valve or makeup valve of control valve may have malfunction.

Check it directly.
Malfunction of
★ For arm and boom, whether a valve has malfunction can be judged
control valve (relief
2 by replacing it with another relief valve or makeup valve.
valve and makeup
valve)
(Do not replace it with the boom-lower relief valve or makeup valve as
their pressures are set differently. )

H-12 Other work equipment moves while single oil circuit is relieved
● Other work equipment moves while single oil circuit of certain work equip-
Trouble
ment is relieved.
Related information ● Set the working mode to (S) in order to perform troubleshooting.
Possible causes and standard value in

Cause Standard value in normal state/References for troubleshooting

normal state

Defective seal of
1 Seal of control valve may be defective. Check it directly.
control valve

Shop Manual - April 2017 7-103

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-13 Travel speed drops considerably while swinging and travelling

Trouble ● Travel speed drops considerably in swinging plus travelling operation.

● If the travel speed is low in only travelling operation, check first ac-
Related information
cording to H-15.
Possible causes and standard value in

Cause Standard value in normal state/References for troubleshooting

normal state

Failure of straight The straight travel valve gives no response. Check the spool and the
1
travel valve logic oil circuit drain port.

7-104 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-14 Machine deviates during travel

Trouble ● Machine deviates during travel.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Travel control lever Pilot valve output pressure
Malfunction of travel
1 Forward 3.5~3.9 MPa
pilot valve
Reverse { 36~40 kg/cm²}
Difference occurs between left
0.4 MPa {4 kg/cm²}
and right output
★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Malfunction of pilot relief
2 Control lever Control circuit source pressure
valve
Possible causes and standard value in normal state

3.5~3.9 MPa
All levers in "NEUTRAL"
{ 36~40 kg/cm²}
3 Failure of regulator Check the regulator by swapping the front and back regulators.
★ Stop the engine. Perform troubleshooting while the engine is
Sluggishness of propor- running at high idle.
4 Travel control lever Proportional valve output pressure
tional solenoid valve
Operate both control levers ≤0.1 MPa
Sluggishness of travel
5 Check the valve spool to see whether it works well.
control valve (spool)
Internal leakage of cen-
6 Check it by swapping the lines.
tral swivel joint
★ Stop the engine. Perform troubleshooting while the engine is
Malfunction of travel running at high idle.
7 Travel control lever Leakage of travel motor
motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
★ Internal defect of the final drive can be determined through
8 Failure of final drive
abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.
★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Travel control lever Pilot valve output pressure
Failure of travel pilot Forward 3.5~3.9MPa
9
pressure sensor Reverse { 36~40 kg/cm²}
Difference occurs between left
0.4 MPa {4 kg/cm²}
and right output
Check the sensor by swapping it with another one.

Shop Manual - April 2017 7-105

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-15 Travel speed or power is low

Trouble ● Machine travel speed is low.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Travel control lever Pilot valve output pressure
Malfunction of travel
1 Forward 3.5~3.9 MPa
pilot valve
Reverse { 36~40 kg/cm²}
Difference occurs between left and ≤0.4 MPa
right output ≤{4 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Possible causes and standard value in normal state

Malfunction of pilot Control lever Control circuit source pressure

2
relief valve
3.5~3.9 MPa
All levers in "NEUTRAL"
{ 36~40 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Travel speed Travel control lever Reading on monitor
3.5~3.9 MPa
3 Failure of sensor Lo Operated
{ 36~40 kg/cm²}
3.5~3.9 MPa
Hi Operated
{ 36~40 kg/cm²}
Check the sensor by replacing it with another one.
Malfunction of travel Spool of travel control valve may have malfunction. Check it direct-
4
control valve (spool) ly.
Malfunction of travel
The makeup valve in travel control valve may have malfunction.
5 control valve (make-
Check it directly.
up valve)
Stop the engine. Perform troubleshooting while the engine is run-
Failure of travel mo- ning at high idle.
6
tor Travel control lever Oil leakage of travel motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
★ Internal defect of the final drive can be determined through abnor-
7 Failure of final drive
mal noise, abnormal heat, and metal powder or debris contained in
the oil drained.

7-106 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-16 Machine is not steered well or steering power is low

Trouble ● Machine is not steered well or steering power is low

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Malfunction of travel Travel control lever Pilot valve output pressure
1
pilot valve Both sides in "NEUTRAL" 0 {0}
3.5~3.9 MPa
Either side operated
Possible causes and standard value in normal state

{ 36~40 kg/cm²}
★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Travel control lever Solenoid valve output pressure
Malfunction of travel
2 3.5~3.9 MPa
pilot pressure sensor Both sides operated
{ 36~40 kg/cm²}
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm²}
Malfunction of travel Spool of travel control valve may have malfunction. Check it
3
control valve (spool) directly.
Malfunction of travel
The makeup valve in travel control valve may have malfunction.
4 control valve (makeup
Check it directly.
valve)
Seal of relief valve in travel motor may be defective. Check it
Failure of travel motor directly.
5
(relief valve) ★ The failure of seal can be determined by swapping the front and
back motors or the left and right motors.
Seal of check valve in travel motor may be defective. Check it
Failure of travel motor directly.
6
(check valve) ★ The failure of seal can be determined by swapping the front and
back motors or the left and right motors.

Shop Manual - April 2017 7-107

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-17 Travel speed cannot be changed

Trouble ● Travel speed cannot be changed.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

Possible causes and standard value in

★ Stop the engine. Perform troubleshooting while the engine is

running at high idle.
Malfunction of travel Solenoid valve output
Travel speed Travel control lever
pressure
normal state

1 speed shifting solenoid

valve Lo Operated 0 {0}
3.5~3.9 MPa
Hi Operated
{ 36~40 kg/cm²}

Failure of travel motor (in Speed shifting assembly of travel motor may have malfunction.
2
speed change) Check it directly.

7-108 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-18 Travel system fails (only at one side)

Trouble ● One side of the tracks cannot make a turn.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

Defective seat of travel
Seat of makeup valve in travel control valve may have malfunction.
1 control valve (makeup
Check it directly.
valve)
Defective seat of travel Seat of relief valve in travel control valve may have malfunction.
2
Possible causes and standard value in normal state

motor (relief valve) Check it directly.

Defective seat of travel
Seat of check valve in travel motor valve may have malfunction.
3 motor valve (makeup
Check it directly.
valve)
★ Stop the engine. Perform troubleshooting while the engine is run-
Speed of travel motor ning at high idle.
4 Travel control lever Leakage from travel motor
drops.
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
★ Internal defect of final drive can be determined with abnormal
5 Failure of final drive
noise, overheat, and metal powder or debris contained in the oil
drained.
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Travel control lever Pilot valve output pressure
Defective pilot pressure Forward 3.5~3.9MPa
6
sensor Reverse { 36~40 kg/cm²}
Difference occurs between left and
0.4 MPa {4 kg/cm²}
right output
Check it with swapping method.

Shop Manual - April 2017 7-109

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-19 Swing operation fails

Trouble (1) ● Upper structure fails to swing in either direction.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

Malfunction of swing
Possible causes and standard value in normal state

1 Parking brake of swing motor may have malfunction. Check it directly.

motor (parking brake)
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Improper adjustment Swing control lever Swing relief pressure
or malfunction of 25.5~28.5 MPa
2 Swing relief
swing motor (relief {260~291 kg/cm²}
valve) If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
valve directly.
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
3 Failure of swing motor Swing control lever Leakage from swing motor
Swing relief ≥10 ml/min
Swing mechanism may have internal defect. Check it directly.
Failure of swing ★ Internal defect of swing mechanism can be determined with
4
mechanism abnormal noise, overheat, and metal powder or debris contained
in the oil drained.

7-110 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

Trouble (2) ● Upper structure only fails to swing in one direction.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Malfunction of pilot Left control lever Pilot valve output pressure
1
valve
normal state

"NEUTRAL" 0 {0}
Swing ≥3.5MPa {≥36 kg/cm²}

Malfunction of swing
2 Spool of swing control valve may have malfunction. Check it directly.
control valve (spool)
Defective seal of Seal of makeup valve in swing motor may have defect. Check it directly.
3 swing motor (makeup ★ Failure of the seal can be determined by swapping the right and left
valve) makeup valves and check for any changes.

Shop Manual - April 2017 7-111

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-20 Swing acceleration poor or swing speed low

Trouble (1) ● Swing acceleration is poor, or swing speed is low.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

Possible causes and standard value in normal state

Malfunction of swing
1 Parking brake of swing motor may have malfunction. Check it directly.
motor (parking brake)
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Improper adjustment Swing control lever Swing relief valve
or malfunction of 25.5~28.5 MPa
2 Swing relief
swing motor (relief {260~291 kg/cm²}
valve) If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
valve directly.
★ Stop the engine. Perform troubleshooting while the engine is run-
Failure of swing mo- ning at high idle.
3 Swing control lever Leakage from swing motor
tor
Swing relief ≤10 ml/min
Clogging of brake
4 Disassemble, clean and check.
control lines

7-112 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

● Swing acceleration is only poor on one side, or swing speed is

Trouble (2)
low.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is run-
Possible causes and standard value in normal state

ning at high idle.

Malfunction of pilot Swing control lever Pilot valve output pressure
1
valve "NEUTRAL" 0 {0}
Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
Malfunction of swing
Pressure compensation valve of swing motor may have malfunction.
2 motor (pressure com-
Check it directly.
pensation valve)
Seal of makeup valve in swing motor may have defect. Check it di-
Defective seal of swing rectly.
3
motor (makeup valve) ★ Swap the left and right makeup valves and observe the result in
order to determine whether the seal fails.
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
One-side leakage of
Swing control lever Pilot valve output pressure
4 swing pilot pressure
"NEUTRAL" 0 {0}
sensor (shuttle valve)
Left swing
3.5~3.9MPa {36~40 kg/cm²}
Right swing

Shop Manual - April 2017 7-113

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-21 Upper structure overruns remarkably when it stops swinging

● Upper structure overruns remarkably when it stops swinging in
Trouble (1)
both directions.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in nor-

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Swing control lever Swing relief pressure
Improper adjustment
25.5~28.5 MPa
1 or malfunction of swing Swing relief
mal state

{260~291 kg/cm²}
motor (relief valve)
If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
valve directly.
★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
2 Failure of swing motor Control lever Leakage from swing motor
Swing relief ≤10 ml/min

Trouble (2) ● Swing acceleration is only poor on one side, or swing speed is low.
● Set the working mode at gear (10) of power mode (S) to perform
Related information
troubleshooting.
Possible causes and standard value in nor-

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Swing control lever Pilot valve output pressure
1 Malfunction of pilot valve
"NEUTRAL" 0 {0}
mal state

Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
Malfunction of swing con- Spool of swing control valve may have malfunction. Check it direct-
2
trol valve (spool) ly.
Seal of makeup valve in swing motor may be defective. Check it
Malfunction or defec-
directly.
3 tive seal of swing motor
★ Swap the left and right makeup valves and observe the result
(makeup valve)
in order to determine whether the seal fails.

7-114 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Troubleshooting

H-22 Large shock is produced when upper structure stops swinging

Trouble ● Large shock is produced when upper structure stops swinging.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in normal

Cause Standard value in normal state/References for troubleshooting

★ Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.

Malfunction of swing Swing control lever Pilot valve output pressure

1
pilot valve "NEUTRAL" 0 {0}
Left swing
state

≥3.5MPa {≥36 kg/cm²}

Right swing
Reverse prevention valve of swing motor may have malfunction.
Malfunction of swing
Check it directly.
2 reverse prevention
★ Replace the valve with a new on in order to determine whether the
valve
valve fails.
Malfunction of swing
3 Swing relief valve may be worn or sluggish.
relief valve

H-23 High noise is produced when upper structure stops swinging

Trouble ● High noise is produced when upper structure stops swinging.

● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Possible causes and standard value in normal

Cause Standard value in normal state/References for troubleshooting

Malfunction of back
1 Back pressure valve may have malfunction. Check it directly.
pressure valve
Malfunction of swing
2 Relief valve of swing motor may have malfunction. Check it directly.
motor (relief valve)
Seal of makeup valve in swing motor may have malfunction. Check it
state

Malfunction of swing directly.

3
motor (makeup valve) ★ Swap the left and right makeup valves and observe the result in
order to determine whether the seal fails.
The swing mechanism is suspected of an internal failure. Check the
inside of the machinery itself.
Failure of swing mecha-
4 ★ Internal defect of swing mechanism can be determined with
nism
abnormal noise, overheat, and metal powder or debris contained
in the oil drained.

Shop Manual - April 2017 7-115

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

H-24 Swing drift excessive

● Hydraulic drift of swing is large (when swing holding brake is ap-
Trouble (1)
plied).
● When swing lock switch is turned ON or when swing holding
Related information brake release switch is in normal position, swing holding brake
operates and upper structure is fixed with disc brake.
Possible causes and standard value

Cause Standard value in normal state/References for troubleshooting

Failure of swing hold- Swing holding brake control lines and holding brake pilot valve may be
in normal state

1
ing brake control lines defective. Check them directly.

Malfunction of swing
2 Parking brake of swing motor may have malfunction. Check it directly.
motor (parking brake)

● Hydraulic drift of swing is large (when swing holding brake is re-

Trouble (2)
leased).
● When swing holding brake release switch is in release position,
Related information swing holding brake is released and upper structure is secured
by only hydraulic pressure.
Possible causes and standard value

Cause Standard value in normal state/References for troubleshooting

Malfunction or defec-
Swing control valve spool may have malfunction or defective seal.
1 tive seal of swing
Check it directly.
in normal state

control valve (spool)

Failure of swing motor

2 Seal of relief valve in swing motor may be defective. Check it directly.
(relief valve)

Failure of swing motor Seal of makeup valve in swing motor may be defective. Check it di-
3
(makeup valve) rectly.

7-116 Shop Manual - April 2017

Troubleshooting SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

7-82 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

Disassembly and Assembly

8 Disassembly and Assembly
8.1 Reading Guide ......................................................................................................... 8-3
8.2 Operating Precautions ............................................................................................. 8-6
8.3 Radiator AS - Remove and Install.......................................................................... 8-10
8.4 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-14
8.5 Final Drive AS - Remove and Install ...................................................................... 8-21
8.6 Final Drive AS - Disassemble and Assemble......................................................... 8-23
8.7 Swing Motor and Swing Drive AS - Remove and Install ........................................ 8-32
8.8 Swing Motor and Swing Drive AS - Disassemble and Assemble........................... 8-34
8.9 Idler AS - Disassemble and Assemble ................................................................... 8-44
8.10 Sprocket - Remove and Install............................................................................. 8-48
8.11 Track AS - Remove and Install............................................................................. 8-49
8.12 Swing Bearing AS - Remove and Install .............................................................. 8-52
8.13 Swing Platform AS - Remove and Install ............................................................. 8-54
8.14 Swivel Joint AS - Remove and Install .................................................................. 8-58
8.15 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-61
8.16 Hydraulic Tank AS - Remove and Install.............................................................. 8-63
8.17 Control Valve AS - Remove and Install ................................................................ 8-66
8.18 Hydraulic Pump AS - Remove and Install ............................................................ 8-71
8.19 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-76
8.20 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-77
8.21 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-79
8.22 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-80
8.23 Work Equipment AS - Remove and Install........................................................... 8-91
8.24 Air Conditioner AS - Remove and Install.............................................................. 8-94
8.25 Counterweight AS - Remove and Install .............................................................. 8-99
8.26 Cab AS - Remove and Install............................................................................. 8-101

Shop Manual - April 2017 8-1

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.27 Cab Window Glass – Disassemble and Assemble ............................................ 8-106

8.28 Front Window AS - Disassemble and Assemble................................................ 8-124
8.29 Monitor - Remove and Install ............................................................................. 8-132
8.30 Controller AS - Remove and Install.................................................................... 8-133
8.31 Radio ................................................................................................................. 8-134
8.32 Battery ............................................................................................................... 8-137
8.33 Start Switch........................................................................................................ 8-140
8.34 Fuse Box............................................................................................................ 8-143
8.35 Wiper ................................................................................................................. 8-144
8.36 Relay.................................................................................................................. 8-147
8.37 Sensor ............................................................................................................... 8-151
8.38 Connector Terminals - Insert and Remove ........................................................ 8-153

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

8-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8 DISASSEMBLY AND ASSEMBLY

8.1 Reading Guide

8.1.1 Removing and Installing an Assembly

8.1.1.1 Special tools

● Special tools for removal and installation of machine parts are listed.

● Necessary characteristics of the tools are noted in the list of special tools.

■: Special tools that cannot be replaced and must be used.

●: Very useful tools, which can be replaced with commercially available ones.

8.1.1.2 Removal

● The "Removal" section contains procedure, precautions and the amount of oil or water to be
discharged.

● The symbols used the in the "Removal" section are described below:

This symbol indicates that safety-related precautions must be observed when doing the
job.

This symbol is followed by instructions or precautions when performing a procedure.

This symbol indicates related rules and precautions that must be obeyed when install-
ing the pats.

This symbol indicates the amount of oil or water to be discharged.

Shop Manual - April 2017 8-3

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.1.2.2 Installation

● Unless specified otherwise, installation of a part is a reverse procedure of removing the part.

● The mark used in the "Installation" section indicates the rules and precautions related to
parts installation.

● Symbols used in the "Installation" sections are shown below:

This symbol indicates that safety-related precautions must be observed when doing the
job.

This symbol is followed by instructions or precautions when performing a procedure.

This symbol indicates that specific coating agent must be used.

This symbol indicates the lubricant required.

This symbol indicates a torque specified.

This symbol indicates the amount of oil or water to be added.

8.1.2 Disassembling and assembling an assembly

8.1.2.1 Special tools

● Special tools for parts disassembly and assembly are listed.

● Necessary characteristics of the tools are noted in the list of special tools.

■: Special tools that cannot be replaced and must be used.

●: Very useful tools, which can be replaced with commercially available ones.

8-4 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.1.2.3 Disassembly

● The "Disassembly" section contains procedure, precautions and the amount of oil or water to
be discharged.

● The symbols used the in the "Disassembly" section are described below:

This symbol indicates that safety-related precautions must be observed when doing the
job.

This symbol is followed by instructions or precautions when performing a procedure.

This symbol indicates related rules and precautions that must be obeyed when install-
ing the pats.

This symbol indicates the amount of oil or water to be discharged.

8.1.2.4 Assembly

● The "Assembly " section contains operating procedure, precautions, technical specification
and the amount of oil or water to be added.

● The symbols used the in the "Assembly" section are described below:

This symbol indicates that safety-related precautions must be observed when doing the
job.

This symbol is followed by instructions or precautions when performing a procedure.

This symbol indicates that specific coating agent must be used.

This symbol indicates the lubricant required.

This symbol indicates a torque specified.

This symbol indicates the amount of oil or water to be added.

Shop Manual - April 2017 8-5

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.2 Operating Precautions

The following precautions must be observed before removing or installing (disassembling or as-
sembling) a component.

1. Precautions to be observed prior to removal operation

● Dispose the engine coolant properly if antifreeze is contained in the engine coolant.

● After disconnecting a hose or tube, cover or plug must be used to prevent invasion of dirt
or dust.

● A suitable container must be prepared to collect oil when draining the oil.

● Matching mark must be made at where is necessary before removing in order to avoid
mistake during reinstallation.

● Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force im-
posing on the wire, hold the connector when disconnecting a wire.

● Tag the wires and the hoses in order to ensure their connecting positions. By doing so,
mistakes can be avoided during reinstallation.

● Count and check the number and thickness of the shims, and keep them in a safe place.

● When raising or lifting components, be sure to use proper lifting equipment of ample
strength and safety.

● When forcing screws are used to remove any components, tighten the screws evenly in
turn.

● The surrounding area must be cleaned before removing a unit. Cover the unit after remov-
al in order to prevent invasion of dirt or dust.

8-6 Shop Manual - April 2017

SY215C9C5K/SY225C9C5KL Crawler Hydraulic Excavator Disassembly and Assembly

Precautions to be observed when disassembling the lines

The lines disassembled must be blinded with plugs.

A: Thread-connected hoses

I.D. (mm) Code Description

Light Thread Connection
6 B210780001189 Plug
8 B210780001190 Plug
10 B210780000077 Plug
12 B210780000078 Plug
15 B210780000883 Plug
20 B210780000079 Plug
22 60056667 Plug
Heavy Thread Connection
12 B210780001142 Plug
16 60002397 Plug
20 B210780000080 Plug
25 B210780000081 Plug

B: Thread-connected adaptors (plug and nut used in combination)

I.D. (mm) Code Description Code Description

Light Thread Connection
6 B210780000903 Taper bore plug 23002925 Nut
8 B210780001146 Plug B210770000011 Nut
10 B210780000088 Plug B210334000011 Nut
12 B210780000089 Plug B210334000012 Nut
15 B210780000882 Plug B210334000004 Nut
20 B210780000090 Plug B210334000010 Nut
22 B210780000091 Plug B210780000112 Nut
Heavy Thread Connection
12 B210780001143 Plug B210780000406 Nut
16 A820205001523 Plug B210780000405 Nut
20 B210780000902 Plug B210780000904 Nut
25 B210780001172 Plug B210334000006 Nut

Shop Manual - April 2017 8-7

Disassembly and Assembly SY215C9C5K/SY225C9C5KL Crawler Hydraulic Excavator

2. Precautions to be observed prior to installation operation

● Tighten all the screws and nuts (sleeve nuts) to specified torques.

● Install the hoses without twisting or interference.

● Replace the gaskets, O-rings, cotter pins and lock plates with new parts.

● Bend the cotter pin or lock plate securely.

● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhesive
to the threaded portion.

● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check the
gasket for contamination or damage. Apply the gasket sealant evenly.

● Clean all parts, and correct any damage, dents, burrs, or rust.

● Apply engine oil to the moving parts.

● Before installing a snap ring, make sure that the snap ring is mounted properly in the circular
groove.

● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water. Make
sure that the wiring connector is connected securely.

● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the eye-
bolt as far as possible and align it to the direction of the hook.

● Before tightening the split flange, tighten it evenly in turn in order to prevent over tightening on
one side.

★ After reassembling the hydraulic cylinder, main pump or other hydraulic equipment that has
been disassembled and repaired, it is necessary to bleed the air from the hydraulic cylinder
prior to initial operation of the cylinder. The purging procedure is performed as the following:

1) Start the engine and run the engine at low idle.

2) Operate the work equipment control lever in order to cycle the movement of the hydraulic
cylinder 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end.

3) Go on operating the hydraulic cylinder 3 or 4 times to its stroke end.

4) You can run the engine at normal speed after this operation.

★ This procedure is to be performed before using your machine for the first time after repair or
long storage.

8-8 Shop Manual - April 2017

SY215C9C5K/SY225C9C5KL Crawler Hydraulic Excavator Disassembly and Assembly

3. Precautions to be observed upon completion of the operations

● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the
specified level. Run the engine to circulate the coolant through the system. Check the
coolant level again.

● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic
unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level
again.

● Bleed the air from the system after removing and repairing the lines or hydraulic unit and
reassembling the parts.

★ Bleed the air. For more information, see “Air in Each Component - Bleed” on page 6-36.

● Add the specified amount of grease (molybdenum disulphide) to the work equipment re-
lated parts.

Shop Manual - April 2017 8-9

Disassembly and Assembly SY215C9C5K/SY225C9C5KL Crawler Hydraulic Excavator

8.3 Radiator AS - Remove and Install

8.3.1 Removal

1. Open the engine hood.

a
2. Open the pressure cap (1). Open the drain
valve to discharge engine coolant from the 1
coolant tank. 1

Coolant: approx. 22.5 L

3. Remove the beam a.

ZX215T-1006028

4. Remove the two U-bolts (2).

5. Disconnect the hydraulic oil cooler inlet

connector (3) and outlet connector (4).
Block the openings to prevent leakage of
hydraulic oil.

6. Discharge hydraulic oil from the hydraulic 2

cooler.
4
Hydraulic oil radiator:
3
approx. 5.6 L
ZX215T-1006029

7. Disconnect the coolant tank hose (5) 、b and c.

b
c
ZX215T-1006030

8-10 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8. Disconnect the cooler inlet hose (6) and

7
outlet hose (7).
6

6
ZX215T-1006031

9. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).

ZX215T-1006031

10. Remove the four bolts (10) from the air

conditioner condenser. Remove the air
conditioner condenser and store it properly.

10

10

ZX215T-1006032

Shop Manual - April 2017 8-11

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

11. Remove the radiator fan guard (11).

11

ZX215T-1006033

12. Remove the four mounting bolts (12) from

the radiator bottom and the two mounting 13
bolts (13) from the left and right brackets.

12
ZX215T-1006034

13. Mount the hoisting bolts (14) to both sides

of the radiator in order to hoist the radiator
assembly.

★ Before the radiator assembly is hoisted,

14
move the radiator assembly axially until
the fan avoids its guard.

ZXT335-1006029

8-12 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.3.2 Installation

● Installation is to be performed in the re-

verse order of removal.

★ Adjust the clearance between the fan and

the fan guard in order to have a uniform
clearance surrounding the fan.

★ Check the values (a) at the four measuring

points in the left, right, top and bottom di-
rections, which should be as the following:

● Standard clearance (a) in all directions:

15±1.5 mm

● Fan diameter (b): ø620 mm

● Fan guard inner diameter (c): ø650 mm

● Engine coolant and hydraulic oil adding

Add a specific amount of coolant and

hydraulic oil. Start the engine to circulate
the coolant and hydraulic oil. Check the
coolant level and the oil level.

Engine coolant: approx. 22.5 L

Hydraulic oil radiator: approx. 5.6 L

Shop Manual - April 2017 8-13

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.4 Engine and Hydraulic Pump AS - Remove and Install

8.4.1 Removal

Lower the work equipment to the ground.

Stop the engine. Disconnect the cable
from the battery negative (-) post.

Loosen the butterfly nut on the breather

valve and press the relief button to re-
lieve internal pressure.

★ Mark the lines to avoid mistakes during

reinstallation.

1. Remove the hydraulic tank suction filter el-

ement and plug the opening.

2. Open the engine hood.

3. Open the radiator cap and drain the engine

coolant.

Coolant: approx. 22.5 L

ZX215T-14011601

4. Disconnect piping (1), (2) and (3).

ZX215T-1006036

8-14 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

5. Disconnect piping (4), (5) and (6).

5
6. Remove the sensors (7) and (8).

8 ZX215T-1006037

7. Remove the clamps (9) and (10). Remove

the line (11) and the cable (12).

11

10

12

ZX215T-1006038

8. Unscrew the connection bolt (13) of the

governor motor and the connection bolt (14) 15
of the engine shutdown device.

9. Disconnect the external cable from the en- 14

gine starter (15).

10. Remove the mounting bolt (16) from the 13

hose clamp.

16
ZX215T-1006039

Shop Manual - April 2017 8-15

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

11. Disconnect the cables (17, 18) and the

tubes (19, 20) from the compressor. 18 20
17

19

ZX215T-1006040

24
12. Disconnect the cooler inlet hose (6) and
7
outlet hose (7).
6

21

9 22

23 ZX215T-1006041

6
ZX215T-1006041

13. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).

ZX215T-1006042

8-16 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

13. Disconnect the air intake hose (25).

25

ZX215T-1006043

14. Disconnect the cable (26).

15. Disconnect the external cable (27) of en-
gine oil pressure sensor.
16. Disconnect the clamps (28) . 27

28
26 ZX215T-1006044

17. Disconnect the engine oil inlet tube (29)

and outlet tube (30).
29 30

ZX215T-1006044

Shop Manual - April 2017 8-17

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

18. Disconnect the cables (31) and (32), and

remove the hose clamp (33).

33

32

31

ZX215T-1006045

19. Remove the hose clamp (35).

20. Disconnect the wiring (34) of the water

temperature sensor.
35

34

ZX215T-1006046

21. Disconnect the cables (36) and (37) of the

water temperature switch.
37

36

ZX215T-1006047

8-18 Shop Manual - April 2017

 SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

22. Disconnect the oil return hose (38).

23. Disconnect the A/C water pipe (39). 38

39
ZX215T-1006048

24. Disconnect the radiator fan guard (40).

40

ZX215T-1006049

25. Remove the fi xing bolt (41) on each of the

four mounting plates of the damper. Lift the
engine and main pump assembly.

Engine and hydraulic pump AS:

640 kg
41 41

ZX215T-1006050

Shop Manual - April 2017 8-19

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.4.2 Installation

● Installation is to be performed in the re-

verse order of removal.

● Open the radiator tank cover to add cool-

ant. Also add coolant to the coolant reser-
voir.

Engine coolant:
approx. 22.5 L

● Refill the hydraulic tank with hydraulic oil.

Hydraulic tank:
approx. 225 L

★ Start the engine to circulate the coolant

in order release the foams, and check the
coolant level again.

★ Start the engine to circulate the hydraulic

oil in the hydraulic system, and check the
oil level again.

● Air bleeding

For more information, see “Air in Each

Component - Bleed” on page 6-36.

8-20 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.5 Final Drive AS - Remove and Install

8.5.1 Removal

1. Remove the sprocket. Refer to “Sprocket -

Remove and Install” on page 8-48.

Lower the work equipment to the ground.

Stop the engine. Operate the breather
valve to release internal pressure.

2. Remove the motor cover plate (1).

1
ZX215-1006051

3. Disconnect the four hoses (2) of the travel

motor and the hose connectors. 2

ZX215T-1006052

Shop Manual - April 2017 8-21

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Remove the 30 mounting bolts from the

final drive assembly (3), and lift the assem-
bly for disassembling.

★ Be careful not to damage the surface 3

of mounting seal installed on the hose
base.

★ Never use the threaded holes to lift the

cover when lifting the final drive.

ZX215-1006053
Final drive assembly: 250 kg

8.5.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Mounting bolts (final drive assembly):

245~309 N·m {25~31 kgf·m}

● Hydraulic oil adding

Add hydraulic oil through the filler opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

● Air bleeding

For more information, see “Air in Each

Component - Bleed” on page 6-36.

8-22 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.6 Final Drive AS - Disassemble and Assemble

8.6.1 Disassembly

1. Oil draining

Open the drain plug to drain the oil from

the final drive casing.

Final drive tank: approx. 4.7 L

2. Cover

Remove the bolts. Use eyebolts [1] to the ①

cover (1).

ZX215-1006054

3. Spacer 2

Remove the spacer (2).

ZX215-1006055

Shop Manual - April 2017 8-23

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. No. 1 planetary carrier assembly

3
1) Remove the No.1 planetary carrier as-
sembly (3).

ZX215-1006056

2) Disassembly of No.1 planetary carrier

assembly.
9 7 4 5 10 8
i) Remove the screws (4). Remove
the coverplate (5) from the plan-
etary carrier assembly (6).

ii) Remove the thrust washer (7), gear

(8), bearing (9), bearing inner race
(10) and a second thrust washer 11
6
(11).
ZX215-1006057

5. No.1 sun gear shaft

12
Remove No.1 sun gear shaft (12).

ZX215-1006058

8-24 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

6. Thrust washer
13 14
Remove the thrust washer (13).

7. No.2 sun gear

Remove No.2 sun gear (14).

ZX215-1006059

8. Disassembly of No.2 planetary carrier

assembly 18 19 15

1) Remove the screws (15). Remove the

16
plate (16) and the planetary gear (17)
17
from the carrier assembly (22).
20
2) Remove the bearing inner race (19) 23
and outer race (18). Remove the plate 21

(20). 22

3) Remove the screw (21) to take the

planetary carrier assembly (22) and the
ZX215-1006060
shim (23) from the body.

9. Hub assembly
②
1) Use eyebolts [2] to remove the hub as-
sembly (24) from the travel motor.

24

ZX215-1006061

Shop Manual - April 2017 8-25

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2) Disassemble the hub assembly as the

following. 26 27

i) Remove the float seal (25).

ii) Remove the bearing (26) and bear-

ing (27) from the hub (28).

★ Do not damage the bearing retainer

when removing the bearing (26).
25 28
ZX215-1006062

3) Remove the float seal (29) from the

travel motor.

29

30
ZX215-1006063

8-26 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.6.2 Assembly

★ Clean all the parts. Check that these parts

are free from any contamination or dam- 26 27
age. Apply some engine oil to the sliding
surface prior to installation.

1. Hub assembly

1) Install the bearing 26 and bearing (27)

by pressing them onto the hub (28).

2) Install the float seal (25). 25 28

ZX215-1006062

★ Remove any oil or dust from the O-ring

or O-ring contact surface. Dry the parts
before installing the float seal.

★ After installing the float seal, check that

the angle of the floating seal is within 1
mm.

★ Apply a thin layer of engine oil to the

sliding surface after the float seal has
been installed. ZX215-1006064

3) Install the float seal (29) to the travel

motor (30).

★ See the above step 2 for the installation

procedure.
29

30
ZX215-1006063

Shop Manual - April 2017 8-27

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4) Use eyebolts [2] to carefully place the

②
hub assembly (24) onto the travel mo-
tor. Tap to press fit the bearing.

24

ZX215-1006061

2. Calculation of shim thickness

1) Measure the thickness (H) of the raised

part of No.2 carrier assembly (22). 22

2) Measurement of raised thickness

Apply 3000 Kg load to the bearing and
measure the value (H) of the raised H
part of the bearing.

★ Turn the hub 2-3 times before applying

a pushing force. ZX215-1006065

★ Do not use a spray gun to cushion the

bearing.

★ Do not push or strike the resin retainer.

3) Shim thickness calculation: C=H-h.

Load 3000Kg
h

ZX215-1006066

8-28 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4) Place the shims on the body and insert

the dowel pin. Press the carrier assem-
bly onto the dowel pin and tighten it
with screw (21). Apply locking adhesive
Tensiometer
to the threads.

Screw-locking adhesive:
(Tonsan 1277)

Screw (21): ZX215-1006067

539±28 N·m {55±2.9 kgf·m}

★ Use a tensiometer to measure the tan-

gential force of hub to motor rotation.

● Tangential force: Max.294 N {30 kg}

● Maximum tangential force occurs

when the rotating direction begins
to change.

3. Assembly of No.2 planetary carrier as-

sembly

1) Assemble the No.2 planetary carrier

18 19 15
assembly according to the following
procedure.
16

★ Replace the plates (20) and (16) with 17

new parts. 20
23
i) Assemble the bearing (18) and 21
bearing (19) to the gear (17). As-
22
semble the top and bottom plates
(16) and (20), and place the gear
assembly into the carrier assembly ZX215-1006060
(22).

ii) Tighten the screw (15).

Screw (15):
539±28 N·m {55±2.9 kgf·m}

★ Check the flexibility of gear (17)

after assembling the planetary
carrier assembly.

Shop Manual - April 2017 8-29

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Thrust washer
13 14
Install the thrust washer (13).

5. No.2 sun gear

Install No.2 sun gear (14).

ZX215-1006059

6. No. 1 sun gear shaft

12
Install No.1 sun gear shaft (12).

ZX215-1006058

7. No.1 planetary carrier assembly

1) No. 1 planetary carrier assembly is as-

9 7 4 5 10 8
sembled as the following.

★ Replace the thrust washers (7) and (11)

with new parts.

i) Assemble the bearings (9) and (10)

onto the gear (8). Assemble the top 11
6
and bottom thrust washers (7) and
(11). Place the gear assembly into ZX215-1006057

the carrier assembly (6).

ii) Fix the coverplate (5) to the carrier

assembly (6) with screw (4).

8-30 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

2) Install No.1 planetary carrier assembly

(3). 3

ZX215-1006056

8. Spacer
2
Install the spacer (2).

9. Cover

Use eyebolts [1] to assemble the cover (1).

Use a torque spanner to tighten the bolts.
ZX215-1006055
Bolts:

73.4±3.63 N·m {7.5±0.4 kgf·m}

10. Oil adding

Tighten the drain plug and add engine oil

through the filler.

Final drive case: approx. 4.7 L

★ Check the oil level after the final drive
Torque wrench
has been successfully installed to the
chassis.

ZX215-1006068

Shop Manual - April 2017 8-31

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.7 Swing Motor and Swing Drive AS - Remove and Install

8.7.1 Removal

Release the residual pressure in the hy-

draulic circuit. Refer to “Residual Pres- 3
sure in Hydraulic Circuit - Release” on
page 6-30.

Lower the work equipment to the ground.

Stop the engine. Press the release button
5
of the breather valve to release residual
pressure in the hydraulic tank. Place the 7
4 1 6
2
hydraulic lockout control in the LOCK po- ZXT225-1106002
sition.

1. Disconnect the hoses (1) to (7).

1) Between hydraulic tank and swing mo-

tor (port DR)

2) Between central swivel joint and swing 8

motor (port DR)
9
3) Between swing motor and main valve
(port M)

4) Between swing motor and main valve

(port HA)

5) Between swing motor and main valve

(port HB)
ZXT225-1106003
6) Between swing motor and main valve
Px port (port SH)

7) Between swing motor and solenoid

valve block (port PG)

2. Remove the 11 fixing bolts (8).

3. Lift the swing motor and swing drive as-

sembly (9) for disassembling.

8-32 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

★ Slowly lift the swing motor and swing

drive assembly in order to avoid dam-
aging the hoses and other parts.

Swing motor and swing drive as-

sembly: 260 kg

8.7.2 Installation

● Installation is performed in the reverse or-

der of removal.

Mounting bolts (swing motor and

swing drive assembly):

490~608 N·m {50~62 kgf·m}

● Hydraulic oil adding

Add hydraulic oil through the filler opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

● Air bleeding

For more information, see “Air in Each

Component - Bleed” on page 6-36.

Shop Manual - April 2017 8-33

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.8 Swing Motor and Swing Drive AS - Disassemble and Assemble

8.8.1 Disassembly

1. Draining of oil

Open the drain plug to drain the oil from

the swing drive.

Swing drive: approx. 4.4 L

2. Swing motor assembly

1) Place the swing motor and swing drive

assembly on a suitable cribbing. Be 1
careful not to damage the drive gear or
let it contact the ground.

2) Unscrew the 14 bolts in order to re-

move the swing motor assembly (1).

Swing motor assembly: 62 kg

ZX225-1006077

3. No.1 sun gear 2

1) Remove No.1 sun gear (2).

ZX215-1006072

8-34 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4. No.1 planetary carrier assembly

3 4
1) Remove No.1 carrier assembly (3) and
the plate (4).

ZX215-1006073

2) Disassemble the carrier assembly.

Cut the rivets on the shaft (8) to re-

move the shaft (8), and remove in turn
6 7 8 9
the gear (6), bearing (9) and plate (7). 5

ZX215-1006074

5. Ring gear
10
Unscrew the mounting bolts to remove the
ring gear (10).

ZX215-1006075

Shop Manual - April 2017 8-35

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6. No. 2 sun gear 11

Remove No. 2 sun gear (11).

ZX215-1006076

7. No.2 planetary carrier assembly

12
1) Remove No.2 carrier assembly (12).

ZX215-1006077

8-36 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

2) Disassemble No. 2 carrier assembly as

per the following procedure.
19 16 15
i) Insert pin (13) and push the shaft 18
(14) out of the carrier assembly (19).
17
★ Pull out the pin (13) after removal of
14
the shaft.
13
ii) Remove the thrust washer (16),
gear (17) and a second thrust
ZX215-1006078
washer (19).

iii) Insert the pin (15) to remove the

bearing (18) from the shaft. Remove
the pin (15).

8. Snap ring 20

Remove the snap ring (20).

ZX215-1006079

9. Disassembly of main shaft

Press 21 22
1) Place the shaft housing assembly on a
press and push the shaft assembly (21)
out of the shaft housing assembly (22).

ZX215-1006080

Shop Manual - April 2017 8-37

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2) Disassemble the shaft assembly in the

Press
following procedure.

Remove the bearing (23) from the shaft

(24).

23

24

ZX215-1006081

10. Bearing
26
Remove the bearing (25) and the oil seal 27

(26) from the housing (27).

25
ZX215-1006082

8-38 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.8.2 Assembly

★ Clean all the parts and check for any

contamination or damage. Apply engine oil 23
to the sliding surface of the parts.

1. Bearing

Press the bearing (23) into the housing

(27).

27
ZX215-1006083

2. Oil seal
27 26
Press the oil seal (26) into the housing (27).

Oil seal installation surface:

Gasket sealant (Loctite 515)

ZX215-1006084

3. Housing assembly
24
1) Position the plate (28) on the shaft (24).

2) Position the housing assembly (22) on

the shaft (24). Press in the bearing.
22

28
ZX215-1006085

Shop Manual - April 2017 8-39

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Bearing
22 25
Press in the bearing (25).

★ When press fitting the bearing, press

the bearing inner race and outer race
simultaneously. Never press only the
inner race.

★ After assembling the bearing, check if

the housing rotates freely.

ZX215-1006086

5. No. 2 Planetary carrier assembly

1) Reassemble No. 2 carrier assembly ac-

19 16 15
cording to the following procedure. 18

i) Assemble the plate (16) in the car- 17

rier assembly (19).
14
ii) Assemble the gear (17) in the car-
13
rier assembly (19). Put the bearing
(18) on the shaft (14). Slightly tap
the pin (15) into the bore after align- ZX215-1006078
ment. Use a rubber hammer to tap
the pin. Make sure that the pin (15)
must not higher than the bearing
(18).

iii) Push the shaft assembly into the

carrier assembly (19). Be careful
not to damage the gear and the
plate. Align the pin bore of the shaft
with that of the carrier assembly,
and install the pin (13). Carefully tap
the pin with a rubber hammer dur-
ing installation.

★ Installation of the shaft requires ro-

tating the planetary gear. Be careful
not to damage the thrust washer.

8-40 Shop Manual - JApril 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

6. Assemble in turn the snap ring (20),

No.2 carrier assembly and No.2 sun No.2 planetary carrier 11 20
gear (11).

ZX215-1006087

7. Installation of ring gear 10

Apply sealant on the mating surface

indicated by (C) and tighten it with screws.
c
Never get the sealant onto the ring gear
(10).

Mating surface:

Sealant (Loctite 515)

8. No. 1 planetary carrier assembly ZX215-1006088

1) No. 1 carrier assembly is assembled as

per the following procedure.

i) Install the plate (7) into the carrier

assembly (5).

ii) Install the gear (6) onto the plate af-

8 9
ter installing the bearing (9) into the 6 7
5
gear.

iii) Press the shaft (8) into the gear (6)

and the carrier assembly (5). Rivet
one end of the shaft.

★ Check if the gear rotates freely.

ZX215-1006074

Shop Manual - April 2017 8-41

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2) Install No. 1 carrier assembly (3) and

3 4
the plate (4).

ZX215-1006073

9. No. 1 sun gear assembly 2

Install No. 1 sun gear (2).

ZX215-1006072

8-42 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

10. Installation of swing motor assembly

Apply sealant to the contact surfaces of the

ring gear and the motor cover, and install
the swing motor assembly.

Contact surface:

Sealant (Loctite 515)

Swing motor assembly: 62 kg

Mounting bolts (swing motor):

156±5 N·m {16±0.5 kg}

★ The 14 bolt holes of the swing motor

and swing drive assembly are distrib-
uted nonuniformly. The mating direction
of each hole is fixed, as shown in the
illustration on the right. The installa-
tion of swing motor requires proper
alignment of the bolt holes in order to
ensure the installation orientation.

ZX215-1006089

11. Lubricant adding

Screw on the drain plug and add lubricant

through the filler to the specified level (the
upper mark of oil stick).

Swing drive: approx. 4 L

Shop Manual - April 2017 8-43

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.9 Idler AS - Disassemble and Assemble

8.9.1 Disassembly

1. Remove the dowel pin (1) and the support 7

(2). 8
6
13 12
2. Remove the float seals (3) from the sup- 10
5
port (2) and the idler (4).

3. Remove the O-ring (11). Remove the idler

(4) from the shaft (5) and the support as- 9 11
3
sembly (7). 1

★ The idler contains 80 ml oil, which

should be drained completely before
disassembling. Spread a cloth on the 4
2
floor to prevent smearing the floor with ZX215-1006090
oil.

4. Remove the float seals (6) on the other

side from the idler (4), shaft (5) and sup- 4 6
port assembly (7). 5

6 7
ZX215-1006091

5. Remove the dowel pin (8) in order to re-

move the support (7) from the shaft (5).
5
6. Remove the bushings (9) and (10) from the 9，10 4
idler (4).

7 8

ZX215-1006092

8-44 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.9.2 Assembly

1. Install the bushings (9) and (10) in the idler

(4).

9 10 4

ZX215-1006093

2. Assemble the O-ring. Install the support (7)

to the shaft (5) with the dowel pin (8).
5
9，10 4

7 8

ZX215-1006092

3. Install the float seals (6) to the idler (4),

shaft (5) and support (7) assembly.

★ Float seals
6

Completely remove the grease from the

contact surfaces (hatched area in the
illustration on the right) of O-ring and
float seal before installing the float seal.
In addition, care must be taken to keep
the contact surface of float seal free ZX215-1006094
from dust.

Shop Manual - April 2017 8-45

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

★ After installation of the float seals,

check that the sealing inclination should
be less than 1 mm and the seal protru-
sion between 5 and 7 mm. a

ZX215-1006095

4. Install the shaft (5) and support (7) assem-

7 5
bly to the idler (4). 4

ZX215-1006096

5. Install the float seal (3) to the idler (4) and

support (2).
4 3
★ Apply oil to the sliding surface of float 2 3
seal. Care must be taken to keep the
sliding surface from any contaminants
or dust.

★ Remove the oil and dust from the

contact surfaces of the O-ring and float
seal. ZX215-1006097

8-46 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

ZX215-1006098

6. Install the O-ring. Install the support (2)

7
with the dowel pin (1). 8
6
13 12
7. Add oil and screw on the plug. 10
5

Oil: approx.
9 11
80 ml (No.18 hyperbola gear oil)
3
1
Plug:

205.8±49 N·m {21±5 kgf·m}

4
2
ZX215-1006090

Shop Manual - April 2017 8-47

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.10 Sprocket - Remove and Install

8.10.1 Removal

1. Remove the track assembly. Refer to “Track

AS - Remove and Install” on page 8-49.

2. Swing the work equipment 90°and lift the

chassis with the work equipment. Place a
block [1] between the track frame and the
track shoe.

3. Remove the sprocket (1).

1

Sprocket: 58 kg

ZX215-1006099

8.10.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Threads (bolt - sprocket):

Thread locker sealant (Tonsan 1277)

Bolts (sprocket):

339±20 N·m {35±2 kgf·m}

8-48 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.11 Track AS - Remove and Install

Special tools

Mark Part Name Necessity Qty

Manual/electric hydraulic
M track removing/installing ● 1
machine

8.11.1 Removal

1. Choose a place that has enough space to

spread the track. Park the machine when
the master pin is between the idler and the
carrier roller.

2. Lower the work equipment. Loosen the

grease fitting (1) and release the track ten-
sion.

The adjustment cylinder is under ex-

tremely high pressure. Never loosen 1
the grease fitting by more than one
turn. Move the machine back and forth ZX215T-1006100
if no grease is seen.

3. Pull out the master pin (2) with the tool (M).
2

ZX215-1006101

Shop Manual - April 2017 8-49

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Remove the tool (M). Move the machine

forward so that the temporary pin [2] is in
front of the idler. Place the block [1].

5. Remove the temporary pin [2] and the

dust seal. Move the machine backward to 3
②
spread the track [3].

ZX215-1006102

8-50 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.11.2 Installation

● Installation is to be performed in the re-

verse order of removal.

★ Refer to "Testing and Adjusting", "Track

Track shoe nut
Shoe Tension - Test and Adjust". Corner
(Square)

● Installation procedure of track shoe bolts R

and nuts R
Corner
1) Bring the R side of the track shoe nut (1) Corner
R
to the link seat surface. Both seat sur-
faces should be in close contact when
assembling the track shoe. Seat surface
in close contact
★ If the track shoe bolts are installed
from the other side, the corner of nut
will interfere with the link seat surface,
causing the nut to raise and the bolt to
loosen.
ZX215-1006103
2) Tighten the bolts of track shoe to the
torque below.

Track shoe bolts:

750±30 N·m {77±3 kgf·m}

★ Use the tool (M) to press the master pin.

Make sure that the protrusion of master pin
meets the size (a).

Master pin protrusion (a): 2.5±1 mm

a
★ Before installing the dust seal, apply
grease (No.2 lithium base) to its contact
surface with the bushing.

ZX215-1006104

Shop Manual - April 2017 8-51

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.12 Swing Bearing AS - Remove and Install

8.12.1 Removal

1. Remove the swing platform assembly. Re-

fer to “Swing Platform AS - Remove and
Install” on page 8-54.
2
2. Dismount the 36 bolts (1) to remove the
swing bearing assembly.

1
ZX215T-1006105

3. Hoist the swing bearing assembly (2).

2
Swing bearing assembly: 314 kg

ZX215T-1006106

8-52 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.12.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Threads (bolt - swing bearing):

Thread locker sealant (Tonsan 1277)

Mounting bolts (swing bearing):

Step 1:
Use a pneumatic spanner to tighten the
bolts.
Step 2:

Torque: 549±59 N·m {56±6kgf·m}

1) When a torque spanner is used to

tighten the bolts, tighten first the four
corners and mark them.

2) Other bolts will be tightened clockwise

or counterclockwise. After one bolt is
tightened, tighten the next one on the
diagonal position and make a mark.

3) Tighten the rest bolts in this way.

★ Let the S mark in the soft zone of the

inner race of the inner ring face the
right side, as shown in the photo, and
install the swing bearing to the track
frame.

★ Apply grease to the inside of the gear

ring of the swing bearing.
Inner race soft zone
● All gear teeth must be covered by
grease .

Swing bearing: ZX215T-1006107

Grease(supramoly lithium base):15 L

Shop Manual - April 2017 8-53

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.13 Swing Platform AS - Remove and Install

8.13.1 Removal

Fully extend the arm and the bucket. Low-

er the work equipment to the ground and
move the hydraulic lockout control lever
to the LOCK position.

1. Disassemble the work equipment assem-

bly. Refer to “Work Equipment AS - Re-
move and Install” on page 8-91.

2. Remove the counterweight assembly. Re-

fer to “Counterweight AS - Remove and
Install” on page 8-99.

3. Remove the four hoses (1) of boom cylin-

der.

★ Cork the hoses to prevent flow of oil.

ZX215T-1006108

4. Lift the boom cylinder assembly (2).

ZX215T-1006109

8-54 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

5. Remove the plate (3) and the pin (4). Lift

the boom cylinder assembly (2) in order to
remove it. 4
★ Remove the boom cylinder assembly
on the other side in the same way.

Boom cylinder AS: 230 kg

3

ZX215T-1006110

6. Remove the plate (5), air intake hose (6)

and fan guard (7).

5
★ Removal of the swing platform requires
removing other parts that interfere with
the lifting of swing platform.
7
6

Shop Manual - April 2017 8-55

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7. Disconnect the six hoses above the swivel

joint assembly.

8) Central swivel joint (port A) -

Left travel control valve (port BTL)

9) Central swivel joint (port C) -

Left travel control valve (port ATL) 10 11
9
10) Central swivel joint (port F) - 12
8
Solenoid valve 13
14 ZX215T-1006112
11) Central swivel joint (port G) -
Swing motor (port T)

12) Central swivel joint (port D) -

Right travel control valve (port ATR)

13) Central swivel joint (port B) -

Right travel control valve (port BTR)

8. Remove the bolt (14).

9. Unscrew the 32 swing platform mounting

bolts in order to remove the swing platform
assembly (15). Lift the swing platform as-
sembly off the machine.
15
★ Remove the front and rear mounting
bolts of the platform. Use a lever block
to adjust the swing platform so that
the platform can reach a balance both
longitudinally and laterally. Remove the
last two bolts finally.

Be careful not to impact the cen-

tral swivel joint while removing the
swing platform assembly.

Swing platform assembly:

ZX215T-1006113

8427 kg (1689 kg for the platform)

8-56 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.13.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Clamping screws (air intake hose):

5.4~6.4 N·m {0.55~0.65 kgf·m}

Mating surface (swing bearing):

Flat surface sealant (Tonsan 1596)

Threads (bolt - swing platform):

Thread locker sealant: (Tonsan 1277)

Mounting bolts (swing platform):

Step 1: Tighten the bolts with a pneumatic

spanner.

Step 2: tighten them again.

490~608 N·m {50~62 kgf·m}

● Hydraulic oil adding

Add through the filler opening the hydraulic

oil to the specified level. Start the engine
to circulate oil in the hydraulic system, and
check the oil level again.

● Air bleeding

Bleed the air from the travel motor.

For more information, see “Air in Each

Component - Bleed” on page 6-36.

Shop Manual - April 2017 8-57

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.14 Swivel Joint AS - Remove and Install

8.14.1 Removal

Release residual pressure in the hydraulic

circuit. Refer to “Residual Pressure in
Hydraulic Circuit - Release” on page 6-30. 4
★ Tag each line so as to ensure correction 3 5
installation.

6
1. Disconnect the 6 hoses from (1) to (6) on
the central swivel joint of the travel motor. 2 1

(1): Central swivel joint (port T)-

ZX215T-1006114
Left travel motor (port T)

(2): Central swivel joint (port T)-

Right travel motor (port T)

(3): Central swivel joint (port B)-

Left travel motor (port PA) 10
9
(4): Central swivel joint (port D)-
13
Right travel motor (port PB)

(5): Central swivel joint (port A)- 7

Left travel motor (port PB) 11 12 8
(6): Central swivel joint (port C)-
14
Right travel motor (port PA) 15
ZX215T-1006115
2. Disconnect the 8 hoses from (7) to (14).

(7): Central swivel joint (port F)-

Left travel motor (port P)
(8): Central swivel joint (port F)-
Right travel motor (port P)
(9): Central swivel joint (port G)-
Swing motor (port T)
(10): Central swivel joint (port F)-
Solenoid valve

8-58 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

(11): Central swivel joint (port C)-

Left travel control valve (port ATL)
(12): Central swivel joint (port A)-
Left travel control valve (port BTL)
(13): Central swivel joint (port D)-
Right travel control valve (port ATR)
(14): Central swivel joint (port B)-
Right travel control valve (port BTR)

3. Remove the fixing bolt (15).

4. Remove the four mounting bolts (16).

16
ZX215T-1006116

5. Remove the six mounting bolts (17) from

the transition plate. Remove the swivel
joint assembly (18)
18

Central swivel joint: 56 kg

Transition plate

16
17
ZX215-1006117

Shop Manual - April 2017 8-59

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.14.2 Installation

● Installation is to be performed in the re-

verse order of removal. BD

Central swivel joint

Install the central swivel joint facing the
direction indicated in the illustration.
Sprocket
(In the illustration, the machine is seen
from the above.)

● Oil adding (hydraulic tank)

AC
Add through the filler opening the hydraulic ZX215-1006118

oil to the specified level. Start the engine

to circulate oil in the hydraulic system, and
check the oil level again.

● Air bleeding

Bleed the air from the travel motor.

For more information, see “Air in Each

Component - Bleed” on page 6-36.

8-60 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.15 Swivel Joint AS - Disassemble and Assemble

8.15.1 Disassembly
1
1. Remove the bolt (1) and the spring washer 2
(2). 3

2. Remove the cover (3). 4

5
3. Remove the gasket (4), O-ring (5) and 6
snap ring (6). 7

4. Remove the rotary shaft (13) from the ro- 8

tary block (9).

★ Be careful not to damage the sliding

9
surface of the seal of the rotary shaft
(13).

5. Remove the spacer (7) and the gasket (8) 10

from the rotary block (9).

6. Remove the dust seal (12) from the rotary 11

shaft (13). 12

13

ZX215-1006119

7. Remove the O-ring seal (11) and the seals

(10) from the rotary block (9).

ZX215-1006120

Shop Manual - April 2017 8-61

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.15.2 Assembly

1. Install the dust seal (12) on the rotary shaft

(13).
Dust seal
★ Let the lip face the housing while
installing the dust seal.
Lip
2. Install the six seals (10) in the rotary block
(9).

3. Fix the rotary shaft (13) on a work bench. Body

Install the rotary block (9) on the shaft (13).

ZX215-1006121
★ Since the clearance between the
rotary block (9) and the shaft (13) is
approximately 0.1 mm, install the rotary
block (9) on the shaft (13) slowly and
vertically. Be careful not to damage the
seals and the O-ring seal.

4. Use a rubber hammer to tap the rotary

block (9) in order to match the rotary shaft
(13) properly.

5. Install the spacer (7) and gasket (8) in the

rotary block (9).

6. Install the gasket (4), O-ring seal (5) and

snap ring (6) on the rotary shaft (13).

7. Install the cover (3). Tighten the bolts (1)

and the spring washer (2).

Fixing bolts: 49 N·m{5 kgf·m}

8-62 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.16 Hydraulic Tank AS - Remove and Install

8.16.1 Removal

1. Drain the hydraulic oil into a suitable

container for storage or disposal. 1

2 5
Hydraulic oil: approx. 225 L 4
3
2. Open the engine hood.

3. Remove the engine hood (1), cover (2) and

control valve cover (3).

4. Remove the cover mounting frame (4) and

the screen (5).
ZX215T-1006122

5. Remove the screen (6) and the partition

frame mounting bolt (7) on the hydraulic 7
6
tank side.

6. Remove the screw (8) and the fuel control

motor (9).

7. Remove the two oil return hoses (10) from 8

the hydraulic tank. 9
10

ZX215T-1406123

Shop Manual - April 2017 8-63

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8. Disconnect the 7 hoses.

(11): Oil return - pilot T block

(12): Oil return - Main pump
(13): Oil return D2- main valve 17

(14): Sensor - temperature

(15): Oil return - solenoid valve 18

(16): Oil return D1/D3 - main valve 15 11

12
(17): Oil return - swing motor 13
16 14
ZX215T-1006125
★ Disconnect the oil inlet hose from the
hydraulic tank after disconnection of
the oil inlet tube from the pump.

★ Attach each hose with an identification

tag.

★ Use a sleeve nut to prevent the fitting

and the cone seal from damage.

19
19

9. Remove the hose clamp (19).

ZXT225-1106008

10. Lift the hydraulic tank assembly and re-

move the six bolts (20).

11. Lift off the hydraulic tank assembly for dis- 20

assembling.

Hydraulic tank assembly: 130 kg

ZX215T-1006127

8-64 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.16.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Drain plug (hydraulic tank):

58.8~78.5 N·m {6.0~8.0 kgf·m}

★ After tightening the hose clamping

screw, check that the screw should be Screw
in the range indicated in the illustration.

Screw (hose clamp):

8.8±0.5 N·m {0.9±0.05 kgf·m} Up

Down

ZX215-1006128

★ Install the hose clamp and tighten the

screw according to the illustration on Pipe Clamp Hose
the right.

Bolt:

245.2~308.9 N·m {25~31.5 kgf·m}

● Oil adding (hydraulic tank) Bulge

ZX215-1006129
Add hydraulic oil through the filler opening
to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

● Air bleeding

For more information, see “Air in Each

Component - Bleed” on page 6-36.

Shop Manual - April 2017 8-65

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.17 Control Valve AS - Remove and Install

8.17.1 Removal

Lower the work equipment to the ground.

Stop the engine. Press the release button
of the breather valve to release residual 1
pressure in the hydraulic tank. Place the
hydraulic lockout control in the LOCK po-
2
sition.

★ Tag each line so as to ensure correction

installation.

1. Lift the hood (1).

2. Remove the cover (2) above the control

valve.

3. Remove the plate (3).

ZXT225-1106010

4. Remove the baffle (4) to (9) of the pres-

sure transducer and tag them.

4): XAK Bucket DIG

(5): XBb1 Boom DOWN 7
4
(6): XAtL Travel LEFT 8
(7): XBa1 Arm IN 5
(8): XBs Swing RIGHT 9
6
(9): XAtr Travel RIGHT

ZXT225-1106011

8-66 Shop Manual - April 2017

SY215C9C5K/225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

5. Disconnect the pilot hoses (10) to (18) and

tag them properly. 10 11 12 13 14

(10): XBtr Travel RIGHT

(11): XAs Swing LEFT
(12): PSP Swing priority 18
(13): XAa1 Arm OUT
(14): XBp2 Bucket confl uence 15
16
(15): XBtL Travel LEFT 17

(16): XAb1 Boom UP ZXT225-1106012

(17): XBK Bucket DIG

(18): XAa2 Arm OUT

6. Remove the port (19) (accumulator to

solenoid valve), port (20) (pilot filter to ac-
cumulator). Remove hose clip (21) of the
central swivel joint.

21
19 20
ZXT225-1106013

7. Disconnect bucket hoses (22) and (23) and

seal the ports.

8. Disconnect arm hoses (24) and (25) and

seal the ports.

9. Disconnect boom hoses (26) and (27) and

seal the ports.
22 24 23
25

26
27 ZXT225-1106014

Shop Manual - April 2017 8-67

Disassembly and Assembly SY215C9C5K/225C9C5K Crawler Hydraulic Excavator

10. Disconnect central swivel joint hoses (28),

(29), (30) and (31). Remove the travel 32
speed switching hose (32) and seal the
port.

30
29
28 31

ZXT225-1106015

11. Remove swing motor hoses (33) and (34).

Remove swing motor oil complement hose
(35). Seal the ports properly. 33

35
34

ZXT225-1106016

12. Remove pipe (36) (main valve to radiator).

36

ZXT225-1106017

8-68 Shop Manual -April 2017

SY215C9C5K/225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

13. Remove pipe (37) (main valve to return oil

tank). Seal the ports properly.

37

ZXT225-1106018

14. Remove hydraulic pump hoses (38) and

(39).

38 39

ZXT225-1106019

15. Remove hoses (40 to 44) under the control

44 43 42 41 40
valve and tag them properly.

(40): PPC lockout valve

(41): Main valve PnA2
(42): Main valve XBP2
(43): Main valve PSP
(44): Travel PT port
ZXT225-1106020

Shop Manual - April 2017 8-69

Disassembly and Assembly SY215C9C5K/225C9C5K Crawler Hydraulic Excavator

16. Remove the fixing bolts (45). Lift the con-

trol valve assembly for disassembling.

Control valve assembly: 220 kg

45
45
46

ZXT225-1106021

8.17.2 Installation

● Installation is to be performed in the re-

verse order of removal.

● Oil adding (hydraulic tank)

Add hydraulic oil through the filler opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

● Air bleeding

Bleed the air from the circuit between the

valve and the hydraulic cylinder. For more
information, see “Air in Each Component -
Bleed” on page 6-36.

8-70 Shop Manual - April 2017

SY215C9C5K/225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.18 Hydraulic Pump AS - Remove and Install

8.18.1 Removal

Lower the work equipment to the ground

and stop the engine. Press the release
button of the breather valve to release re-
sidual pressure in the hydraulic tank.

Disconnect the cable from the negative (-)

post of the battery before performing the
job.

★ Tag each line so as to ensure correction

installation.
Oil stopper
1. Remove the oil inlet filter element from the
hydraulic tank and stop oil outflow with an
oil stopper.
ZX215-1006144
★ If no oil stopper is used, remove the
drain plug and drain the oil from the
hydraulic tank and from circuits.

Hydraulic tank: Approx. 225 L

2. Lift the engine hood (1).

ZX215T-1006145

Shop Manual - April 2017 8-71

Disassembly and Assembly SY215C9C5K/225C9C5K Crawler Hydraulic Excavator

3. Remove the pin (2) and the bolts (3). Lift

the engine hood in order to remove it.

4. Remove the right upper cover (4).

4

ZX215T-1006147

5. Disconnect the oil feed hose (5) of the

lower proportional valve and the oil outlet
hose (6) of the pilot pump. Seal the oil port
properly.

5 6

ZX215T-1006148

8-72 Shop Manual - April 2017

SY215C9C5K/225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

6. Disconnect the shutdown wire (7).

7
ZX215T-1006149

7. Remove the right door (8).

8. Remove the plate (9).

9
ZX215T-1006150

9. Disconnect the oil drain hose (10) and seal

10
the openings properly.

10. Disconnect the high-pressure hoses (11)

and (12) connecting to the control valve,
and seal the openings properly.

11. Disconnect the harness (13) of the pres- 12

sure transducer. 11

12. Disconnect the pilot pump oil inlet hose (14) 13

and seal the openings properly. 14
15
13. Disconnect the pilot pump oil inlet tube (15) ZX215T-1006151

and seal the openings properly.

Shop Manual - April 2017 8-73

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

14. Remove solenoid valve harness (16) and

(17). Remove the cable straps (18) and
(19).

16 18 19 17
ZX215T-1006152

15. Remove the four bolts (20) of the hydraulic

pump. Lift the hydraulic pump assembly
(21) to remove it.
21
Hydraulic pump assembly: 112 kg

20

ZX215T-1006153

8-74 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.18.2 Installation

● Installation is to be performed in the re-

verse order of removal.
Screw

★ After tightening the hose clamping

screw, check that the screw should be
in the range indicated in the illustration. Up
Down

Screw (hose clamp):

8.8±0.5 N·m {0.9±0.05 kgf·m}

ZX215-1006128

★ Install the hose clamp and tighten the

screw according to the illustration on Pipe Clamp Hose
the right.

Mating surface (hydraulic pump

housing):
Bulge
Gasket sealant: (Loctite 515) ZX215-1006129

● Oil adding (hydraulic tank)

Add hydraulic oil through the filler opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

Hydraulic tank: approx. 225 L

● Air bleeding

For more information, see “Air in Each

Component - Bleed” on page 6-36.

Shop Manual - April 2017 8-75

Disassembly and Assembly SY225C9C5K/225C9C5K Crawler Hydraulic Excavator

8.19 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install

8.19.1 Removal

1. Remove the hydraulic pump assembly (1).

Refer to “Hydraulic Pump AS - Remove
and Install” on page 8-71.
1
2. Remove the screw (2). Remove the bear- 2
ing cover (3). 3
4
3. Pry the oil seal (4) out with a screwdriver.

★ Be careful not to damage the shaft

while prying the oil seal.
ZX215-1006154

8.19.2 Installation

● Installation is to be performed in the re-

verse order of removal.
4

Seal lip:

grease (No.1 Calcium base grease)

Seal circumference:

grease (No.1 Calcium base grease)

★ Apply a thin layer of grease to the oil

seal circumference. ZX215-1006155

8-76 Shop Manual - April 2017

SY215/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.20 Pilot Valve AS (Work Equipment) - Disassemble and Assemble

★ This section discusses only the precautions

when reassembling the work equipment
pilot valve assembly.

8 9

1 2 3 4 5 6 7 10

ZX215T-1006156

8.20.1 Assembly

● Reassembly of the work equipment pilot

valve assembly

1. Install the plate (9) in the valve body (8)

with O-ring seal. Tighten the socket bolt
(10).

Socket bolt:

25~33 N·m {2.55~3.36 kgf·m}

2. Insert the spring (7) into the spool hole in

the valve body (8). Put the spool (6) in the
spring. Install the plug (5) on the spool.
Push the plug (5) to the spool hole.

3. Install the plate (4) on the plug (5). Tighten

the U-joint (3).

4. Install the plate (2). Align the position of the

plate (2) and tighten the nut (1).

Nut:

98~133 N·m {10~13.5 kgf·m}

★ Location of each oil port is stamped on

the bottom of valve body.

Shop Manual - April 2017 8-77

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Plug (5) circumference:

Grease (No.1 Calcium base grease)

U-joint moving surface:

Grease (No.1 Calcium base grease)

Threads in valve body:

Thread locker sealant (Tonsan 1277)

★ Apply the thread locker sealant (Tonsan

1277) to two points on the inner
5~7 mm
threads, as indicated in the illustration
below. The amount of application is
approximately 0.02 g.

U-joint (3):

98~133 N·m {10~13.5 kgf·m}

★ Tightening is to be made to the speci-

fied torque. ZX215-1006157

Contact surface between plug

(5) and plate (2):

Grease 0.3~0.8cc (No.1 Calcium base

grease)

★ See also “Pilot Valves (Work Equipment

and Swing) - Adjust” on page 6-26.

8-78 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.21 Pilot Valve AS (Travel) - Disassemble and Assemble

★ This section discusses only the precautions when reassembling the travel pilot valve assem-
bly.

Plunger

9 8 7 6 4 3 2 1
5

ZX215T-1006158

8.21.1 Assembly

● Reassembly of the pedal pilot valve as-

sembly

1. Install the spring (8) into the spool installa-

tion hole in the body assembly (9). Install
the spool (7). Place the cover assembly (6)
on the spool and press the cover assembly
(6) with a hand.

2. Install the cover (4) after aligning the holes.

Tighten the socket bolts (1).

Bolt (socket):
98~114 N·m {10~11.6 kgf·m}

3. Install the dust ring (3) on the plug. Install

the cover (2) and fix the cover (2) with the
camshaft (5).

Contact surface between the plug

and the dust ring (5):
Grease (No.1 Calcium base grease)

Shop Manual - April 2017 8-79

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.22 Hydraulic Cylinder AS - Disassemble and Assemble

Special tools

Application Tool Shape Necessity Quantity

Pulling out/pushing
■ 1
in the bushing

Press fitting the

■ 1
dust ring

O-ring seal correc-

■ 1
tion

Inserting tool Correcting tool

Inserting the cylin-

■ 1
der head

Inserting the piston ■ 1

8-80 Shop Manual - April 2017

SY215/235C9C3KL Crawler Hydraulic Excavator Disassembly and Assembly

8.22.1 Disassembly

1. Drain the oil and remove the tubing.

2. Fix the cylinder.

● Fix the cylinder in a vertical or level

manner. A vertically fixed cylinder can
be disassembled and assembled eas-
ily.

● The pin bore in the head end can be

used for fixing of the cylinder. The pin
roll can prevent the cylinder from turn-
ing.

● Remove the tubing in case of tubing in-

terference while fixing the cylinder.
Fix the cylinder

ZX215-1006164

3. Removal of cylinder head

Approx 1.5m
● Unscrew the bolts with Allen Wrench.

● Using an extension rod, as shown in

the illustration on the right, will make
the work easy.

ZX215-1006165

Shop Manual - April 2017 8-81

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Pulling out the piston rod

● Be sure to have removed the tubing

cover.

● Prepare a suitable container to collect

oil coming out of the oil port. 1 2

● After pulling out the piston rod to its

limit, slowly loosen the cylinder head
and pull it out. Sleeper

● Remove the piston rod (1) with the

cylinder head (2) and place them on a ZX215-1006166
wooden sleeper.

5. Fixing the piston rod

● Use pin bore on the rod end or the flat

part of the ear to prevent turning of the Fixing 5
piston rod.

ZX215-1006167

8-82 Shop Manual - April 2017

SY215/235C9C3KL Crawler Hydraulic Excavator Disassembly and Assembly

6. Remove of the piston nut (5)

Drill bit
1) Remove the fixing screw (3) from the 3
piston nut (5).

NOTE: Around the fixing screw there

are two points that have been punched
against loosening. After removing the
riveted part with a hand drill, loosen
and remove the fixing screw (3).

2) Remove the steel ball (4). 4 ZX215-1006168

3) Remove the piston nut (5).

NOTE: The piston nut (5) is very tight.

To loosen the piston nut (5), prepare 5
a hydraulic jack or a spanner powered
by hydraulic cylinder. An extension rod
should be ready when removing the
piston nut (5) manually.

Hydraulic jack

Hydraulic cylinder

ZX215-1006169

7. Removal of piston assembly

● Remove in turn the piston (7), buffer

sleeve (6) and cylinder head (2).
2 6 7

ZX215-1006170

Shop Manual - April 2017 8-83

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8. Removal of the buffer sleeve (8) on the

bottom end Thread

1) Remove first the piston nut (5).

Piston rod
2) Use a tool like rubber hammer to tap
the piston nut (5) slightly for removal
while keeping the piston rod and the
buffer sleeve (8) intact. Remove the
elastic ring (9). 9 8 11
10
one gap (2 pcs)
3) Slide the buffer sleeve (8) toward the
ZX215-1006171
piston threads in order to remove the
two-piece stopper ring.

4) Remove the buffer sleeve (8).

5) There is an opening in the buffer seal

(10). Take advantage of this opening to
remove the buffer seal (10).

9. Removal of piston seal

Screwdriver
1) The slide ring (12) and the guard
ring (13) can be simply removed with 14 12
Piston
hands.

2) The seal (14) can be removed with a Bench clamp

hammer and a flat-head screwdriver.

3) Remove the O-ring seal (15) with a pry

bar.
15 13
NOTE: The removed seals should not ZX215-1006172

be reused.

10. Removal of buffer ring (16)

NOTE: The buffer ring (16) is installed

in the inner groove in the cylinder head. 18
Use a tool with sharp end to pry it out and
remove it with a scraper.

20
17 16 19

ZX215-1006173

8-84 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

11. Removal of the U-ring (17) and the dust

ring (18)
Press
1) Remove the U-ring (17) with a tool such
as screwdriver.
Cushion
2) Pierce a tool (such as a screwdriver)
into the dust ring (18) and hammer the
screwdriver to remove the dust ring 21
(18).

NOTE: The removed seals should not

be reused. Support
ZX215-1006174

12. Removal of bushing (19)

1) Remove the elastic ring (20) from the

cylinder head (2) with a screwdriver.

2) Push the bushing (19) out with the help

of clamps and press.

13. Removal of bushing (21)

1) Remove the dust ring (22) on the side

of cylinder barrel and piston rod with a
tool such as screwdriver.

2) Remove the bushing (21) with the help

of a suitable cushion block.

Shop Manual - April 2017 8-85

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.22.2 Assembly

1. Installation of bushing (21)

1) Use a mounting tool to press the bush- Press

ing (21) into the bushing (lubricated
with hydraulic oil) on the side of piston Mounting tool
rod and cylinder barrel. Cushion
21 Piston rod
2) Install the dust ring (22) with the help of 22
a suitable cushion block.
21

ZX215-1006175

2. Assembly of cylinder head (2)

Hydraulic press
1) Use the press to push in the bushing
(19).
2
Tool
NOTE: Apply hydraulic oil to the inside
of cylinder head in advance. Make
sure that the bushing (19) pushed in is
free from a raised shoulder.
19
2) Use the press to push in dust ring (18). Pressure surface

ZX215-1006176

3) Install the guard ring and the U-ring (17)

sequentially in the U-groove.
18
NOTE: Tool
U-groove
● Install the U-ring (17) in correct direc-
tion. Make sure that the U-ring is intact
before installation. Press in

● Inverse installation will cause leak of

oil.

● Make sure that the U-ring is free from ZX215-1006177

any corrugation or permanent deforma-

tion after installation.

8-86 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4) Installation of buffer ring (16)

NOTE: Make sure that the seal is in-

stalled in correct direction. Inverse in-
stallation can cause high pressure be-
tween the buffer ring (16) and the U-ring 18
(17), which may lead to deformation or
breakage of oil cylinder.

5) Install the elastic ring (20) to prevent

the fall of the bushing (19). 20
17 16 19
3. Assembling the piston assembly
ZX215-1006173
1) Installation of seal (14).

NOTE: Install first the O-ring seal and

the one-side guard ring (13) on the pis-
Press
ton. Place the piston on the press. As Block Press
shown in the illustration on the right,
Tool
the seal (14) is installed with the tools
13
indicated.
Tool
2) Correction of seal (14) Corrector

NOTE: Install the seal (14) and the Piston

guard ring (13) on the other side. In 12 O-ring

order to prevent the expansion of the 14
seal (14), a corrector must be used to 13
correct the seal (14) which has been ZX215-1006179
stretched during installation. The piston
rod may not be able to go in the cyl-
inder barrel if the seal (14) is not cor-
rected timely.

3) Installation of slide ring (12)

NOTE: Slightly open the slide ring (12)

and install it axially. Excessive opening
of the slide ring (12) can fail installation.

Shop Manual - April 2017 8-87

Disassembly and Assembly SY215/235C9C3KL Crawler Hydraulic Excavator

4. Assembling the piston rod assembly

1) Fix the piston rod (1). Assembly tool 2

2) Install the cylinder (2) on the piston rod.

NOTE: Make sure that the dust ring lip

or the U-ring lip is not stopped by the
shoulder of any part. Install the cylinder
head and the piston rod with the tools.
1
3) If the bottom side of cylinder contains
ZX215-1006180
a buffer (not for bucket cylinder), install
the buffer bearing and the buffer seal in
the following order.

4) Let the notched side of the buffer seal

(10) face the piston while installing the
buffer seal (10) in the groove.

5) Install the buffer sleeve (8) according to

the indication in the illustration on the Gap facing thread direction
right. Thread

6) Install the stopper ring in the groove.

Install the elastic ring after the buffer Piston rod
sleeve (8) is pushed to the bottom. A
rubber hammer should be used for the
tapping job in order to avoid damaging
the piston rod and the buffer bearing.
9 10 8 11
7) If the head side of cylinder contains a One gap (2 pcs)
buffer, install the buffer sleeve (6) and Head end buffer
ZX215-1006181
the buffer seal (23) according to the fol-
lowing order.

8) The piston nut must be installed after

installation of the buffer bearing.

9) The buffer seal (23) must be installed in

the groove, with its notches facing the
piston.

8-88 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

10) The buffer sleeve (6) must be installed 23 6

according to the illustration on the right. 5

11) Tighten the piston nut (5).

Piston nut (arm):

9600 N·m {979.6 kgf·m}

Piston nut (boom and bucket):

6200 N·m {632.6 kgf·m}

Gap facing piston side
NOTE: Rod end buffer
ZX215-1006182
● Insufficient tightening can cause oil
leakage, loose nut and thread break-
age. In addition, excessive tightening
can cause expansion of the buffer shaft
on the extending side or deformation of
piston on the contact side.

● Thoroughly clean and grease (with ba-

nana oil) the threaded portions of the
piston, nuts and piston rod before tight-
ening the nuts.

12) Treatment of the piston against loosen-

ing

NOTE: After the piston nut (5) is tight-

ened, put in the steel ball (4), tighten Punch
the setscrew (3) and punch to rivet the Rivet
two peripheral points.

Setscrew (3):

66.9 N·m {6.8 kgf·m}

3

ZX215-1006183

Shop Manual - April 2017 8-89

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

5. Install the piston into the cylinder barrel Tool

Nylon sleeve
1) Fix the barrel in a vertical or level man- (2 pcs type)
ner.

2) Install the piston rod into the cylinder (Spread the

gaps by 180°)
barrel.

NOTE:

● If fixed in a vertical manner, the piston

rod falls into the barrel under its gravity.

● Make sure that the slide ring does not

fall while the piston is inserted into the
barrel.

ZX215-1006184

6. Tightening of cylinder head

8 1
Tighten the cylinder head according to the
sequence shown in the illustration on the 4 9
right.
12 5
Bolt: 267 N·m {27.2 kgf·m}
6 11
7. Install the tubing.
10 3

2 7
Tightening sequence
ZX215-1006185

8-90 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.23 Work Equipment AS - Remove and Install

8.23.1 Removal

Fully extend the arm and the bucket.

Lower the work equipment to the ground.
Move the hydraulic lockout control to the
LOCK position.

Release residual pressure in the hydraulic

circuit. See “Residual Pressure in Hydrau-
lic Circuit - Release” on page 6-30.

1. Disconnect the grease hose (1).

2. Lift the boom cylinder assembly (2). Re-

5
move the lock bolt (3).
1
3. Remove the plate (4) and then the pin (5).
3
2

★ There are shims installed. Count the

shims and check the thickness. Place 4
the shims in a safe place.

4. Start the engine and retract the piston rod. ZX215T-1006186

★ Secure the piston rod with a wire rope

in order to prevent the piston from
slipping out. Place the cylinder on a
bench or support. The grease fitting on
the bottom side must be removed in the
later case.

★ Remove the other boom cylinder in the

same way.

5. Remove the hose (6) of bucket cylinder

and the hose (7) of the arm cylinder.
6 10 7
★ Cork the hoses to prevent outflow of oil. 8 9
Secure the hoses to the side of valve.

ZXT225-1106028

Shop Manual - April 2017 8-91

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

6. Remove the inter-connector (8) used for

work lamp.

7. Lift the work equipment and remove the

plate (9). Remove the pin (10) from the 12
bottom.

11

ZXT225-1006196

★ There are shims installed. Count the

shims and mark their locations. 11

8. Lift and disassemble the work equipment

assembly (11).

Work equipment assembly:

3578 kg
ZX215T-1006189

8-92 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.23.2 Installation

● Installation is to be performed in the re-

verse order of removal.

★ A clearance (a: 0.5 - 1.5 mm) should be

left between the plate and the nut when
tightening the locknut.

Greasing after assembling pin:

Grease (supramoly lithium base)

Do not put your finger in the pin bore

while aligning the pin bore.
a
★ Adjust the shim thickness in order to
ZX215-1006190
have a desired clearance (a: 0.5<a<1
mm) between the piston end (12) and
the plate (4).

★ Standard shim thickness: 1.0 mm and 12 a

2.0 mm. 4

Greasing after assembling pin:

Grease (supramoly lithium base)

Do not put your finger in the pin bore

while aligning the pin bore.
ZX215-1006191

● Hydraulic oil adding

Add hydraulic oil to the specified level.

Start the engine to circulate the oil in the
hydraulic system, and check the oil level
again. Add more hydraulic oil if necessary.

● Air bleeding

Bleed the air from travel motor.

For more information, see “Air in Each

Component - Bleed” on page 6-36.

Shop Manual - April 2017 8-93

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.24 Air Conditioner AS - Remove and Install

Special tools

ID Part Name Model Necessity Qty

Refrigerant Robinair
● 1
charger 34711-2K
S
Refrigerant Inoue Qing-
● 1
charger Hua

8.24.1 Removal

Disconnect the cable from the negative (-) S

post of the battery.

1. Drain the coolant. ZX215T-1006192

Coolant: approx. 22.5 L

2. Recover refrigerant from the air-condition-
ing system with the tool (S).

1
3. Remove the pad (1) on the cab floor.

ZX215T-1006193

8-94 Shop Manual - April 2017

SY215C9c5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4. Open the left rear cover of the cab with the

ignition key. Remove the outer filter ele-
ment (2).

2 ZXT335-1006899

5. Remove the fuse box (3) and storage box

(4).

6. Remove outer covering (5).

7. Remove the air conditioner cover (6).

4
3
6 ZX215T-1006196

8. Remove the back air duct (7).

9. Remove the left air duct (8).

10. Remove the baffle (9).

10 7
11. Remove the right air duct (10). 8

ZXT225-1006205

Shop Manual - April 2017 8-95

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

12. Remove the cover (11).

13. Remove the cab's center connector (12).

14. Remove the radio antenna wire(13).

13
12

11
ZXT225-1006206

15. Remove the air duct (14), connector (15)

and air conditioner wiring connection (16).
Remove the two air conditioner relays (17), 17
three mounting bolts (18). Remove the
16
electrical mounting plate (19).
19

14
15 18 ZXT225-1006207

16. Remove the air conditioner water pipes (20)

and (21) as well as the dripping tube (22).

22 20 21

ZX215T-1006200

8-96 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

17. Remove the air conditioner unit (23).

★ Also disconnect the two hoses connect-

ing to the bottom of the air conditioner 23
when removing the air conditioner unit.

ZX215T-1006201

Shop Manual - April 2017 8-97

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.24.2 Installation

● Installation is to be performed in the re-

verse order of removal.

★ Keep the hoses free from contamination by

dirt, dust or water while installing the return
hose of the air conditioner.

★ Make sure that the O-ring seal is present

in the connection before connecting a hose
of the air conditioner.

★ Make sure that the O-ring seals are free

from any damage or deformation.

★ Apply compressor oil (ND8#) to the

threads of the parts connected with the
refrigerant lines. Tighten the line con-
nections with a double-end spanner.

Screw (hose clamp):

8.83~14.7 N·m {0.9~1.5 kgf·m}

Bolt (pressure plate):

13.5±1.2 N·m {1.38±0.12 kgf·m}

● Refrigerant charging

Charge refrigerant (HFC-134a) into the air

condition return lines with tool (S).

8-98 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.25 Counterweight AS - Remove and Install

8.25.1 Removal
1
1. Remove the cover (1) from the counter-
weight. Install eyebolts to the counter-
weight. Hold the counterweight.

ZX225-1106004

2. Remove the four bolts (2).

3. Lift the counterweight levelly with wire rope

or chain hoist.
Wire rope

2
★ Be careful not to damage the engine,
radiator or cooler.

Counterweight assembly:

3901 kg ZX225-1106005

3
ZX225-1106006

Shop Manual - April 2017 8-99

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.25.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Threads (mounting bolt - counter-

weight):

Thread locker sealant (Tonsan 1277)

Mounting bolt (counterweight):

1,180~1,470 N·m {120~150 kgf·m}

● Counterweight Installation and adjustment

1) Move the counterweight with a crane to

a suitable position on the frame.
Door
2) Push the counterweight and install the
c=0±5mm

bolts. Adjustment is to be made accord- Counterweight

ing to the following specification.

● Clearance with swivel: 10±5 mm(L&R) a=10±4mm

● Clearance with access door:10±5

mm(L&R) b=0±5mm

● Step difference from swivel in left to Swivel

right direction b: max. 5 mm ZX215-1006205

● Step difference from bodywork door in

left to right direction a: 10±4

● Step difference from top cover in upper

to lower direction c: max. 5 mm

8-100 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.26 Cab AS - Remove and Install

8.26.1 Removal

Disconnect first the cable connecting to

the negative (-) post of the battery.

1. Remove the floor mat (1).

ZX215T-1006193

2. Remove the fuse box (2) and storage box

(3).

3. Remove outer covering (4).

4. Remove the air conditioner cover (5).

3
2
5 ZX215T-1006001

5. Disconnect the left wire harness (6), moni-

tor harness connector (7) and window
washer harness (8).
7]’ 6
6. Remove the right side air duct (9).

ZXT225-1006216

Shop Manual - April 2017 8-101

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

7. Remove external air filter (10).

10
ZXT335-1006999

8. Disconnect the external air duct (11).

11

ZX215T-1006210

9. Remove the storage box on the armrest

(12).
12

ZX215T-1006211

8-102 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

10. Remove the radio connector (13).

11. Remove the radio wire harness (14).

13

14

ZX215T-1006212

12. Remove the window washer reservoir (15).

15

ZX215T-1006213

13. Remove the window washer pipe (16).

16

ZX215T-1006214

Shop Manual - April 2017 8-103

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

14. Remove the decor cover (17).

17

ZX215T-1006215

15. Remove the four mounting nuts (18) and

the five mounting bolts (19).
18

19

ZXT335-1006995

16. Lift the cab assembly (20) for removal. 20

Cab assembly: 633 kg

8-104 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.26.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Bolt: 200 N·m {20.4 kgf·m}

Nut: 210 N·m {21.4 kgf·m}

Shop Manual - April 2017 8-105

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.27 Cab Window Glass – Disassemble and Assemble

10 10

9
8
1

10

2
7

10 11
4

5
12

10
3

ZX215-1006218

1) Right window glass 7) Left side rear window glass

2) Front window glass 8) Rear window glass
3) Lower front glass 9) Roof window glass
4) Cab door window glass (upper) 10) Rubber sealing strip
5) Cab door window glass (lower) 11) Center adjusting seal
6) Cab door window glass (upper) 12) Front window AS (Glass and frame)

● Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame.

● When replacing front window glass (2), disassemble front window assembly (12). (If the cab
is install with a front window assembly, do not only replace the front window glass.) For more
information about front window replacement, see “Counterweight Assembly - Remove and In-
stall” on page 8-110.

8-106 Shop Manual - April 2017

SY215C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.27.1 Removal

CAUTION
● Removing shattered or cracked window
glass may cause finger cuts.

● Wear proper PPEs when removing shat-

tered cab window glasses.

NOTE: To avoid finger cut during when remov-

ing a shattered or cracked glass, cover it with
a piece of adhesive film or tapes.

1. Removal of glass (3)

Glass (3) is hold in place by sealing strips.

Pull it upward carefully to remove it.

ZX215-1006219

2. Removal of glass (4) and (6)

1) Remove the sealing strip from the

frame of the cab door.

2) Push the glass outward carefully from

inside of the cab and remove glass (4)
and (6) together with the frame.
6

ZX215-1006220

Shop Manual - April 2017 8-107

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3) Remove glass (4) and (6) from the

frame with a screw driver.

Frame
Seal

ZX215-1006221

3. Removal of glass (8)

1) Remove the retainer from the groove 8

on the rubber with an ordinary screw
driver.

2) Put a thin bamboo chip inside part A of

the retaining rubber and detach the re-
tainer along the edge.

3) Pat the glass from inside of the cab

and remove it. This job may require two
people. ZX215-1006222

Rubber retainer side

Rubber retainer Glass

Cab side Retainer

A A
Cab

ZX225-1006231

8-108 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4. Removal of glass (1), (2), (5), (7) and (9).

9
1

ZX215-1006223

1) Remove the resin board, decor strip

and retainer along the edge of the Cab
glass. Glass
Drill
2) Punch a hole through the adhesive with
a drill (or a cutter) as illustrated.

Adhesive

ZX215-1006224

3) Pull a piece of piano string (or steel

wire) through the hole as illustrated.

Piano string
(or steel wire)

ZX215-1006225

Shop Manual - April 2017 8-109

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4) Fix both ends of the piano string onto

two screw drivers. Pull the wire back Cab (Outside)
and forth in order to cut the adhesive
and detach the glass from the cab. This Glass

job may require 2-3 people.

● Run the string along the center of the

adhesive. The string may break when
it becomes very hot. Use different sec-
tions of the string while cutting the ad-
Adhesive
hesive.
(Inside)
ZX215-1006226

8-110 Shop Manual - April 2017

SY215/235C9C3K Crawler Hydraulic Excavator Disassembly and Assembly

8.27.2 Installation

● Reverse the disassembling sequence

when installing glasses (3), (4), (6) and
(8). Follow the procedures below to install
glasses (1), (2), (5), (7) and (9).

1. Clean the remaining adhesive and rubber

on cab frame (contact surface) with a knife
or scraper [5].

● Remove the remaining adhesive and

rubber so that they will not affect the
[5]
application of new adhesive. Do not
scrape the original paint on the surface.
ZXT215-1006227
(Scraping of paint reduces the perfor-
mance of the adhesive.)

2. Clean the grease, dust and dirt on the cab

(8) and the glass (9) with unleaded gaso-
line.

● Contaminant on the contact surface re-

duces the performance of adhesive.

● Clean the black part on the back of the 8

glass.

● After cleaning, dry the glass for at least

5 minutes.
ZXT215-1006228

ZXT215-1006229

Shop Manual - April 2017 8-111

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3. Priming coat (10)

● Priming paint expires 4 months after

production. Do not use expired paint.

● Use the paint within 2 hours after it is

Cab
unsealed. 11

● Use the paint within 24 hours even if it

10
is sealed again immediately after un-
Old adhesive edge
sealing. (Dispose the paint 24 hours on cab side
after it is unsealed)

1) Make sure the adhesive paint and glass

priming paint are well agitated before ZX215-1006230

application.

● If the priming paint is stored in a refrig-

erator, keep it under ambient tempera-
ture for at least half a day before agita-
tion.

● (If the paint is unsealed immediately af-

ter it is taken out of a refrigerator, water
will condense on it.)

2) Always wash a used brush (11) with

unleaded gasoline before using it.

● Check the brush for contaminants after

it has been washed.

● Prepare two brushes for priming paint,

one for painted surface and the other
for glass surface.

8-112 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

3) Apply priming paint (for painted sur-

face) evenly onto the surface where
sealing rubber is to be adhered and
where adhesive agent is to be applied 8
(on the cab (8)).

Priming paint (for painted sur-

face): Sunrise MSI Primer 24

● Do not apply primer more than twice;

otherwise, the performance of the prim-
er will be reduced.
ZXT215-1006231

● Applying location: Cover the whole area

of (a). Dimension of (a): 25mm
8

ZX215-1006232

● Besides the above locations, apply

primer also onto the right window glass
and the cab door lower window glass.

● Additional priming area on the right

b
window glass: (b)

● Additional priming area on the cab

door lower window glass: (c)

ZX215-1006233

Shop Manual - April 2017 8-113

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● Dry the primer for at least 5 minutes

(within 8 hours).

● Do not use wrong priming paint.

If, for example, glass primer is mistak-

enly used, wash it with unleaded gaso-
line.
c

ZX215-1006234

4) Apply priming paint (for glass surface)

onto the contact surface of window 9
glass (9).

Glass primer:

Sunrise MSI Primer 35

● Do not apply the primer more than

twice; otherwise, the performance of
the primer will be reduced.

ZX215-1006235

● Priming area: Apply the priming paint

on the contact surface of glass (9)
8
(rubber seal (6)adhering location) and
along cab frame (8).

● Leave a 5 mm margin uncoated along 6

the black strip adjacent to the clear
area of the glass. d

● When priming paint has been coated,

dry it for at least 5 minutes (within 8 9

hours).
ZX215-1006236
● Do not use wrong primer.

If wrong glass primer is used, wash it

with unleaded gasoline.

8-114 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4. Adhere rubber seal (6) (with adhesive tape

on both sides) along the inner edge of the
contact surface of the glass.

● Do not detach the waxed paper on the

rubber seal before the window glass is
installed.

● Do not touch the cleaned area on the

glass before rubber seal is adhered.

● Be careful not to allow the rubber seal 6

ZXT225-1006245
on the corners to peel off.

● When sticking rubber seal (6) along the

window frame, do not overlap the two
ends of the seal. A 5 mm gap between
the two ends of the seal is recommend-
ed.
e 6
1) Stick rubber seal (6) onto the right cab
window frame as illustrated.

ZXT225-1006246

● Adhere additional rubber seal (6a) onto f

the right cab window 6a

Position of the additional rubber seal:

(f): 50 mm
h
(g): 90 mm

(h): 250 mm

g
ZXT225-1006247

Shop Manual - April 2017 8-115

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2) Adhere rubber seal (6) on the left cab

window as illustrated.

ZXT225-1006248

3) Adhere rubber seal (6) onto the lower

cab door window as illustrated.

ZXT225-1006249

● Adhere additional rubber seal (6b) onto

j
the lower cab door window frame as il-
lustrated.
6b
Position of additional rubber seal:

(j): 110 mm m
(k): 90 mm

(m): 200 mm

k ZXT225-1006250

8-116 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

4) Adhere rubber seal (6) onto the front

window glass as illustrated. 6

ZX215-1006243

● Different from the rubber seal (6) on

other window, rubber seal (6c) on the
bottom of the front window shall be 6
adhered onto the external edge of the 6c
lower part of the front window frame.
(If it is adhered along the inner edge,
the rubber seal will be seen through the
clear part of the glass.)

ZXT225-1006252

5. Positioning of new window glass

1) Check the clearance between the edge

of glass and the cab in 4 directions, 9
and position the glass. Make sure the
clearance is even.
n
2) Put a tape [6] across the glass (9) and
cab (8) and draw a line (n) on it for
alignment. [6]

● Adhere tape [6] at 3 points as illustrated

for precise alignment of right window
glass, left rear window glass and cab
8
door lower window glass. ZXT215-1006245

3) Cut the tapes across the glass (9) and

the cab (8) and remove the glass.

● Do not remove the tape on the left side

of the glass until the glass is installed.

Shop Manual - April 2017 8-117

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● When positioning front window glass

(4), cover it across the width of the win-
dow frame in the horizontal direction. [6]
[6]
Set the clearance (p) between the top
edge of the glass and the upper frame
at 3 mm when positioning it in the verti- 8 [6]

cal direction.

ZX215-1006246

ZX225-1006255

8-118 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

6. Adhesive

● Store adhesion agent in dark places

where temperature is blow 25°C.
13
● Do not heat the adhesive to above
30°C.

● Before using adhesive that has been

unsealed, remove the hardened part at 12
the nozzle.

1) Open the aluminum seal (13) on the

head of the cylinder (12) and install the
nozzle (14). ZX215-1006247

Adhesive:

Sunrise MSI SR sealant U90 4463876

2) Cut the tip of nozzle (14) as illustrated.

Dimension of the cut:
14
(q): 10 mm r

(r): 5 mm

3) Set the cylinder (12) in the gun [7].

12 [7]
● An electrical caulking gun is more ef-
ficient.

ZX215-1006249

Shop Manual - April 2017 8-119

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4) Remove the waxed paper of the rubber

seal on the surface where adhesive is
to be applied. 15
6
5) Apply adhesive (15) along the external
edge of the rubber seal (6).

ZX215-1006250

● Adhesive (15) for rubber seal (6) on

cab (8) shall be applied as illustrated:
8
Dimension of (s): 10 mm s

Dimension of (t): 15 mm
6
● Adhesive (15) shall be thicker that the
rubber seal (6). t
15
● Apply adhesive of the same thickness
evenly.

ZX215-1006251

8-120 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

● Apply adhesive (15) onto the additional

rubber seal of the right window (6a) and 6a
additional rubber seal of the cab door 15
lower window (6b).

ZX215-1006252

6b 15

ZX215-1006253

7. Install window glass

1) Install window glass (9) and align it with

the mark on the cab. (See step 5)

● Since the glass can not be remove

once installed, be very careful when
performing this task.
9
● Install the glass properly within 5 min-
utes after adhesive has been applied.

2) Press the perimeter of the glass (9)

after is has been put in place until it is ZXT215-1006254
securely stuck to the rubber seal.

● Press the corners of the glass hard.

Shop Manual - April 2017 8-121

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

● After the front window glass has been

installed, fill the clearance between the
glass on area (s) and the center adjust-
A
ing seal (16) to the dimension of (t) and
(u). Coat primer onto glass (4) on sec-
A
tion A-A and apply the adhesive as fill- S
ers.
t
4
Dimension of (t): 2 mm

Dimension of (u): 5 mm
u
● Use a rubber spatula to cover the edge
of the glass and trim the adhesive. 16
A-A
● Remove surplus adhesive. ZX215-1006255

Glass primer:

Sunrise MSI Primer 35

Adhesive:

Sunrise MSI SR Sealant U90 4463876

8. Fix the glass

1) After the right window glass (1) has

been adhered to the cab, put position-
ing chips a (1 or 2 pcs) beneath the
glass in order to fix it.

a
ZXT215-1006256

8-122 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

2) Use foam polystyrene blocks [9] and

rubber band [10] to fix the glass and [10]
the rubber seal as illustrated.

9. After the glass has been fixed, remove all

the remaining primer and adhesive on the
cab and on the glass.

● Clean the adhesive with unleaded gas-

oline before it is hardened.
[9]
● Do not apply impacting force onto the
glass when cleaning it.
ZX215-1006257

10. Protection of fixed window glass

1) Remove the positioning chips, foam

polystyrene blocks and the rubber band
after 10 hours.

(Condition: Temperature: 20; humidity:

60%)

2) Wait for another 14 hours after the re-

moval of positioning chips, foam poly-
styrene blocks and rubber band before
operating the machine.

Shop Manual - April 2017 8-123

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.28 Front Window AS - Disassemble and Assemble

NOTICE
● Before removing the front window as-
sembly, lower the work equipment onto
the ground and shut down the engine.

The front window assembly must be removed

from the cab in order to replace the front win-
dow glass.

8.28.1 Disassemble

1. Raise the front window assembly to the

roof and secure it with the rear locks (at
both sides).

2. Remove left corner plate (1) and right cor-

ner plate (2).

● Mounting bolt (4) and washer (3) of the 2

left corner plate will be used in Step 6
4
to hang the pull rod. 3
1

ZX215-1006258

3. Release the rear lock of the cab.

4. Lower the front window assembly carefully

a bit. Take out and hold the rollers (5) and
(6) at the bottom of the front window from
the removed parts in Step 2.

5. Remove roller (5) and (6) from both sides

of the bottom of the front window.

6 5
ZX215-1006259

8-124 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

6. Remove pin (7) at the lower left side.

● Plate (8) at the end of the pull rod (9) 9

will come out by removing of pin (7).
8
● Hang plate (8) onto the mounting bolt
of left corner plate (using the washer)
and fix it.
6

NOTICE
7
● A return load of 58.8 N {6 kg} is applied ZX215-1006260
onto the rear of the cab. Be very care-
ful when removing pin (7) to disconnect
pull rod (9).

9 8

ZX215-1006261

7. Pull out the front window assembly (10)

from the opened part of the guide rail and 10
lower the assembly gradually.

ZX215-1006262

Shop Manual - April 2017 8-125

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8. Lower the front window assembly (10)

completely.
10
● Be careful not to allow the front window
assembly to damage the machine mon-
itor.

ZX215-1006263

9. Move the front window assembly (10) to

the right and the left and remove the two 12 11
upper rollers (11) and (12) from the guide
rail. Then, remove the front window as-
sembly (10).

10 ZX215-1006265

8-126 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.28.2 Assemble

● Reverse the disassembling sequence.

● Adjust the opening and closing of the front

window assembly as per the following in-
struction.

1. Open and close the front window assembly

and check if it interferes with the guide rail.
Check if the roller is jammed.

2. If the front window can not be opened or

closed properly, loosen the mounting bolt
of the roller adjusting bracket (13) and
adjust the condition of the front window.
Tighten the mounting bolt after adjusting.

Mounting bolt:
13
34.3 N·m {3.5 kgf·m} ZX215-1006266

3. Raise the front window assemble and fix it

with rear locks (at both sides).

● Check if the locks at the rear of the cab

are securely fixed.
a
4. Install the right corner plate (2).

● After the "locked" position is adjusted in

Step 6, tighten the corner plate. 2

a
● Install the right corner plate. Clearance
ZX215-1006267
(a) between the guide rail and the right
corner plate (2) is 0 – 2.0 mm.

● Install the right corner plate. Keep the

surface (R) of the roller without a level R
error.

ZX215-1006268

Shop Manual - April 2017 8-127

Disassembly and Assembly SY215C9C5K/SY225C9C5KCrawler Hydraulic Excavator

7. Install left corner plate (1)

● After the "locked" position is adjusted in

Step 6, tighten the corner plate. b

● Install left corner plate. Clearance (b)

between the guide rail and the left cor-
ner plate (1) is 0 – 2.0 mm.
b
● Install left corner plate and keep the
surface (R) of the roller without a level
error. (See previous illustration). 1

ZX215-1006269

8. Adjust the "locked" position of the lock of

front window assembly as per the following
instruction.

1) Tighten the left corner plate (1) and the

right corner plate (2) in a nearly correct
position so that front window glass (14) 15
is pressed closely against the adjusting
seal (15) on the cab.
14

ZX215-1006270
1) Open and close the front window as-
sembly and check the working condi-
tion of left lock (16) and right lock (17).

● If left lock (16) and right lock (17) do

not work properly, Loosen the mounting
bolt (19) of the lock and move the lock
(16) forward. Tighten the bolt after that.
16 17
● Adjust the right lock with the same
method.

2) Check again the adaptability between

the front window assembly (14) and
the adjusting seal (15) on the cab.
(Checked in Step 1)
ZX215-1006271
● Tighten the mounting bolts of the left
and right corner plates when the left
and right locks (16, 17) are properly in
place.

8-128 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

5. After adjustment is finished, flush the front

window glass and check if any water leaks
into the cab.

16 19
ZX215-1006272

6. Adjust the "locked" position of the lock of

front window assembly

1) After the "locked" position of the lock of

front window assembly is adjusted in
Step 6 and Step 7, raise the assembly
to the roof.

2) Set the locks of the front window as-

sembly at the rear of the cab at the 19 18
"locked" position, and check the follow-
ing items:

● Check the conditions of left lock (16)

and right lock (17). ZX215-1006273

● The front window assembly must con-

tact the left and right rubber stopper
(18), and the rubber stoppers must be
pushed backward by 1.5 – 3.0 mm.

● The front window assembly shall push 18 20

the limit switch 4 – 7mm backward.

ZX215-1006274

Shop Manual - April 2017 8-129

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

2) Close the front window assembly (10).

3) Loosen the retaining nut (20) at the left

and right side of rubber stopper (18),
and pull the two rubber stoppers (18)
inward so that they can not contact the
23
"unlocked" front window assembly.
21 22

4) Adjust the position of latch bolt (21).

● Latch bolt(21): M10, Inner diameter of

plate (23): ø14.5 mm ZX215-1006275

5) Adjustment of left and right rubber stop-

per (18)

● Allow front window assembly (10) to

contact the left and right rubber stopper
(18). (when the lock is "unlocked")

6) Lock front window assembly (10).

10 18

ZX215-1006277

7) Turn the left/right rubber stopper (18) to

the left by one and a half round.

● Turning the rubber stopper (18) leftward

for one round is equivalent to pressing
it by 1.5 mm.

● When front window assembly is "un-

locked", it must move the left/right rub-
ber stopper (18) by 1.5 – 3.0 mm. 18

8) Tighten the retaining nuts (20) at both

sides of the rubber stopper (18). ZX215-1006278

8-130 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

9. Adjust the front window assembly retainer

(24).

● Adjust and lock both sides of the retain-

er (24) so that surface (d) of stopper
(D) of front window assembly contacts
surface (c) of retainer (24) when front 24
window assembly is raised. 10

D
ZX215-1006279

10. Check the locking ability of front window

assembly.

● After the adjustment from Step 6 to

Step 9 is finished, check the locking 24
force of left lock (16) and right lock (17). D

● Check the locking force at the "locked" d

side (front of cab) and the "unlocked"
side (rear of cab).

Left lower pin: c

27 – 34 N·m {2.75 – 3.47 kgf·m}

Mounting bolt:

Adhesive(LT-2)

16 17

ZX215-1006271

Shop Manual - April 2017 8-131

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.29 Monitor - Remove and Install

8.29.1 Removal

Disconnect first the cable from the nega-

tive (-) post of the battery. 3 4

1. Unscrew the three bolts (4). Remove the 5

2
mounting plate and the monitor assembly
from the bracket (3).
1
2. Remove the nut (1) and the gasket (2) to
separate the monitor (5) from the mounting
plate.

ZX215-1006281

8.29.2 Installation

● Installation is to be performed in the re-

verse order of removal.

8-132 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.30 Controller AS - Remove and Install

8.30.1 Removal

Disconnect first the cable from the nega-

tive (-) post of the battery.

1. Remove the fuse box (1) and storage box

(2).

2. Remove cover plate (3).

3. Remove air conditioner cover (4). 3

2
1
4 ZXT335-1006800

4. Remove the controller wiring connectors

(5) and (6).

5. Remove the 4 bolts. Remove the controller

assembly (7).

6
5

ZX215-1006283

8.30.2 Installation

● Installation is to be performed in the re-

verse order of removal.

Shop Manual - April 2017 8-133

8-134
2) Wiring
8.31 Radio

8.31.1 Structure

1) Main structure
RED — L. SOUND TRACK INPUT

AUDIO INPUT

WHITE — R. SOUND TRACK INPUT

Disassembly and Assembly

RED — ACC IGNITION

YELLOW — BATT POWER SUPPLY

BLACK — GROUND

GRAY — R. SOUND TRACK OUTPUT +

POWER, GROUND AND AUDIO OUTPUT

BACK PANEL
— R. SOUND TRACK OUTPUT –

Shop Manual - April 2017

WHITE — L. SOUND TRACK OUTPUT +

BLACK — L. SOUND TRACK OUTPUT –

RADIO ANTENNA

ZX215-1006285
ZX215-1006284
SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator
SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.31.2 Removal and installation

8.31.2.1 Removal

1. Remove the console cover. Arm rest cover

NOTICE
● Disconnect the power supply prior to
removal.
Radio
ZX215-1006286

2. Remove the radio connector CN-003F.

Connector CN-003F Cab harness

ZX215-1006287

3. Remove the four screws and the washers

in order to remove the radio and the radio
mounting brackets from the console cover.
Arm rest
4. Remove the four screws and the washers
in order to remove the radio from the radio
mounting brackets.

Radio
Mounting bracket Washer
8.31.2.2 Installation
Screw
ZX215-1006288
● Installation is to be performed in the re-
verse order of removal.

Shop Manual - April 2017 8-135

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.31.3 Connector model and wiring

1 2 3

1 2 3 20b R+ L+

4 5 6 7 0 28 R- L-

4 5 6 7

Harness socket terminals

Raido wiring terminals
Type: Yasaki 7119-3070

ZX215-1006289

8-136 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.32 Battery

8.32.1 Structure

A
2 B

10 J
C
11

6 E
D

F
8 7 5 9 4 3 1

ZX215-1006290

1) Spinning post 7) Paste (active material)

2) Charge densiometer 8) "Bag-type" screen
3) Heat-sealing cover 9) Polar group
4) PP casing 10) Liquid-gas separator
5) Central polar ear 11) Central busbar
6) Forged grid

Shop Manual - April 2017 8-137

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.32.2 Removal and installation

NOTICE
● Turn the start switch to the OFF posi-
tion before removal.

● Do not remove the charge densimeter.

Tighten the densimeter clockwise, if it
is loosened, with a suitable tool.

CAUTION
● Battery gas can cause explosion. No
sparks or flames are allowed near the
battery.

8.32.2.1 Removal

1. Remove the four bolts on the battery cover

and then remove the battery cover.

ZX215T-14011603

2. Disconnect the negative lead cable (1) of

the battery. 2 3 1

ZX215T-14011604

8-138 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

● Pull up the terminal cover (4), unscrew 4

the bolt (5), and remove the lead wire 5
from the battery post.

3. Disconnect the positive lead cable (2) and

the battery connection cable (3) in the
same manner.

ZX215T-14011605

4. Remove plate (7) and take the battery out 7

of the compartment.

8.32.2.2 Installation

● Installation is to be performed in the re-

verse order of removal. ZX215T-14011606

8.32.3 Replacement

There are two 12V batteries with ground-

ing negative (-) posts in the machine. If one
battery fails in the 24V system, it must be re-
placed with one of the same type. Batteries of
different types are probably charged at differ-
ent speeds, which may cause one of them to
fail due to overloading.

NOTICE
● During installation, apply vaseline to
battery terminals in order to prevent
corrosion.

Shop Manual - April 2017 8-139

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.33 Start Switch

8.33.1 Structure

23 22 20 18 17 15 13 12,11 28 6 10,9,8,7

25,24 21 1 14 19 16 26 5 4,3,2

27
4 5 6

1 2 3

ZX215-1006294

1) Housing 2) Key 3) Ring 4) Knob 5) Nut

6) Cylinder 7) Cap 8) Shield 9) Pin 10) Spring
11) Disc 12) Spring 13) Plug 14) Rotor 15) Cover
16) Spring 17) Ball 18) Spring 19) Contact SPR-B 20) Contact A
21) Seat 22) Contact SPR-A 23) Contact B 24) Terminal 25) Bolt
26) O-ring seal 27) Harness AS 28) Washer

8-140 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.33.2 Removal and installation

8.33.2.1 Removal

1. Remove the setscrew to remove the con- X

T MA

sole cover.
STAR
ON

OFF
CK
LO
MIN

Start swich Console cover Set screw

ZX215-1006295

2. Remove both setscrews in order to remove Set screw Console cover

the mounting plate and the start switch
from the console cover.

NOTICE
● Disconnect the power supply of the
start switch before removal.

Mounting plate Start switch

ZX215-1006296

3. Remove the nut so as to remove the start

switch from its mounting plate.

Start switch Mounting plate Nut

ZX215-1006297

Shop Manual - April 2017 8-141

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Working principle and wiring of start switch

Working principle

ON/OFF
Key Position Preheat Plug
Battery (B) Battery Relay (BR) Accessory Start Relay (C)
(R1) (R2)
HEAT
OFF
ON
START

Wiring

1 B BR ACC 3 1 22 13 3

4 R1 R2 C 6 4 16 11 6

HARNESS PLUG TERMINALS

JACKET MODEL：YAZAKI 7123-7464-30
KEY SWITCH WIRING TERMINALS
JACKET MODEL：YAZAKI 7222-7464-30

ZX215-1006299

8-142 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.34 Fuse Box

8.34.1 Removal and installation

Removal Cover

1. Remove the cover.

ZX215-1006300

2. Remove the bolts and take off the back

cover along with the fuse box. Back cover Fuse box cover

Bolt
ZX215-1006301

3. Remove the bolts so as to separate the

Fuse box harness
fuse box and harness assembly from the
back cover. Bolt

Back cover

ZX215-1006302

Shop Manual - April 2017 8-143

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.35 Wiper

8.35.1 Structure and working principle

Structure

Blade

Rotating mechanism

Arm

Wiper motor

Connector

Mounting bracket

ZX215-1006303

Working principle

GREEN (LOW SPEED)

YELLOW (RESET)
M
BLUE (HIGH SPEED)

RED (POWER+)

BLACK (POWER-)

ZX215-1006304

8-144 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.35.2 Removal and Installation

Removal

1. Remove the decorative button in order to

remove the interior decoration. Decoration
button

Inner decor

ZX215-1006305

2. Remove the moving mechanism and the

motor.
Bolt
● Unscrew the bolts to remove the wiper
motor and moving mechanism from the
cab. Moving
mechanism

Wiper motor

Bolt

ZX215-1006306

3. Remove the arm and the blade.

● Unscrew the nut to remove the wiper

arm and blade from the cab.
Arm bracket

Cap

Locknut

Cab
ZX215-1006307

Shop Manual - April 2017 8-145

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

Installation

● Installation is to be performed in the re-

verse order of removal.

8.35.3 Angle adjustment of wiper arm

● The arm should stops moving when the Stopper

blade reaches the stopper.

● If the arm is still working when the blade Blade

reaches the stopper or the arm already
stops working before the blade reaches the
stopper, the moving angle of wiper should
be adjusted to prevent breakdown of the
Arm
wiper.

● Adjust the wiper in such a way. Loosen the

locknut; adjust the arm working angle ac-
cording to actual condition. Make sure that
the wiper motor stops working at the mo- Locknut
ment that the blade reaches the mechani-
cal stopper.

ZX215-1006308

8-146 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.36 Relay

8.36.1 Engine relays

1. Starter relay - check S

● Check the conduction and action. Replace

the relay in case of any failure.
B

S
B 1 SW(-) SW L

AA2A
2 L(-)

ZX215-1006309

2. Mains relay - check

● Check the conduction and action. Replace 1(+)

2(-)
the relay in case of any failure.

3 4
Battery (+) terminal
3 4

1(+)
2(-)

ZX215-1006310

3. Heater relay
5(-)
● Check the conduction and action. Replace
the relay in case of any failure.
1
5 1 2 3 4
(-) (+)

2 4(+)
Fuse 3

ZX215-1006311

Shop Manual -April 2017 8-147

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

4. Safety relay

Measure the resistance between terminal

2 and terminal 3.

Standard Value Approx. 200W

● Check the conduction and action. Replace

the relay in case of any failure.
(P)6
3(R)
5
2(L)
(E)4
1(S)
ZX215-1006312

8-148 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.36.2 Other relays

8.36.2.1 Function and location

Relay harness

Starter control relay

Work lamp relay

Headlight relay

Parking relay Pilot control relay

Horn relay

Mounting plate

ZX215-1006313

Shop Manual - April 2017 8-149

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.36.2.2 Removal and Installation

Removal
Relay harness Mounting plate
1. Remove relay from its seat.

2. Remove the screw in order to remove the

relay seat and harness from the mounting
plate.

Installation

● Installation is to be performed in the re-

verse order of removal.
Relay seat Screw Relay
ZX215-1006314

8.36.2.3 Relay connector and wiring

1 4 2

RELAY WIRING TERMINALS

RELAY MODEL:HELLA 4RD 007 903-027

HORN WORK LAMP PILOT CONTROL STARTER CONTROL PARKING HEADLIGHT

K5 K6 K10 K3 K7 K8

32 34 12 65 70

0 31 0 33 0 606 105 0 105 0 63 13 0 72

23 24 27 11 64 71

HARNESS SOCKET TERMINAL

SOCKET MODEL: JACKET 8JA003526-00
ZX215-1006315

8-150 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.37 Sensor

1. Water temperature sensor - check

● Put the sensor into a vessel containing en-

gine oil.
1
● Heat the oil to the specified temperature.
Stir the oil at the same time.
Sensor body
● Measure the resistance value between the
terminal 1 and the sensor body at different
temperatures.

50±0.2°C 80±10Ω
60°C 56.3Ω(ref.) ZX215-1006316

Standard 80°C 29.5Ω(ref.)

Value 100°C 16.5Ω(ref.)
106±0.3°C 14.3±1.0Ω
120°C 10Ω(ref.)

● Replace the sensor if the measured value

exceeds the standard one.

2. Engine speed sensor - check

● Measure the resistance between terminal

1 and terminal 2.

Std. Value(25°C) 2.3±0.2kΩ

● Replace the sensor if the measured value

exceeds the standard one.

2 1

NOTICE
ZX215-1006317
● Insufficient tightening of the engine
speed sensor may cause signal output
failure. Tighten the sensor to specified
torque.

Shop Manual - April 2017 8-151

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

3. Pressure sensor - check

● Input volt: 4.75~5.25VDC

Coupler Body Connector
● Output volt: 0.5~4.5V

● Pressure range: 0~50BAR

Terminal A Terminal B

Terminal C
ZX215-1006318

4. Fuel level sensor - check

● Swing the float up and down in order

Float
to measure the effective angle of radial
swing, i.e. the line through the float and the
turning point will swing 105°.
Lever
● Swing the float up and down. The vertical
distance between the upper limit and the
lower limit of the float should be 500 mm.

● Move the float to its upper limit. Measure

Ternimal R
the resistance between the sensor terminal Casing
R and ground with a multimeter. The mea-
sured resistance should be Ru≤9.6Ω. Connector

● Move the float to its lower limit. Measure

ZX215-1006319
the resistance between the sensor terminal
R and ground with a multimeter. The mea-
sured resistance should be Rd≥86Ω.

8-152 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator Disassembly and Assembly

8.38 Connector Terminals - Insert and Remove

8.38.1 Insertion

1. Hold tightly a wire terminal at a distance of

about 25 mm from its end.

ZX215-1006320

2. Hold the connector. Let the rear seal face

you.

ZX215-1006321

3. Align the terminal with a hole on the seal

and push it perpendicularly to the bottom.
Slightly pull back the wire in order to en-
sure that the terminal is locked in place.

ZX215-1006322

Shop Manual - April 2017 8-153

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

8.38.2 Removal

1. Hold the connector, with its back end fac-

ing you. Select a suitable tool and clip on
the wire.

ZX215-1006323

2. Push the tool along the wire into the con-

nector so that the tool can expand the ter-
minal lock shoulder and reach its flanged
part.

ZX215-1006324

3. Pull out the tool to remove the wire with

terminal.

ZX215-1006325

8-154 Shop Manual - April 2017

Disassembly and Assembly SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

E
G
PA
K
AN
BL

8-164 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

System Schematics
9 System Schematics
9.1 Hydraulic Circuit Diagram ...................................................................... 9-3
9.2 Electrical Diagram ................................................................................................... 9-4
9.3 Cab Circuit Diagram ............................................................................................... 9-6
9.4 Console Circuit Diagram ......................................................................................... 9-7
9.5 Control Switch Circuit Diagram ................................................................................ 9-8
9.6 Chassis Diagram ..................................................................................................... 9-9

Shop Manual - April 2017 9-1

System Schematics SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator

9-2 Shop Manual - April 2017

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics
9.1 Hydraulic Circuit Diagram

Shop Manual - April 2017 9-3

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.2 Electrical Diagram

Shop Manual - April 2017 9-4

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - June 2016 9-5

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - June 2016 9-6

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-7

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-8

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-9

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-10

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-11

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-12

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-13

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-14

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

Shop Manual - April 2017 9-15

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.3 Cab harness

Shop Manual - April 2017 9-16

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.4 Control Switch Harness

Shop Manual - April 2017 9-17

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.5 cab left side harness

Shop Manual - April 2017 9-18

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.6 Pump room Harness

WX201606150017

Shop Manual - April 2017 9-19

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.7 Vehicle Body Harness

Shop Manual - April 2017 9-20

SY215C9C5K/SY225C9C5K Crawler Hydraulic Excavator System Schematics

9.8 Boom Harness

Shop Manual - April 2017 9-21