SANY Ecavator Failures

Quality Changes the World
挖机故障维修案例
Failure cases of excavator
International Service Department of Sany Heavy Machinery Ltd

September 28, 2011
目录 CATALOG
第一节液压系统 Hydraulic System……...…………...……………………………………….……- 8 -

01、整车突然没动作 The excavator has no action suddenly .............................................................................................. - 8 -
02、整车动作慢，负载时更明显 Excessive cycle time for all the actions, especially load is taken ............................... - 10 -
03、回转动作慢 Swing operation has a long cycle time ................................................................................................... - 11 -
04、回转滑行量过大 Slippage is excessive when the swing operation is stopped ........................................................... - 14 -
05、左行走、回转单独动作速度慢 Left travel or swing operation has a long cycle time .............................................. - 16 -
06、机器动作慢无力 Machine has a long cycle time ....................................................................................................... - 18 -
07、小臂回转速度慢，单边行走无力 Stick, swing, single track travel has a long cycle time........................................ - 20 -
08、铲斗动作慢 Bucket operation has a long cycle time .................................................................................................. - 24 -
09、大臂无力，提升速度慢 Boom up has a long cycle time ........................................................................................... - 26 -
10、左行走前后都慢，回转慢 Left travel, swing has a long cycle time ......................................................................... - 29 -
11、回转异响 Swing operation has abnormal noise .......................................................................................................... - 31 -
12、全车无动作 Machine has no actions. ......................................................................................................................... - 34 -
13、破碎操作不受控制 Hydraulic hammer is out of control ............................................................................................ - 36 -
14、SY230 启动着后动臂上升 Boom up automatically after engine is started ............................................................... - 37 -
15、挖掘机全车无动作 Excavator has no action .............................................................................................................. - 38 -
16、挖掘机没动作 The excavator has no action ............................................................................................................... - 40 -
17、SY230 冷机动作慢 SY230 has long cycle time before machine is warm up .............................................................. - 42 -
18、SY210C 挖机发动机启动困难 SY210C engine is hard to start ................................................................................ - 44 -
19、挖掘机降动臂过程异常 Boom down operation is abnormal ..................................................................................... - 46 -
20、挖掘机正常工作时转速异常 Engine speed is abnormal when the machine is working ........................................... - 48 -
21、SY135 行走跑偏 SY135 has excessive travel offset ................................................................................................... - 50 -
22、挖掘机整车无动作 Excavator has no action .............................................................................................................. - 52 -
23、行走马达不工作 Travel motor failed to work ............................................................................................................ - 54 -
24、行走跑偏故障 Failure of exessive travel offset .......................................................................................................... - 56 -
25、SY330 热车时憋车、冒黑烟 Engine speed drops and heavy black smoke............................................................... - 59 -
26、SY360 不能行走 SY360 failed to travel .................................................................................................................... - 61 -
27、SY215 工作无力 SY215 has insufficient power to work ............................................................................................ - 62 -
28、SY215 行走跑偏 SY215 has excessive travel offset .................................................................................................. - 64 -
29、铲斗动作非常慢，并且挖土无力 Bucket operation is very slow, and hard to dig soil ............................................ - 66 -
30、行走跑偏 Excessive travel offset ................................................................................................................................ - 68 -
31、SY230 机器无动作 SY230 excavator has no action .................................................................................................. - 70 -
32、SY230 斗杆油缸无法完全升出和缩回 Stick cylinder can not be operated in full stroke .......................................... - 72 -
33、左侧履带不能行走 Left track can not travel .............................................................................................................. - 74 -
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34、机器热机出现抖动 Machine vibrated after it is warmed up ...................................................................................... - 76 -
35、斗杆自动下降 Stick drops automatically ................................................................................................................... - 78 -
36、SY230C8B 挖掘机整机动作发抖 Machine vibrated obviously .................................................................................. - 80 -
37、SY210C 发动机工作中熄火 SY210C engine shutoff automatically during the work................................................. - 82 -
38、SY230 冷机动作不协调 SY230 has a delay response before the machine is warmed up........................................... - 84 -
39、SY360 无法启动 SY360 can not be started ................................................................................................................ - 86 -
40、发动机无法启动 Engine can not be started................................................................................................................ - 88 -
41、回转无力 Swing operation performs poorly ............................................................................................................... - 91 -
42、SY75 小臂回收时动作速度慢 SY75 stick in operation has a long cycle time .......................................................... - 94 -
43、SY360-8 全车动作迟缓无力 SY360 has long cycle time for all actions ................................................................... - 95 -
44、斗杆自动伸展 Stick extends out automatically after engine is started ....................................................................... - 97 -
45、左右回转刹车漂移量大 Overswing when the swing operation is stopped................................................................. - 99 -
46、SY200 动作慢、无力 SY200 has a long cycle time ................................................................................................. - 101 -
47、SY215C8 挖机动作慢 SY215C8 has a long cycle time ........................................................................................... - 103 -
48、SY215 挖机铲斗油缸抖动故障 Bucket cylinder of SY215 vibrated ...................................................................... - 106 -
49、SY230 动作慢，偶尔憋车 SY230 has a long cycle time ans stalled sometime ....................................................... - 108 -
50、SY75C 行走无力 SY75C travel operation performed poorly .................................................................................... - 111 -
51、挖机右行走不工作 Right travel motor failed to work ............................................................................................. - 112 -
52、SY210C 铲斗动作慢并且挖掘无力 Bucket operation is poor and failed to load ..................................................... - 114 -
53、动作无力缓慢 Machine has a long cycle time ......................................................................................................... - 116 -
54、SY230C6B 热机时出现抖动 Vibrates excessively after the machine is warmed up ................................................. - 118 -
55、左侧履带不能行走 Left track can not travel ............................................................................................................ - 120 -
56、发动机无法启动 Engine can not be started.............................................................................................................. - 122 -
57、SY215C8M 回转无力 Swing operation is poor ........................................................................................................... - 124 -
58、泵输出压力不稳定 Pump output pressure is unstable ............................................................................................. - 126 -
59、单边行走无力，单独回转无力 One track travel/Swing performs poorly .............................................................. - 128 -
60、高速行走严重跑偏 High speed travel has an excessive offset ................................................................................. - 130 -
61、SY215C8 机斗杆掉臂 SY215C8 stick drops severely ............................................................................................. - 132 -
62、SY215 回转无刹车 Swing operation is hard to stop ................................................................................................. - 134 -
63、行走阀杆回中位后，左行走停不下来 Pilot valve in neutral position, left travel can not be stopped .................... - 135 -
64、发动机正常熄火次日不着车 Engine is shutoff normally, can not be started next day ........................................... - 138 -
65、手柄回中位后，动臂仍缓慢上升 Pilot valve returns to neutral, boom up continued ............................................ - 140 -
66、新安装的破碎器,不击锤 Newly installed hammer failed to work.......................................................................... - 143 -
67、行走马达上液压油管破裂 Hydraulic hose of travel motor cracked........................................................................ - 145 -
68、往前行走速度慢，后退正常 Backward travel is normal while forward slowly ..................................................... - 147 -
69、工作过程中上部车体缓慢左回转 Uper structure left swing slowly during the work ............................................. - 149 -
70、SY200 回转启动时有异响 Abnormal noise is detected when swing operation begins ............................................ - 151 -
71、SY215C 挖机工作时小臂回收突然无动作 Stick in operation failed suddenly........................................................ - 153 -
72、SY215C 挖机发动机启动困难 Engine is hard to start ............................................................................................ - 155 -
73、手柄重并有反弹力 Pilot lever is heavy and has a rebound force ............................................................................ - 156 -
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74、SY230 行走跑偏 SY230 has the excessive travel offset .......................................................................................... - 158 -
75、整机突然无动作 Machine has no action suddenly................................................................................................... - 160 -
76、油缸漏油 Hydraulic cylinder leaks oil ...................................................................................................................... - 162 -
77、SY360C 机大臂下降动作失控 Boom down operation is out of control ................................................................... - 163 -
78、215C8 机型斗杆伸出发卡 Stick out operation has a restriction ............................................................................... - 165 -
79、SY210C6 型挖机憋车 Engine stalled ......................................................................................................................... - 167 -
第二节电气系统 Electrical system .............................................................................................- 169 -
01、OPUS46 显示屏显示档位异常 Displayed throttle position on the monitor is abnormal ........................................ - 169 -
02、机器无法启动 Engine can not be started .................................................................................................................. - 172 -
03、行走高低速无法切换 High / Low travel speed can not be shifted .......................................................................... - 175 -
04、工作灯不亮 Working lamp failed to work ................................................................................................................ - 178 -
05、发动机不能升速降速 Engine speed can not be accelerated and decelerated........................................................... - 180 -
06、OPUS46 显示屏无法断电 OPUS46 monitor can not be power off ......................................................................... - 183 -
07、机器工作中自动熄火 Machine shut down automatically during the work.............................................................. - 185 -
08、发动机憋车 Engine stalled ....................................................................................................................................... - 187 -
09、显示屏数据偶尔显示为零 Data displayed in the monitor is zero occasionally ...................................................... - 189 -
10、无通讯，无升速 No communication, engine speed can not be accelerated ............................................................ - 191 -
11、高速时转速不稳 Engine speed is unstable at high speed ......................................................................................... - 192 -
12、整车无电 Machine has no electric power ................................................................................................................. - 194 -
13、发动机无法熄火 Engine can not be shut down ........................................................................................................ - 196 -
14、420RC 显示屏有时无数据显示 420RC has no data displayed occasionally .......................................................... - 198 -
15、马达能带动发动机运转但不能着车 Engine can be cranked but can not be started ............................................... - 200 -
16、SY215 无法加速，仪表各参数为零 Can not be accelerated, parameters value is zero........................................... - 202 -
17、旋挖钻全车无动作 Rotary drill has no actions ........................................................................................................ - 204 -
18、发动机不能启动 Engine can not be started .............................................................................................................. - 206 -
19、发动机不能着车 Engine can not be started.............................................................................................................. - 208 -
20、自主控制器程序故障 Program failure of the controller .......................................................................................... - 210 -
21、SY205 挖机回转动作慢 SY205 swing operation has a long cycle time ................................................................... - 211 -
22、挖掘机不能起动 Engine can not be started.............................................................................................................. - 213 -
23、偶尔右边行走无力 Right side travel motor has a poor performance occasionally .................................................. - 214 -
24、雨刮器不工作 Wiper fails to work ........................................................................................................................... - 215 -
25、OPUS 显示屏参数为零 Paramaters value displayed on the Opus monistor is zero ................................................ - 217 -
26、机器无动作，油门加不上 Machine has no action, engine can not be accelerated ................................................. - 219 -
27、无法熄火，油门失控 Can not be shut down, throttle is out of control ................................................................... - 221 -
28、SY230C6B 挖机无法启动 SY230C6B can not be started.......................................................................................... - 223 -
29、控制器显示故障代码 20 Trouble code 20 is displayed ........................................................................................... - 226 -
30、SY135 无法正常熄火、断电 SY135 can not be shut down and power of normally ................................................ - 228 -
31、SY215 喇叭不响 SY215 horn fails to work .............................................................................................................. - 230 -
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32、收音机收听时有时无 Radio failed intermittently .................................................................................................... - 232 -
33、所有参数为零无法升降速 All the parameters are zero, speed can not be changed ................................................ - 234 -
34、燃油油位显示异常 Displayed fuel level is abnormal .............................................................................................. - 236 -
35、翘板开关故障案例 Failure case of the turnup switch .............................................................................................. - 238 -
36、210C5B 无法升速及无显示 210C5B can not be accelerated and no display .......................................................... - 240 -
37、210C5B 油门旋钮失效 210C5B dial switch failed .................................................................................................. - 242 -
38、SY205 全车无电 SY205 machine has no electric power .......................................................................................... - 244 -
39、360 正流量挖机行走跑偏 360 PFC excavator has a travel offset ........................................................................... - 246 -
40、SY230 控制器烧坏 SY230 controller failed ............................................................................................................ - 248 -
41、显示屏无显示全车无动作 Monitor has no display, machine has no action ............................................................ - 250 -
42、SY135C 转速异常 SY135C engine speed is abnormal ............................................................................................ - 252 -
43、SY235C8E 发动机无法启动 SY235C8E engine can not be started .......................................................................... - 254 -
44、SY55C 发动机频繁地自动熄火 Engine shut down automatically frequently ......................................................... - 256 -
45、德国显示屏无法正常计时 Germany monitor can’t count the work hours normally ............................................... - 258 -
46、OPUS 德国显示屏白屏 Germany monitor Opus has a white screen displayed ....................................................... - 260 -
47、SY215 偶尔无法启动 SY215 can not be started occasionally ................................................................................. - 262 -
48、SY75 自动怠速功能故障 Auto idle speed function of SY75 is abnormal ................................................................ - 264 -
49、整车无怠速 Machine has no idle speed.................................................................................................................... - 266 -
50、SY215C8 行走跑偏 SY215C8 has a travel offset .................................................................................................... - 268 -
51、全车无电 Machine has no electric power ................................................................................................................. - 270 -
52、215C8M 无自动怠速 Auto idle speed function of 215C8 failed ................................................................................ - 272 -
53、发动机无法加油门 Engine speed can not be accelerated ........................................................................................ - 274 -
54、发动机无法熄火 Engine can not be shut down ........................................................................................................ - 276 -
55、显示屏显示数据偶尔显示为零 Displayed data on the monitor is zero occasionally.............................................. - 278 -
56、135C 不能停机熄火 135C can not be shut down ..................................................................................................... - 280 -
57、发动机无法升速 Engine speed can not be accelerated ............................................................................................ - 282 -
58、显示屏显示时间错误 Displayed working hour is incorrect .................................................................................... - 284 -
59、左行走异常 Left travel is abnormal ......................................................................................................................... - 286 -
60、发动机能启动但整车无动作 Engine can be started but machine has no action ..................................................... - 288 -
61、SY215F1 保险更换 2 次仍烧坏 SY215 has the fuse F1 burnt frequently ............................................................... - 290 -
62、SY75 整机无动作 SY75 has no action ....................................................................................................................... - 292 -
63、挖掘机出现 1 级锁机状态且无法解锁 Machine is locked and can not be unlocked ............................................. - 295 -
64、SY210 机型全车动作慢 All actions have a long cycle time .................................................................................... - 297 -
65、显示器显示水温高温 Monitor displayed coolant temperature is very high .......................................................... - 299 -
66、SY215 工作无力 SY215 has not enough power ........................................................................................................ - 301 -
67、卸载时斗杆有停顿现象 Arm is not smooth during the stick out operation ............................................................ - 304 -
68、215C8M 斗杆回收速度慢，右回转工作无力 Stick in and swing right slowly ........................................................ - 306 -
69、SY200 挖掘机转速异常 SY200 engine speed is abnormal....................................................................................... - 308 -
70、SR180 旋挖加速不良 SR180 accelerated poorly ...................................................................................................... - 310 -
71、SY135C 挖机回转不工作 SY135C can not swing .................................................................................................. - 313 -
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72、SY215 全车无动作 SY215 has no action .................................................................................................................. - 315 -
第三节发动机 Engine ........................................................................................................................- 317 -
01、6D24 发动机启动着马上熄火 6D24 engine shut down soon once it is started ..................................................... - 317 -
02、冷却液温度高达 106°C Coolant temperature arrives at 106°C ................................................................................ - 321 -
03、工作 10-20 分钟憋车并熄火 Engine stalled after working 10-20 minutes .............................................................. - 323 -
04、怠速过高 Idle speed is too high ................................................................................................................................ - 325 -
05、210C6M 机不能升速熄火故障 Engine can not be accelerated and shut down ....................................................... - 327 -
06、210C 发动机高温 210C overheating ........................................................................................................................ - 329 -
07、工作中发动机掉速达 400 转 Engine speed drops 400 rpm during the work .......................................................... - 331 -
08、发动机启动困难 Engine is hard to start ................................................................................................................... - 333 -
09、发动机水温高报警 High coolant temperature alarm ............................................................................................... - 335 -
10、发动机转速无法下降 Engine can not be decelerated .............................................................................................. - 337 -
11、SY215C 停机半小时后难启动 Engine is hard to start after stopping half an hour ................................................. - 339 -
12、发动机机油受污染 Engine oil is contaminated ....................................................................................................... - 341 -
13、发动机抖动 Engine vibrated .................................................................................................................................... - 343 -
14、发动机无力，有时自动熄火 Engine has insufficient power, and auto shut down occasionally ............................. - 345 -
15、发动机低速、中速抖动 Engine vibrated at low and middle speed ......................................................................... - 347 -
16、SY135 动作慢 SY135 has a long cycle time ............................................................................................................- 348 -
17、SY215 低温启动困难 SY215 engine is hard to start in the cold weather ................................................................. - 350 -
18、发动机水温过高 Engine coolant temperature is excessively high ........................................................................... - 352 -
19、SY75C 高水温 SY75C engine overheated ............................................................................................................... - 354 -
20、SY360-8 全车动作迟缓无力 All actions of SY360-8 have a long cycle time ......................................................... - 356 -
21、发动燃油消耗大 Fuel consumption is excessive ..................................................................................................... - 358 -
22、机油油面升高 Engine oil level increased................................................................................................................. - 360 -
23、SY75 发动机有异响 SY75 engine has abnormal noise............................................................................................. - 362 -
24、SY135C 冒白烟 SY135C emitted white smoke ......................................................................................................... - 364 -
25、发动机增压器有异响 Turbocharger has abnormal noise ......................................................................................... - 366 -
26、发动机抱瓦 Engine bearing seized........................................................................................................................... - 368 -
27、发动机烧机油 Engine oil consumption is excessive ................................................................................................ - 372 -
28、发动机后油封漏油 Engine oil leaks out from the rear crankshaft seal .................................................................... - 374 -
29、SY210C 挖机发动机偶尔憋车 SY210C engine stalled occasionally ...................................................................... - 376 -
30、发动机自动熄火 Engine shut down automatically .................................................................................................. - 378 -
31、SY235C-8 发动机无法启动 SY235C-8 engine can not be started ........................................................................... - 380 -
32、发动机冒蓝烟 Engine emitted blue smoke .............................................................................................................. - 382 -
33、SY65C 冷车时启动困难 SY65C engine is hard to start when it is cold .................................................................... - 384 -
34、设备憋车 Engine stalled ........................................................................................................................................... - 386 -
35、SY135 冒黑烟，动力不足 SY135 emits black smoke, power insufficient .............................................................. - 388 -
36、发动机冒黑烟，憋车 Engine emits black smoke and speed drops obviously ......................................................... - 390 -
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37、发动机转速下降 800 转 Engine speed drops 800 rpm ............................................................................................ - 392 -
38、发动机正常熄火后打不着车 Engine can not be started after shut down normally ................................................. - 393 -
39、发动机拉瓦 Engine bearing seized........................................................................................................................... - 395 -
40、发动机憋车、掉速熄火 Engine stalled ................................................................................................................... - 397 -
41、发动机能转动但不能着车 Engine can be cranked but can not be started ............................................................... - 399 -
第四节空调系统 Air conditioning system .................................................................- 401 -
01、空调制冷不良 A/C has a poor refrigeration ............................................................................................................. - 401 -

02、215C-8 空调不制冷 215C-8 a/c fails to refrigerate ................................................................................................. - 403 -
03、135C8 机器空调不制冷 135C8 a/c fails to refrigerate............................................................................................ - 405 -
04、空调制冷不良 A/C refrigerates poorly .................................................................................................................... - 407 -
05、空调不制冷 A/C fails to refrigerate ......................................................................................................................... - 409 -
06、空调系统不制冷 A/C fails to refrigerate ..................................................................................................................- 411 -
第五节操作保养 Operation and maintenance ...........................................................- 413 -
01、动臂销轴异响 Boom root pin has abnormal noise .................................................................................................. - 413 -

02、挖机无法回转 Excavator can not swing.................................................................................................................. - 415 -
第六节结构件 Structure .............................................................................................................- 417 -
01、托链轮漏油 Carrier roller leaks oil .......................................................................................................................... - 417 -

02、履带张不紧 Track can not be tensioned .................................................................................................................. - 418 -
03、斗杆油缸与斗杆连接的耳板处开裂 Stick cracks at the nose the stick cylinder rod pin installed ....................... - 420 -
04、座椅扶手无法固定 Armrest of the seat can not be fixed ........................................................................................ - 421 -
05、机顶罩锁无法正常关闭 Engine hood can not be locked normally ........................................................................ - 422 -
06、回转支承间隙过大 Swing beraing has excessive clearance ................................................................................... - 423 -
07、动臂与平台连接销处间隙过大 Clearance between boom and platform is excessive............................................ - 424 -
08、张紧油缸打不进黄油 Grease can not be pumped into track tension cylinder ........................................................ - 425 -
09、动臂上升、下降出现抖动、发涩 Boom operation has interference ..................................................................... - 427 -
10、330 设备大臂销轴异响 330 Boom pin has abnormal noise ................................................................................... - 429 -
11、挖机回转时异响 Excavator has abnormal noise during swing operation ............................................................... - 430 -
12、驾驶室晃动 Cab vibrates severely ........................................................................................................................... - 432 -
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第一节液压系统 Hydraulic system
01、整车突然没动作 Machine has no action suddenly
故障现象：SY230C-8型正流量挖掘机，在工作中突然全车无动作，发动机工作正常。
Failure phenomena: The PFC excavator SY230C-8 has no action suddenly while the engine works
normally
故障分析：在发动机转速正常情况下，全车无动作。电气方面问题：保险丝熔断，
先导电磁阀继电器故障、先导开关故障、先导电磁阀故障，先导控制线
束断线、短路搭铁。液压方面问题：主溢流阀卡死在常通位置无系统压
Spline gear
力，先导泵损坏无先导压力油输出，发动
机与液压泵的联轴器损坏造成无动力输出。
Failure analysis: At the engine works normally, the whole machine has no movement. Possible failures
in the electrical system includes: the fuse fails, the relay of pilot solenoid valve fails, the pilot switch fails,
the pilot solenoid valve fails, the harness of the pilot solenoid valve open or short circuit. Possible failures
in the Hydraulic system includes: the main relief valve is always opened. The pilot pump failled, the
coupling between engine and pump is damaged, so there is no power output.
故障原因：发动机与液压泵联轴器损坏造成无动力输出。
Root cause of the failure: Coupling between engine and pump is broken. So, there is no power output.
排故方法：1、先检查保险丝有无熔断--无，正常；
2、检查先导电磁阀606号线是否有24V电压--有，证明先导开关、继电
器、先导控制连接线束正常；
3、检测先导电磁阀电阻值是否约为34欧--是，正常。
4﹑检测先导泵压力是否为40公斤--否，0公斤，检测主溢流压力是否
为350公斤--否，0公斤，现可以判定液压泵没有工作。液压泵与发
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动机是靠一联轴器连接输出动力。故判定联轴器损坏。
5、拆下主泵检查联轴器发现联轴花键全部磨损，导致液压泵无动力输入，
液压泵不工作。更换新联轴器后，故障排除。
Troubleshooting:
1. Check the fuse status. It is not broken, it is normal.
2. Check the line 606# line of the pilot solenoid valve if there is the 24V voltage or not. If there is it, that
means the pilot switch, the relay, and the harness are normal.
3. Check the resistance of the pilot solenoid valve, if the resistance is about 34 Ohm, it is normal.
4. Check the pilot pressure if it is about 40kgf, check the main system pressure if it is 350kgf. The
reasult is that the pressure is zero. That means the pump is not working. The pump is driven by engine
through the coupling. Coupling is suspected to be failed.
5. Remove the pump and find that the splines of the coupling are damaged which makes the hydraulic
pump not work and no power output. Replace the coupling, the machine works normally
排故体会：电气方面：先检查有无保险丝熔断，先导电磁阀有无得电，如没有得电
故障点就在电气上。液压方面：检查先导压力、主溢流阀压力是否在正
常范围内。
Experience：For the electric system, check the fuse and the pilot solenoid valve whether they are normal
or not，if it is abnormal，the problem should be in the electrical system. For the hydraulic system, the pilot
oil pressure and the main relief valve should be checked first whether they are normal or not.
——提供者：刘志刚 Service engineer: Liu Zhi Gang
-9-
02、整车动作慢，负载时更明显 Excessive cycle time for all the actions, especially with load.
故障现象：一台SY215C-8型正流量机器在S模式工作时动作慢无力，负载增大时更加
明显，并伴有发动机冒黑烟。
Failure Phenomenon：There is a PFC excavator SY215C-8.When it is working at S model，the
movement is slow and doesn’t have enough power，and obvious with load，and engine has black smoke.
故障分析：造成整车动作慢无力：
1、动力方面：发动机功率不足，发动机转速是否在标准范围内（S模式：
10档：2100±50，H模式11档：2200±50），燃油滤芯供油是否不畅受
阻，进气系统进气量是否存在不足。
2、电气方面：各低压传感器反馈电压值是否在标准范围内（0.5—4.5V），
主泵比例电磁阀电流值是否在标准范内（350—750mA）。
3、液压方面：先导压力是否为40公斤，主溢流压力是否为350公斤。
Failure Analysis: Possible cause of the failure includes:
1. Engine: eninge power is insufficient. Check the engine speed whether it is in the normal range（S
model：2100±50 rpm at 10th throttle position，H model：2200±50 rpm at 11th throttle position）. Check
the fuel filter if it is blocked or not. Check the air inlet system if there is some failure or not.
2. Electric system: check the sensor of the pilot pressure if it is within the standard range(0.5V-
4.5V）,check the current of the PRV if it is within the standard range（350—750mA）.
3. Hydraulic system: whether the pilot pressure is 40kgf and the main pressure is 350kgf or not.
故障原因：川崎控制器故障造成发动机转速过低，致使发动机输出功率明显不足，
使主泵的排量减小，造成整车动作慢。
Root cause of the failure: The KPM controller is failed. The engine speed is lower than the specification
obviously. Engine output power is insufficient and the pump output oil flow decreased. So the machine
has all actions a long cycle time.
排故方法：1、先检查发动机空气滤芯、燃油滤芯其清洁度良好，进气、供油顺畅。
- 10 -
2、检测先导压力为40公斤，主溢流压力为350公斤，正常。
3、检测各低压力传感器，在操作手柄中立时电压为0.5V,全程操作手柄时
电压为4.4V，主泵比例电磁阀电流值在操作手柄中立时电流为350mA，全
程操作手柄时电流为750mA，这些都正常。
4、进入显示屏内部菜单查看发动机转速，发现发动机最高转速只有1750
转左右，明显低于标准值。使用川崎转速标定器重新标定发动机转速使之
达到标准的转速（怠速：1000±50转，自动怠速：1400±50转，S模式10
档：2100±50转，H模式11档：2200±50转），挖机正常工作。
Troubleshooting:
1. Checked and found the air filter and the fuel filter are clean. Air and fuel are not restricted.
2. Checked and found the pilot pressure is 40kgf, and the main pressure is 350kgf. Normal.
3. Check the pilot pressure sensor and the proportion solenoid va lve. When the joysticks are in th e
neutral position, t he s ensor vol tage i s 0.5 V, the valve c urrent i s 350m A. A nd w hen i t i s a t t he f ull
stroke position, the sensor voltage is 4.4V, the valve current is 750mA. All of them are normal.
4. Check the engine speed in the monitor and find the highest speed is only 1750rpm. The output power
is obviously not enough which makes t he pum p output flow lower than the specification and t he
machine operation is slow. Using the KPM speed setter to calibrate the engine speed to the
specification. （low idle speed：1000±50rpm，A/I：1400±50rpm，S mode 10th：2100±50rpm，
H mode 11th：2200±50rpm）. Tested and found then the machine works normally. Problem solved.
排故体会：动作慢一般为液压系统故障，先导压力不足，主溢流压力过低。但如发动
机转速不够液压泵排量减少也会造成整机动作变慢。
Experience: Pilot oil pressure and / or main oil pressure is lower than the specification is usually the root
cause of the failure of machine has a long cycle time. But if the engine speed is lower than t he
specification, pump output oil flow will decrease and the machine will have a cycle time.
- 11 -
03、回转动作慢 Swing operation has a long cycle time
故障现象：一台SY205正流量挖机单独回转速度慢，其它动作正常。
Failure phenomenon: A SY205 PFC excavators swings speed is slow, other actions are normal.
故障分析：回转手柄操作时，控制器通过先导压力传感器检测回转2次先导压力，通
过控制器计算向主泵电比例阀输送比例电流，调节主泵输出流量，二次先
导压力控制主阀芯移动控制回转马达供油，供油量越大，回转速度越快。
Failure analysis: When the swing pilot control lever is operated, pilot oil pressure is detected by the pilot
oil pressure sensor and sends to t he MC. After cal culating, MC sends proper current to main pump
proportional solenoid valve to adjust the pum p flow. Pilot oil pressure c ontrols m ovement of m ain ctrl
valve spool. The bigger the supplied oil amount, the faster the machine swings.
故障原因：1、回转马达损坏故障；
2、主阀回转阀芯卡滞；
3、先导操作阀故障，主阀上回转先导二次压力不够，阀芯不能全
行程打开；
4、回转先导压力传感器损坏或线路故障，引起控制器检测不到先
导二次压力信号。
Possible root cause of the failure:
1. Swing motor failed.
2. Swing valve spool of the main control valve seized.
3. Swing pi lot va lve f ailed. Insufficient pi lot oi l pr essure r esults i n the swing va lve s pool c an not be
opened completely.
4. The swing pilot pressure sensor or its circuit failed, lead to MC can’t detect signal of pilot pressure.
排故方法：1、起机、打开显示屏，操作回转先导手柄，检查回转先导压力为0，前
主泵主压力为10Mpa,前泵电比例阀电流30mA，判定无回转2次先导压力信
号到控制器，故而前泵比例电流低，主泵按最小流量输出；
- 12 -
2、安装压力表检测量主阀回转阀芯上先导压力为3.9 Mpa，正常，排除
先导操作阀及先导油路故障；
3、将回转先导压力传感器与左行先导压力传感器对调，回转动作恢复正
常，左行走动作慢；
4、更换回转先导压力传感器，故障消失。
Troubleshooting process:
1. Checked in the monitor and found that the swing pilot oil pressure is zero, the front pump pressure is
10 Mpa, the current of the front pump PRV is 30 mA. It means that no swing pilot pressure sends to
MC, the current sends to the front pump is low, pump outputs the minimum flow.
2. Install a pressure gauge to test the swing pilot oil pressure on the main valve spool. The tested swing
pilot oil pressure is 3.9 Mpa, normal. Pilot valve and pilot oil circuit have no problem.
3. Interchange the s wing pi lot pressure sensor with the le ft tr avel pilot pressure sensor. The operation
speed of the swing is normal while the left travel is slow.
4. Replace the failed pilot sensor, problem solved.
排故体会：当先导压力传感器损坏或它的线路故障，控制器检测不到先导压力信号，
则控制器按最小流量向主泵输送比例电流，引起主泵排量为最小量，动
作缓慢。
Experience: When the pilot pressure sensor or its wire is failed, the MC can not receive the signal of the
pilot oil pressure. MC will send t he c urrent t o t he proportional solenoid valve which makes t he p ump
output the minimum flow, related action will have a long cycle time.
——提供者：张小飞 Service engineer: Zhang Xiao Fei
- 13 -
04、回转滑行量过大 Slippage is excessive when the swing operation is stopped
故障现象：SY230C6在回转停止时滑行量过大，上坡行走时上部车身自行滑动。
Failure phenomenon: SY230C6 excavator slide too much when swing stops, upper structure slides when
the machine travels uphill.
故障原因：造成回转滑行过大、自行滑动：
1、控制阀回转主阀芯是否磨损；
2、回转溢流压力是否在正常范围内（280—290公斤）；
3、回转刹车延时阀是否发卡，回转刹车解除压力SH是否为35公斤左右；
4、回转刹车片是否磨损严重。
Possible root cause of the failure:
1. Swing valve spool of the main control valve is worn severely.
2. Pressure setting of the swing line relief valve is lower than specification (280 -290 kg).
3. Swing brake control valve seized, swing brake released pressure at SH port is lower than 35 kgf.
4. Swing brake disc is worn heavily.
故障分析：1、回转停止时马达由于惯性将继续滑行，控制阀回转主阀芯已回到中位
位置，马达低压侧将形成高压，由于溢流阀锥面密封不严造成高压油
大量泄漏，出现回转停止时滑行量过大的故障。
2、机器在行走中，上部车身主要靠回转刹车片保持，由于刹车片磨损造
成机器在上坡行走中车身滑动。
Failure analysis:
1. When swing stops, motor continues to swing by inertia, swing valve spool of the main control valve
returns to neutral position, oil pressure in the return circuit increase rapidly. If the line relief valve is
failed, oil will leaks into the tank and causing excessive slippage when swing stops.
2. When excavator travels, swing brake is functioned. If the swing brake disc is worn severely, the upper
structure will slide when the machine travels uphill.
排故方法：1、先检查控制阀回转主阀芯是否磨损---无磨损；
- 14 -
2、检查回转刹车阀无发卡，测量回转刹车 SH 口压力为 35 公斤--正常；
3、测量回转溢流压力为 255 公斤左右--不正常--偏低，将溢流阀压力调
整至 285 公斤，故障未排除。对溢流阀进行拆检发现溢流阀锥面磨出一
道圆形沟槽，更换回转溢流阀后，回转停止时滑行量过大故障排除；
4、测量回转刹车解除 SH 口压力为 Disc of swing

brake is worn.
35 公斤，在正常范围内。拆检发现
回转刹车片磨损，橡胶刹车片上的
橡胶脱落，金属刹车片上磨出不规
则划痕，更换刹车片后，上坡行走时上部车身滑动故障排除。
1. Checked and found the swing valve spool is not worn. It is normal.
2. Swing brake delay valve works normally.Pilot pressure at SH port is 35 kg. It is normal.
3. Measure the swing relief pressure i s 255k gf which i s not normal, t oo l ow. Adjust pressure of relief
valve to 285 k g, problem not solved. Dismantle the relief valve and the wear groove is found on the
cone. Replace the failed relief valve, solves the problem of sliding too much when swing stopping.
4. Measure the swing brake release pressure at SH port, it is normally 35 kgf. Dismantle swing m otor
and find the swing brake disc is worn out and the plate has irregular scratch on it. Replace the failed
disc and plates, tested and found the failure of upper structure slide when travels uphill is solved.
排故体会：机器在回转时停车靠过载溢流阀制动，而不动时是靠回转刹车片制动。
Experience: Swing ope ration i s s topped w ith t he a ssistance of t he s wing l ine r elief va lve. When t he
swing brake is activated, the upper structure is hold by the swing brake.
- 15 -
05、左行走、回转单独动作速度慢 Left travel or swing operation has a long cycle time
故障现象：一台 SY215C8M 型挖掘机，单独左行走或回转时动作速度慢，做复合动作
时正常，做其它动作正常。
Failure phe nomenon: SY215C8M e xcavator has a l ong c ycle t ime w hen t he s wing ope ration or l eft
travel operation is carried out. Other single task operation and the combined operation are normal.
故障分析：根据故障现象：在做其它动作时正常，可以判定主溢流压力、先导压力
都在标准范围内，主泵工作正常。因左行走、回转为同一侧主控制阀芯，
单独动作时速度慢，复合动作时正常，说明故障点在主控制阀的上。经
过仔细分析液压系统原理图，如主控制阀 CSP 单向阀卡在常通位置，就
能造成左侧主控制阀的压力油（平行油道的油）通过系统内部油道回油
箱，致使单独左行走或回转时动作速度慢无力。
Failure an alysis: According t o F ailure ph enomenon, s ince t he other operations are normal, the main
relief valve pressure and t he pilot oil pressure are w ithin s pecification. Main hydraulic pump w orks
normally. Left travel valve spool and swing valve spool ar e at the s ame side of the main control valve.
The single operation is slow while the combined operation is normal which indicates that the main control
valve is suspected. Consult the hydraulic system schematic carefull and found that if the CSP check valve
of the main control valve is kept on open position, the pressure oil in the paralled circuit will return to the
hydraulic oil tank. Sing task of left travel and the single task of swing operation has a long cycle time.
故障原因：主控阀 CSP 单向阀卡在常通位置。

Root cause of the failure: CSP check valve of the main control valve is always opened.
排故方法：1、测量主溢流压力为 348 公斤，先导压力为 38 公斤--正常；
2、测量先导手柄至左行走阀芯、回转阀芯先导压力为 38 公斤--正常
3、将前泵，后泵至主控制阀的高压油管相互调换后，故障依然存在，证
明主泵工作正常，故障点在主控制阀；
4、拆检 CSP 单向阀发现卡在常通位置，无法关闭。对主控阀 CSP 单向

- 16 -
阀进行修复后，左行走、回转单独动作恢复正常工作，故障排除。
（因
左侧主控阀平行油道的液压油可以经 CSP 单向阀供给中心油道。当单
独做左行走或回转动作时 P1 泵既向左行走或回转供油，又由 CSP 单
向阀供给中心油道，经斗杆、铲斗合流阀芯回油箱。当左行走或回转
同时与斗杆或铲斗动作时，由 CSP 单向阀供给中心油道的油被切断无
法回油箱所以左行走或回转恢复正常）
。
1. Measured main relief pressure is 348 kgf and the pilot oil pressure is 38 kgf. It is normal.
2. Measured pilot oil pressure of left travel and swing is 38 kg. It is normal.
3. Interchange the output oil hose of the front pump and the rear pump, problem still existed, it means
the main pump works normally and the main control valve is suspected.
4. Checked and found t he check valve C SP of t he m ain control valve is st uck on open pos ition. After
repairing the check valve, tested and proved the left travel operation and the swing operation has the
normal cycle time. Problem solved. (Hydraulic oil in parallel passage of left main control valve could
supply oil to cen tral passage through C SP check v alve. When the s ingle ope ration of left travel or
swing is done, P1 pump supplies oil to left travel or swing, and also supplies oil to centeral passage
through t he CSP check v alve. Then r eturns t o o il t ank passes through stick valve s pool a nd bucket
confluence spool. W hen the c ombined ope ration w hich ha s l eft travel or s ing i s c arried out , the o il
from C SP to c enter c ircuit is blocked a nd can not ba ck t o the oil t ank, s o the left travel and s wing
operation recovers to normal.)
Fig 1：CSP checke valve Fig 2：CSP check valve
——提供者：唐子光、刘志刚 Service engnineer: Tang Zi Guang, Liu Zhi Gang
- 17 -
06、机器动作慢无力 Machine has a long cycle time
故障现象：一台07年SY230负流量挖机动作慢，无力,负载增加时更明显，发动机转速
正常，不掉速。
Failure phenomenon: An NFC SY230 excavator made in 2007 has a long cycle time and insufficient
power, obviously with load increased. The engine speed is normal.
故障分析：在发动机转速正常情况下，动作慢,无力1般是系统压力内泄，先导压力过
低，系统压力内泄使挖机在挖掘时的压力达不到设定值，先导压力过低
使主阀芯开度不到位，从而导致动作慢。
Failure an alysis: Engine speed i s n ormal while th e a ction h as a lo ng c ycle time , and t he po wer i s
insufficient. Usually, i t i s s uspected t hat the internal leakage existed and the pilot pr essure is low. T he
internal leakage will cause the system pressure lower than the specification. The low pilot pressure will
cause the valve spool can not open fully and the long cycle time of the operations.
排故原因：液压系统内有杂质，造成溢流阀无法复位，工作时主溢流阀产生内泄。
Root cause of the failure: Foreign material enters into the hydraulic system, main relief valve can not be
reset and has an internal leakage.
排故方法：1、先测量先导压力,测得先导压力为39公斤--正常；
2、测量主控制阀至主泵调节器负反馈压力,测量前后泵负反馈压力，操
作手柄中立时为38公斤,全行程操作手柄时为4公斤左右--正常；
3、测量主溢流阀溢流压力为255公斤,溢流压力--不正常。因为正常主溢
流压力为330公斤，由此判断压力不正常需要调整；
4、调整主溢流阀时,将主溢流阀调整螺钉顺时针旋紧1圈后，测量溢流压
力无变化，这时可以判断主溢流阀故障；
5、拆检主溢流阀发现内部有杂质,造成提动头无法完全复位,从而产生系
统压力内泄。清洗、调整主溢流阀压力到330公斤,试车1切正常。
- 18 -
Main relief vlave Foreign m aterial
blocked, hy d oil
internal leaked
Troubleshooting:
1. Measured pilot oil pressure is about 39 kgf. It is normal.
2. Measured negative feedback pressure of the two main pumps. It is 38 kgf when all the pilot valves are
in neutral position and 4 kgf when the joystick is at full stroke. The measurement is normal.
3. Measured main oil pressure is 255 kgf which is lower than the specification 330kgf. So the main relief
valve is suspected.
4. Screw in one circle of the adjusting screw of the main relief valve, the measured oil pressure does not
change. Main relief valve fails to work normally.
5. Dismantle the main relief valve and find there are some impurities which cause the spool can not reset
and interal oil leakage. Clean and adjust the main safety valve pressure to 330kgf, tested and proved
the machine works normally. Problem solved.
排故体会：主溢流阀故障，使系统压力达不到设定值，就会导致正常挖掘时动作无
力的故障.
Experience: If the m ain relief valve i s failed, the s ystem pr essure will u nable to reach t he s tandard
pressure. So the machine can not work normally.
- 19 -
07、小臂、回转速度慢，单边行走无力 Stick, swing, single track travel has a long cycle time
故障现象：一台 SY210 型负流量机器，更换主泵，主控制阀后出现小臂回收外扬动作
速度慢，在复合动作时略有好转，单独回转时速度慢，复合动作时速度
正常，单独操作一边行走无力，同时操作两边行走动作正常。
Failure phe nomenon: There i s a SY210 N FC e xcavator. After re placing the m ain pum p a nd t he m ain
valve, t he s tick extends s lowly while it is a l ittle i mproved w hen c ombined w ith other operation. The
single swing s peed i s l ow but i s normal when c ombined with other operation. Single track travel h as a
long cycle time but the cycle time is normal when two tracks are operated at the same time.
故障分析：1、更换的主泵，主控制阀为全新配件，故可以排除主泵、主阀故障。
2、检测主泵比例电磁阀电流值是否在标准范围内（350 - 800mA）、电磁
比例阀电阻是否为（14 - 17 欧)。
3、在更换主泵、主控制阀时先导管路、主管路连接是否正确。
4、检测主控制阀至液压泵调节器的负反馈压力是否在标准范围内。阀芯
中位时约 38 公斤，阀芯全行程操作时 1 - 5 公斤。
5、检查主控制阀到主泵调节器的负反馈压力油管是否接反。
Failure analysis:
1. Main pump and the main control valve are newly installed. They should not be suspected.
2. Current to the proportional solenoid valve of the m ain pum ps s hould be 350 to 800mA. T he
resistance of the proportional solenoid valve should be 14 - 17 Ohm.
3. When replace the pump and the main valve, pilot hoses and main oil hoses are connected correctly?
4. Measured negative feedback pressure of the two pumps should be 38 kgf when all the pilot valves are
in neutral position and 1-5kgf when the pilot valve is at full stroke.
5. Negative oil hose from the main valve to the front and rear pump should be connected correctly.
排故原因：主控制阀至主泵调节器的负反馈压力油管接反。
Root cause of the failure: The negative hose of the front and rear pump is installed interexchanged.
- 20 -
排故方法：1、测量主泵主溢流阀压力为 340 公斤，先导溢流压力为 38 公斤--正常
2、根据故障现象，检查主控制阀各阀芯、过渡块上先导管路连接正确。
3、测量前后泵比例电磁阀电流值，503、504 号线，手柄中立时电流值为
900mA 左右,手柄全行程操作时电流值为 350mA 左右--正常，将前后
泵比例电磁阀线束 503、504 互换后试机，故障依然存在，证明比例
电磁阀电流值、线束连接正确，可排除此处故障。
4、测量前泵后泵负反馈压力：
（1）复合动作时操作大臂提升、铲斗回收外扬时负反馈压力为 4 公
斤--正常，操作小臂回收，外扬时负反馈压力：前泵为 4 公斤
--正常、后泵为 18 公斤--不正常。
（2）单独操作回转时前泵负反馈压力为 39 公斤--不正常。单独操作
左右行走时负反馈压力为 39 公斤--不正常，同时操作左右行走时
前泵后泵负反馈压力均为 4 公斤--正常。
5、在全程操作小臂回收，外扬时负反馈压力：前泵为 4 公斤--正常、后
泵为 18 公斤---不正常。因在之前曾多次检测维修造成小臂阀芯 2 有
卡滞，因小臂阀芯 2 有卡滞造成小臂阀芯
切换不到位，使后泵负反馈压力为 18 公
斤，而降低不到 4 公斤，致使后泵排量在
做小臂动作时不能将排量增加到最大，所
以小臂动作速度慢。
6、通过对主泵负反馈压力的测量可以判定是前泵与后泵负反馈压力油管
接反。原因为：主控制阀到液压泵调速器的负反馈油管接反后，当做
- 21 -
回转或左行走动作时左主控制阀到主泵调速器的负反馈压力降低后，
并没有将前泵的排油量加大，而是将后泵的排油量加大了，所以单独
回转或行走动作慢，而复合动作时左右两边主控制阀的负控制压力都
降低，前后泵的排量同时加大，所以动作速度正常。
7、将主控制阀到液压泵调节器的负反馈油管重新连接，清洗小臂阀芯 2
重新安装，小臂回转动作速度正常，操作单边行走时无力的故障排除，
挖机恢复正常。
1. Measured the main system pressure is 340kgf, and the pilot pressure is 38kgf. They are normal.
2. Checked a nd f ound t he pi lot hos es be tween t he m ain c ontrol va lve a nd t he pi lot t rasition bl ock a re
connected correctly.
3. Measured current of t he proportional solenoid valve of t he t wo pum ps at w ire 503# and 504 # is
900mA when the joysticks are at the neutral position and 350mA when the joystick is at the full stroke.
Interchange t he l ine 503 a nd l ine 504, pr oblem still e xists. It me ans the current of t he pr oportional
solenoid valve and its wire is correct.
4. Measure the negative feedback pressure of the two pumps.
a) The negative f eedback p ressure of the pump is 4kgf during the combine operation of boom up
and the bucket in/out. During the stick in/out operation, the front pump negative pressure is 4kgf,
and the rear pump negative pressure is 18kgf which is abnormal.
b) Swing only, the front pump negative feedback pressure is 39kgf which is abnormal. Operate the
left t rack or the r ight t rack onl y, t he ne gative f eedback pr essure i s 39k gf w hich i s abnormal.
Operating the t wo t racks together, the ne gative f eedback pr essures o f t he t wo pum ps a re 4 kgf
which is normal.
5. When the stick is operated in the full stroke, the front pump negative pressure is 4kgf which is normal.
The negative pressure of the rear pump is 18kgf which is abnormal. Checked and found the stick 2
valve spool is seized in the main control valve which cause the negative pressure of the rear pump is
18kgf not the normal pressure 4kgf. So the rear pump output flow is lower than the specification and
result in the stick operated slowly.
- 22 -
6. According t he measurement of t he ne gative f eedback oi l pr essure, it is c lear that t he t wo ne gative
feedback oil hos es of t he t wo pum ps a re i nstalled w rongly. W hen the s wing o r le ft tr ack tr avel is
operated, the decreased negative pressure to the front pump should increase the front pump output oil
flow. As the front pump negative oil hose is connected to the rear pump, the rear pump not the front
pump out put oi l f low i ncreased! During t he conbimed ope ration, bot h the f ront and t he r ear pu mp
have its output oil flow increased, the operation speed become normal.
7. Correct the connection of the negative pressure hose form the main control valve to the two pumps.
Clean the stick 2 valve spool, tested and proved problem solved.
排故体会：在维修挖机时，不管是什么故障，必须思路清晰，逐步把问题缩小在最
小的范围。
Troubleshooting experience: When repair the excavator, whatever the failure it is, the troubleshooting
logic must be clear. Steps by steps narrow the failure to the less range.
- 23 -
08、铲斗动作慢 Bucket operation has a long cycle time
故障现象：一台 07 年 SY210 负流量机器，铲斗在单独动作和复合动作时速度都慢，
铲斗收回后会自动下落，其它动作都正常。
Failure phenomenon: A N FC ex cavator SY210C made i n 2007 h as a long c ycle t ime du ring b oth t he
bucket s ingle t ask ope ration a nd t he bucket combined ope ration. B ucket drops after after t he b ucket i n
operation is complete. Other operations are normal.
故障分析：整机其它动作正常，证明主溢流压力（330公斤）、先导压力（39公斤）
--正常，根据故障现象，初步判定为铲斗动作油路有内泄现象，问题可
能出在铲斗阀芯、过载溢流阀、铲斗油缸，造成系统压力内泄，使铲斗
动作速度慢。
Failure an alysis: Other operations of t he ex cavator are normal. It me ans th at the main relief v alve
pressure (330kgf) a nd pilot oil pressure (39kgf) i s nor mal. A ccording t o f ailure ph enomenon, it is
suspected t hat t herer i s i nternal leakage in buc ket operation oil c ircuit. Possible f ailure m ay h appen i n
bucket valve spool, bucket line relief valve, and the bucket cylinder which leads to the internal oil leakage
and the bucket operation has a long cycle time.
故障原因：铲斗油缸油封损坏，压力内泄，导致机器工作时铲斗挖掘无力铲斗回收
后自动下落。
Root cause of the failure: The bucket cylinder seals are damaged, internal oil leakaged occurred in the
bucket cylinder. Bucket in operation has insufficient power during the working and bucket drops down
when the bucket in operation is stopped.
排故方法：1、因为其它动作正常，说明先导压力及主压力正常。检查手柄到铲斗
阀芯的先导压力为39公斤--正常；
2、做铲斗溢流动作时系统压力为170公斤--不正常，正常的铲斗过载溢
流压力为350公斤。将铲斗的过载溢流阀与其它动作的过载溢流阀互
换后试车，故障依然存在；
3、拆解铲斗合流单向阀（CK1）检查无
- 24 -
卡滞、破损；
4、根据铲斗有下沉的现象，将铲斗主阀芯
拔出检查是否磨损---无磨损.
5、将液压油回油滤芯拆洗检查发现有非金属
杂质，于是拆检铲斗油缸，发现铲斗油缸活塞油封破损严重。更换铲
斗油缸油封后铲斗动作恢复正常。
1. Since t hat the ot her operations a re n ormal, it me ans th at th e p ilot oil p ressure an d t he main o il
pressure are normal. Checked and found that the pilot oil pressure between the joystick and the bucket
valve spool is 39kgf which is normal.
2. Operate t he buc ket c ylinder t o t he f ull s troke a nd hol d on t o m easure the ma in oil pressure. T he
measurement is 170kgf which is lower than the specification 350kgf. Interchange the bucket in line
relief valve with other operations, tested and proved problem still exist.
3. Remove the check valve of the bucket confluence valve. No failure with this valve.
4. As the bucket drops automatically, remove the bucket valve spool and checked it is normal and not
worn.
5. Checked and found there is non-metal foreign material in the hydraulic return oil filter. Dismantle the
bucket cylinder. It is found that the seals of the bucket cylinder are worn severely. Replace the failed
seals, tested and proved problem solved.
排故体会：油封损坏造成系统压力内泄，压力低造成铲斗动作慢,无力。
Experience: If the cylinder seal is failed, the internal oil leakage will be occurred. Pressure decreased and
the bucket operation performed poorly.
- 25 -
09、大臂无力，提升速度慢 Boom up has a long cycle time
故障现象：SY200C5 大臂无力,抬升动作慢。
Failure Phenomenon: SY200C5 Boom up operation has a long cycle time.
故障分析：1、液压主泵压力不够；
2、支路安全阀压力过低；
Relief valve and
check valve is
suspected
3、主阀芯内泄；
4、大臂 2 阀芯发卡或单向阀(ccb)卡死,造成不能合流；
Check va lve a nd b oom 2 valve
will cause confluenc failed
5、大臂油缸内泄；
6、先导压力低；
7、大臂保持阀的单向阀压力过低。
Holding va lve
and t he c heck
valve are
suspected
Failure Analysis:
1. The pressure of hydraulic pump is lower than specification.
2. The pressure setting of line relief valve is too low.
- 26 -
3. Valve spool of the main control valve has internal oil leakage.
4. The boom 2 valve spool or the check valve seized result in confluence failed.
5. Boom cylinder has internal leakage.
6. Pilot oil pressure is lower than specification.
7. The pressure in the check valve of boom holding valve is too low.
排故过程：1、通过监控器发现发动机的最高转速 2100 左右(因挖机时间过长,所以
认为正常)；
2、因为其它动作正常,所以排除主泵及先导压力的故障；
3、将机器作油缸内漏试验,排除了内漏的可能(启动机器,将大臂抬到最
高端,熄火,泄掉液压油箱的压力,缓慢地拆掉大臂油缸的有杆腔的油管
并用堵头堵住拆下机身端的油管接头;然后启动机器,作大臂溢流动作,
如果杆端的油管有油泄漏证明油缸内漏,需更换密封;反之正常)；
4、确定了大臂保持阀单向阀是好的(做完上述的第 3 步后,可以做大臂保
持阀是否有问题的测试:将大臂抬到最高,熄火,观察大臂的沉降量,如果
保持阀有问题,那么大臂会很快下沉,反正则大臂保持阀正常).
5、拆卸大臂 2 阀芯,大臂 1 主阀芯均无异常.
6、将支路安全阀与备用阀互换后,证明安全阀也是好的；
7、无意中发现,抬大臂的过程中大臂下降的先导油管有振动,拆下大臂主
阀芯大臂下降的先导油管,提升大臂发觉有较大压力的液压油从管口喷
出,所以确定先导手柄阀内漏。
Troubleshooting:
1. The hi gh i dle s peed i n t he m otor i s 2100 rpm. It i s considered as normal s ince t he working hou r i s
very long.
2. As t he other operations a re normal, both t he m ain oi l pr essure a nd t he p ilot oi l pr essure s hould be
normal.
- 27 -
3. Do the cylinder internal leakage test and found the boom cylinder has no failure. (Start the engine and
raise t he boom t o hi ghest pos ition. Shut dow n the engine a nd release the r esidual p ressure i n the
hydraulic oil tank. Remove the rod end hose of the boom cylinder slowly and plug the hose from the
control valve. If the oil leaks out from the boom cylinder rod end tube, it means the boom cylinder has
inernal leakage. Boom cylinder needs repairing. Otherwise, it’s normal)
4. Make certain the check valve of boom holding valve is normal. (After done the three steps above, you
could start boom holding valve test. Raise boom to highest position and shut down engine. Observe
the drop volume o f boo m. If hol ding va lve ha s problem, boom w ill drop fast, ot herwise, the boom
holding valve is normal).
5. Checked and found both the boom 1 and boom 2 valve spool are normal. Not worn.
6. Interchange the boom line relief valve with the line relief valve of the spare valve, tested and proved
the boom line relief valve is normal.
7. Checked an d found the boom dow n pi lot hos e s hakes when the boom i s up. Disconnect t he boo m
down pilot hose from the main control valve and do t he boom up ope ration. It is found that pressure
oil sprayed out from the disconnected pilot hose. This is the proof of boom pilot valve failed and has
intermal leakage.
故障原因：将右先导手柄阀总成更换后,试机,大臂提升速度明显加快,证明故障点已
找到,故障现象已经解除。
Root cause of the failure: Boom pilot valve is failed. Replace the failed pilot valve, tested and proved
problem solved.
排故体会：其实这个故障如果仔细的试机的话,可以感觉到抬大臂时，铲斗有轻微的
动作.如果早注意到这个现象,排故的过程将大大缩短,提高效率。
Experience: If t he r unning test is done carefully before t he t roubleshooting, the phe nomena of buc ket
slight ope ration dur ing t he boom up ope ration. If t he buc ket ope ration i s not iced dur ing t he boom up
operation, the process of troubleshooting will be shortened greatly and the efficiency will be increased.
——提供者：李纪平 Service engineer: Li Ji Ping
- 28 -
10、左行走前后都慢，回转慢 Left travel, swing has a long cycle time
故障现象：一台LSY210C挖掘机出现左行走前进后退和回转都很慢现象。
Failure phenomena: A SY210C excavator has long cycle time during the swing operation or the left
travel forward / backward operation.
故障分析：该型号挖掘机是通过采集负压信号通过控制器控制液压泵调节器实现液
压泵和发动机功率的匹配,在系统压力升高时液压泵排量减少；系统压力
降低时液压泵排量增加.该型号挖机另有一套液控模式,在电器系统发生
故障时改为液控仍可正常工作。
Failure Analysis: This model of excavator is featured in the perfect real time match of its hydraulic
pump and engine, which is realized by sending the negative pressure signal acquired to the main
controller so as to regulate the adjustor of the hydraulic pump. When the system pressure increases, the
flow of the main pump reduces, and vice versa. This model of excavator also has another hydraulic
control mode, which can be functional in case of the electric system failure.
故障原因：1、负压传感器故障； Pump adjuster Servo piston of

the adjuster seized
2、线路故障；
Hyd pump
3、控制器故障；
4、液压泵调节器故障。
Probable failure cause:
1. Malfunction of the negative pressure sensor.
2. Circuit malfunction.
3. Machine Controller malfunction.
4. Malfunction of the hydraulic pump adjustor.
排故方法：1、检查相应传感器读数,(前泵负压)在操作行走和回转时变化不正常(基
本不变化)，将设备调为液控模式,故障仍然存在,可判断该故障由液压
泵调节器引起,与电气无关；
- 29 -
2、拆解前泵调节器清洗后,故障消除。
Troubleshooting:
1. Check the reading of negative pressure sensor on the front pump. The reading does not change much
when the excavator travels and swings. Then put the machine on hydraulic control mode. If the
malfunction still exists, it can be concluded that the fault is caused by the hydraulic pump adjustor,
and it has nothing to do with the electric part.
2. Dismantle the front pump adjustor and clean it, tested and proved problem solved.
排故体会：液压泵的变量由调节器控制,当调节器发生故障时会引起设备工作不正常,
而设备在使用了2--3年后由于液压系统内有部分液压油很少流动,容易
引起油品老化变质,使相应部件运动不正常,引发故障。
Experience: The main pump is controlled by the adjustor, which will directly cause the malfunctioning
of t he m achine w hen i t g oes w rong. E specially when t he m achine h as b een u sed f or 2 to 3 years, t he
deterioration of s ome s tagnant h ydraulic oi l i n the s ystem i s l ikely t o c ause abnormal m ovement of
relevant parts, which result in malfunction of the machine.
——提供者：张小亮 Service engineer: Zhang Xiao Liang
- 30 -
11、回转异响 Swing operation has abnormal noise
故障现象：一台 SY200C 型负流量机器，在向右回转后，停止转动时出现回转自动滑
行，不能定位，并伴随“咔吱”异常响声。如果在有坡度的地方工作，故
障更为明显,其它动作正常。
Failure phe nomena: A S Y200C e xcavator with ne gative f low h ydraulic s ystem. A fter a r ight s wing
movement is operated, the swing mechanism couldn’t lock on the stop position with strange noise. When
the excavator is operated on a slope, the fault becomes much more obvious. Other operations are normal.
故障分析：1、在向右回转时发响可能为回转减速机内齿轮、回转轴承损坏；
2、回转减速机传动轴与回转支撑齿轮接触面损坏、回转支撑轴承损坏可
能造成异响声；
3、回转马达制动无法解除可能造成异响声；
4、回转补油单向阀磨损严重或卡滞可能造成异响声；
5、回转阀芯、缓冲溢流阀磨损严重可能造成异响声。
Failure analysis:
1. The occurring of strange noise may result from the damage of gear and rotary bearing inside rotary
speed reducer.
2. Damage on connecting area between rotary reducer transmission shaft and rotary support gear and
broken-down of rotary support bearing.
3. Rotary motor brake cannot be released, causing strange noise.
4. Rotary oil feed one-way valve is heavily abraded or choked.
5. Rotary valve core and overflow buffer valve are heavily abraded.
故障原因：回转补油单向阀卡死在阀座上。
Root cause of the failure: Check valve of the swing motor is choked on the valve seat
排故方法：1、在做回转动作时发响，但回转速度正常，而且其它动作工作正常，可
判定先导压力、主溢流压力正常在标准范围。故可以排除先导压力、
- 31 -
主溢流压力故障。
2、根据故障现象可知：在向右回转时，若回转减速机和回转轴承损坏，
不会只出现右回转时异响，故可 Makeup check valve
排除减速机故障。
3、因异响声在回转马达的上部，而且只
有在右回转时才有异响声，故可以排除回
转减速机传动轴与回转支撑齿轮接触面损
坏、回转支撑轴承损坏的故障，如损坏在
左右回转都会发出响声。
4、控制回转马达的有缓冲溢流阀、操作手柄，当回转马达内部损坏，其
响声应在回转左右转动及停止时都应出现，故可以排除回转马达故
障。
5、主控制阀回转阀芯如磨损严重或切换不到位，会造成回转时启动无力，
制动时又停不住，但停止转动时不会出现“咔吱”异常响声,故可以
排除主控制阀故障。 Makeup check valve is

choked on its seat
6、通过上述对故障的分析，故障点可
能在回转马达盖上。拆解马达盖检查，
发现马达盖上的补油单向阀卡死在单向
阀座上。后将单向阀从马达盖上取下，
进行研磨修复，重新安装后试车，异常
响声消失，故障排除。
Troubleshooting:
- 32 -
1. Strange noise is heard when rotary movement is operated with normal rotary speed and other actions
normal. It is sure that pilot pressure and main overflow pressure among stand range. Thus the fault is
not caused by abnormal pilot pressure or overflow pressure.
2. According to the fault symptom, it is judged that if the rotary speed reducer and bearing are damage,
not only the noise is heard when the right rotary movement is made, but other faults shall occur. Thus
the fault is not caused by malfunction of reducer.
3. Since the noise is heard only on the top of rotary motor and only when the right movement is operated,
it i s obvi ous t hat t he f ault i s not c aused b y d amage on connecting a rea between r otary r educer
transmission s haft a nd r otary s upport gear a nd b roken-down of r otary s upport be aring, w hich s hall
result in strange noise when both right and left rotary movements are operated.
4. Rotary motor is controlled by buffer overflow valve and operating handler. Once the damage inside
rotary m otor oc curs, t he s trange noi se s hall b e he ard w hen bot h r ight a nd l eft m ovements are
operated.
5. If t he m ain control valve rotary v alve cores i s heavily abraded or not s hift t o t he right pos ition, the
rotary movement i s not easily t o be s tarted or s topped onc e s tared. W hen i t s tops r otating, s trange
noise cannot be heard.
6. According t o t he above a nalysis, t he fault m ay c aused b y m alfunction on t he r otary m otor cover.
Uncover and the motor cover. It is found that the oil feed one-way valve is choked one the valve seat.
Remove t he va lve f rom the s eat, pol ish i t a nd i nstall. R estart t he m achine, s trange noi se won’t b e
heard any more.
排故体会：回转马达单向阀卡死在常通位置，是一个比较常见的故障,在平时的维修
过程中注意经验的积累,有利于以后排故的迅速,准确。
Experiences: The makeup check valve of the swing motor is seized at open position is a common failure.
The accumulation of this kind of experience during daily repair and maintenance shall grantee quick and
accurate troubleshooting.
- 33 -
12、全车无动作 Machine has no actions
故障现象：发动机启动后，压下左侧操纵台安全杆，操作左、右手柄，全车无动作。
Failure phenomena: After the engine is started, unlock the hydraulic activation control lever on the left
side and operate the joysticks, machine has no actions.
故障分析：1、检查 6#保险丝无烧毁，正常；
2、测量先导作业切断开关处 0.85Y 线端电压 24V 正常，电阻 NO-C 断开
时无穷大、闭合时为 0 正常；
3、测量先导作业切断电磁阀处 0.85YG 线端电压 24V 正常，线圈两端电
阻为 13.5 欧姆正常；
4、检查作业切断电磁阀阀芯活动正常；
5、测量齿轮泵的压力，只有 5-7BAR，调整齿轮泵溢流阀，压力无变化，
解体后发现溢流阀内弹簧断裂。
Failure analysis:
1. Check whether 6# fuse is burnt down.
2. Measure 0.85Y line voltage when the pilot solenoid valve is cut off, the voltage is normal at 24V. The
resistance NO-C value is at infinity when it is disconnected and at 0 while connected.
3. Measure 0.85Y line voltage when the pilot solenoid valve is cut off, the voltage is normal at 24V. The
resistance of wires is normal at 13.5 Ω.
4. Check the working condition of cutting off the solenoid valve.
5. Measure t he gear pum p pr essure, onl y at 5 -7BAR. A djust t he gear pu mp ove rflow va lve, a nd t he
pressure is stable. Uncover the valve and the spring inside is found to be have been broken.
故障原因：溢流阀内弹簧断裂，导致先导压力过低，不能推动阀芯移动，全车无动
作。
Root cause of the failure: The s pring i nside relief valve i s broken, causing l ow pressure, which is not
strong enough to push the movement of valve core. Thus the excavator has no actions.
排故方法：1、首先检查 6#保险丝无烧毁，正常；
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2、按照上述 2-4 点检查后正常；
3、测量齿轮泵的压力，只有 5-7BAR，调整齿轮泵溢流阀，压力无变化，
由此得解体检查，后发现溢流阀内弹簧断裂；
4、交换弹簧，清洗后 OK。
Troubleshooting:
1. Firstly check the 6# fuse, which is normal without being burnt down.
2. Everything is normal after check is done according to the 2-4 steps.
3. Measure t he gear p ump pressure, onl y 5 -7 B AR. A djust t he g ear pum p ove r-flow va lve a nd t he
pressure is not changed. Thus uncover the valve and the spring inside valve is broken.
4. Replace the spring and the fault is removed.
排故体会：在排故过程中应遵循先简单后复杂，先外表后内部，先电气后机械的原
则。在特殊情况下，可以进行变通。
Experiences: During the troubleshooting, obey the principle from simple to complicated, from outside to
inside, from electrical to mechanic. In special situations, try to be flexible.
——提供者：伍锡斌 Service engineer: Wu Xi Bin
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13、破碎操作不受控制 Hydraulic hammer is out of control
故障现象：松开破碎脚踏，破碎器继续工作，其他正常。
Failure phenomena: Release break operation pedal, the breaker still works. Other actions are normal.
故障分析：1、检查破碎先导阀是否卡死；
2、检查主阀芯是否卡死；
3、检查破碎管路是否安装正确；
4、检查破碎压力是否正常。
Failure analysis:
1. Check whether the breaker pilot valve is choked or not.
2. Check whether the main valve spool is choked or not.
3. Check whether the break circuit is installed correctly or not.
4. Check whether the break pressure is normal or not.
故障原因：破碎主阀芯卡死在打开位置。
Root cause of the failure: The break main valve spool is choked at the open position.
排故方法：1、通过显示器检查破碎锤先导压力正常；
2、检查主阀芯，发现阀芯卡死在打开位置；
3、破碎管路安装时没彻底清洗干净，回油油路没直接回油箱；
4、清洗主阀芯，清洗管路，重新把破碎器回油管路接到油箱。
Troubleshooting:
1. The breaker pilot pressure displayed on the LCD is normal.
2. Check the main valve core, which is found to be choked on the open position.
3. The breaker circuit is not clean. The oil-return pipe is not directly connected to the oil tank.
4. Clean main valve core and oil pipe. Reconnect the breaker oil-return pipe to the oil tank.
排故体会：安装破碎器时一定注意清洗管路，破碎锤回油建议直接回油箱。
Experience: When t he br eaker i s i nstalled, pa y a ttention t o cl eaning b reaker circuit. T he r eturning of
breaker oil is advised to deliver to the oil tank directly.
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14、SY230 启动着后动臂上升 Boom up automatically after engine is started
故障现象： SY230C8B 启动后动臂自动上升、无法下降。
Symptom: SY230C8 boom up automatically and cannot be got down after engine is started.
故障分析：1.先导阀芯发卡；
2.动臂阀芯 1 或 2 发卡。
Failure analysis:
1. Pilot valve core is choked.
2. Boom valve core 1 or 2 is choked.
故障原因：动臂阀芯发卡。
Root cause of the failure: Boom valve core is choked.
排故方法：1、挖机启动后，不做动作，动臂只上升却不能下降，从显示器进入系统
检查数据，动臂提升先导信号为 0，先导阀未开启，与先导阀芯无关；
2、动臂只上升却不能下降，检查动臂阀芯，动臂阀芯 1 发卡；
3、取出阀芯，进行清洗后将阀芯装入阀座，试车故障排除。
Troubleshooting:
1. Once the excavator is started, it has no action. Its boom arises automatically and shall not be got down.
Check the data stored in the control s ystem and the boom lifting pilot signal is 0. Pilot valve is not
opened. It is judged that the fault has nothing to do with the pilot valve core.
2. Check boom valve cores and core No.1 is found to be choked.
3. Take out and clean the boom valve core. Tested and proved problem removed.
排故体会：先要根据工作原理，判断是哪一部分出现故障。
Experience: Figure out the fault reasons according to the system operation.
——提供者：张会龙 Service engineer: Zhang Hui Long
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15、挖掘机全车无动作 Excavator has no action
故障现象：SY360C挖掘机出现全车无动作故障。
Symptom: Here is one unit of SY360C excavator, which has no actions.
故障分析：1、液压油箱油量不够，主泵吸空；
2、吸油滤清器堵死；
3、发动机联轴器损坏（如胶盘、弹性盘）；
4、主泵损坏；
5、伺服系统压力过低或无压力。
Failure analysis:
1. The hydraulic oil is not enough. Main pump absorbs air but oil.
2. Oil absorption filter is blocked.
3. Engine coupling is damaged (e.g. plastic plate, flexible plate).
4. Main pump damaged.
5. Servo system pressure is too low or has no pressure.
故障原因：1、液压油不足，需要加足；
2、吸油滤清器堵死，更换滤清器，清洗系统；
3、发动机联轴器损坏（如胶盘、弹性盘），需更换联轴器；
4、主泵损坏，更换或维修主泵；
5、调整到正常压力，如伺服溢流阀调不上压力，则拆开清洗，如弹簧疲
劳可加垫或更换；
6、安全阀调定压力过低或卡死，调整到正常压力，如调不上压力，则拆
开清洗，如弹簧疲劳可加垫或更换。
Probable root cause of the failure:
1. The hydraulic oil is not enough, which shall be feed to correct level.
2. Suction screen is blocked, replace the suction screen and clean the system.
3. Engine coupling is damaged (e.g. plastic plate, flexible plate).Replace coupling.
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4. Main pump damaged. Replace or repair main pump.
5. Adjust the pressure to normal value. If the servo overflow valve pressure cannot be raised, uncover
and clean it. If the spring inside is weary, shim or replace it.
6. Safe valve pressure is too low or safe valve is choked. Adjust the pressure to normal value. If it cannot
be raised, remove the clean. If the spring inside is weary, shim or replace it.
排故方法：1、按照以上思路，逐步排查故障原因，排除前述三种故障原因的干扰；
2、检查发现液压泵损坏；
3、更换柱塞泵K3V140DT、壳牌抗磨液压油VG46、壳牌抗磨液压油VG46(18
升/桶)。
Troubleshooting:
1. Figure out the specific reasons according to the thoughts mentioned above. Get rid of disturbs about
the three fault reasons mentioned above.
2. Check the hydraulic pump, which is found to be damaged.
3. Replace the piston pump K3V140DT, Shell Brand anti-abrasion hydraulic oilVG46(18liters/barrel)
排故体会：加强对挖机操作手的日常保养维护的培训；引导用户使用厂家纯正部品,
尤其是油品。
Experience: It is necessary to offer trainings to the end-users, specially the excavator operators on daily
maintenance. Guide the users to use the genuine parts, especially the oil.
——提供者：简笑回 Service engineer: Jian Xiao Hui
- 39 -
16、挖掘机没动作 The excavator has no action
故障现象：SY200C6M 挖机，在发动机启动后，放下液压锁，不能动作。
Symptom: SY200C6M excavator h as n o act ion af ter t he engine is s tarted and t he h ydraulic act ivation
control lever is unlocked.
故障分析：
1、先导继电器坏了，可能也会使挖机没动作；
2、主控制器 EPEC 损坏也会使挖机不动作；
3、先导电磁阀损坏，先导油打不开会使挖机没动作；
4、主泵损坏，导致液压系统不起作用，机器不能动作；
5、联轴器损坏，导致发动机与液压泵没输出。
Failure analysis:
1. Pilot relay is damaged.
2. Main controller EPEC is failed.
3. Pilot solenoid valve is damaged. Pilot oil cannot be supplied to the pilot valve.
4. Main pump is damaged and result in hydraulic system fails to work normally.
5. Coupling is damaged, which cause engine and hydraulic pump no output.
故障原因：由于联轴器是塑料的，由于时间过久，温度高容易老化。
Root cause of the failure: Coupling which connects engine and main hydraulic pump is damaged. Since
the coupling is made of plastic, it will age under high temperature after a long time usage.
Photo of the failed coupling
排故方法：
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1、进入显示屏，操作先导锁，发现显示屏上先导显示灯由红变绿，正常；
2、进入显示屏，发现机油、柴油等发动机工作参数都正常，EPEC 正常；
3、检查先导电磁阀的电压有 24V，证明电磁阀正常；
4、检查先导泵的输出油管，发现没液压油输出，说明泵或联轴器有问题；
5、拆下主泵，发现与主泵连接的联轴器损坏，更换新联轴器，故障排除。
Troubleshooting:
1. Checked in the monitor. Unlock the hydraulic activation control lever. The light color on the monitor
changes to green from red, which is normal.
2. Checked and found in the monitor the engine parameters such as fuel and oil are normal. It means the
EPEC works normally.
3. Check the pilot solenoid voltage, which is at normal value 24V. The solenoid valve works well.
4. Check the pilot oil outlet hose. No hydraulic oil is found to be output, which means malfunction of
pump or coupling occurs.
5. Remove t he m ain pum p. It i s f ound t hat t he c oupling c onnected i s da maged. Replace t he f ailed
coupling, tested and proved problem solved.
排故体会：先一步一步检查，有简单到复杂。
Experience: Troubleshooting from simple to complex steps by steps.
——提供者：陶家宝 Service engineer: Tao Jia Bao
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17、SY230 冷机动作慢 SY230 has long cycle time before machine is warm up
故障现像：冷机时操作手柄到满行程时执行元件才有动作，手柄回到中位后，该动
作还会延续 1-2 秒钟。温度达到正常工作范围后，机器恢复正常。

Symptom: Only when the pilot control lever is at the full stroke, related actuator starts to work. When the
pilot control lever returns to neutral position, the operation will last for 1-2 seconds. After hydraulic oil
temperature reaches at normal value, excavator could work normally.
故障分析：冷机时检查发现，在操作手柄半行程时测得 1 级先导压力为 33-39kg/C
㎡（正常）
；测得二次先导压力为 0.8-1kg/C ㎡（异常），说明先导泵工作
正常而操作阀自身存在问题。而压力消失只有几种可能：
1、外漏（无）；
2、内泄（如果那样的话热机后会更历害）；
3、操作阀内部卡滞（冷机液压油粘度大,加上阀芯有轻微卡滞现像）。
Failure a nalysis: When the m achine cold, t he primary pilot p ressure i s m easured t o b e 33-39kg/cm2
(Normal) with the pilot control lever at half stroke and the pilot pressure measured at the pilot transition
block is 0.8-1kg/cm2 (abnormal). The measurement means pilot pump works normally but the pilot valve
works abnormally. Possible reasons cause the pilot pressure difference is listed below:
1. External oil leakage (Not found).
2. Internal leakage (If yes, the symptom is much more obvious after the machine is warmed up.)
3. Pilot valve spool is seized.(Valve spool is seized slightly with the heavy viscosity of hydraulic oil in
cold condition.)
故障原因：由于操作阀内阀芯有轻微卡滞现像，加上冷机时液压油粘度大，造成半
行程时机器无动作。以及手柄回到中位后该动作还会延后 1-2 秒。
Root cause of the failure: Pilot valve spool is seized slightly with heavy viscosity of the cold oil which
causes the machine has no action when the pilot control lever is at half stroke and the operation last for
another 1-2 seconds after the pilot control lever returns to the neutral position.
- 42 -
Valve spool seized
Schematic of the pilot control valve
排故方法：更换操作阀，更换液压油及相关滤芯，调整全车液压系统压力。机器恢
复正常。
Troubleshooting:
Replace the pilot valve, hydraulic oil and filters. Check / adjust the pressure setting of the hydraulic
system to the specification. Tested and proved problem solved.
排故体会：面对故障时冷静分析，掌握机器各部件的结构与工作原理，一步一步的排
查，就能找到问题所在。
Experiences:
Be carefully analysis and familiar with all the components and their working principles. Trobleshoot step
by step and figure out the root cause.
——提供者:王学辉 Service enineer：Wang Xue Hui

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18、SY210C 挖机发动机启动困难 SY210C engine is hard to start
故障现象：一台 SY210C 挖掘机发动机启动困难，工作时冒黑烟严重，动作慢（工作

小时 6500H）。
Symptom: SY210C has 6500H working hours. Engine is hard to start. Heavy black smoke emits during
the work and the machine has excessive cycle time.
故障分析：1、发动机柴油油路故障，如油箱脏、油管或滤网堵塞等；
2、发动机高压油泵故障，如柱塞偶件磨损等；
3、主泵调节器故障.
4、主控阀故障。
Failure analysis:
1. The malfunction of engine fuel circuit. Dirty fuel tank, dirty hose / pipe or blocked filter, etc.
2. Malfunction of engine fuel injection pump, e.g. plunger is worn.
3. Malfunction of main pump adjuster.
4. Malfunction of the main control valve.
故障原因：备用阀芯发卡、调节器发卡致机器启动困难、动作慢、冒黑烟故障。
Root cause of the failure: Choke of spare valve core and the pump adjuster cause engine’s difficult to be
started, long cycle time and heavy black smoke.
排故方法：
1、首先客户反映机器刚刚大修过发动机，而且刚刚更换过机油、机油滤芯、
柴滤和空滤（排除燃油系统故障和进气系统故障）；
2、启动发动机，进入显示屏监控界面，在整车没有动作的时候主压力18MPa
（异常），可以判断回油压力过高，打开先导手柄开关，不动先导手柄时
整车无动作；
- 44 -
3、打开主控阀备用阀盖，发现阀芯发卡,阀芯不在中位引起回油压力过大，
处理以后回油压力正常；
4、做溢流动作时主压力正常，发动机冒黑烟，检查主泵调节器，发现调节
器拨叉发卡，清洗调节器，故障排除。
Troubleshooting:
1. The customer reflects that the engine overhaul is just done. Engine oil, oil filter, fuel filter and the air
cleaner are newly replaced.(Fuel system or air inlet should not be suspected.)
2. Start t he en gine. C hecked i n t he m onitor, t he m ain oil pressure i s 18 MPa ( abnormal) w hen th e
machine ha s no a ctions. It means that th e r eturn oil pressure i s t oo hi gh. Unlock t he hydraulic
activation control lever, machine has no action as the pilot lever is not operated.
3. Checked a nd f ound the spare va lve s pool i s s eized i n the main c ontrol v alve. T he di splacement of
valve core leads to high return oil pressure. After repairing, the pressure returns to normal value.
4. Tested a nd f ound th e p ressure s etting o f th e ma in r elief v alve is n ormal w hile engine emits b lack
smoke. Check the m ain pump a djustor which i s found seized. C lean t he pump adjustor, t ested an d
proved problem solved.
排故体会:1、处理故障的时候要从易到难逐步的排除故障。
2、处理故障需要服务人员具备多方面的专业知识，才能进行综合分析进
而找到问题根源。
Experience:
1. Troubleshooting from simple to complex.
2. The service engineers should be equipped with kinds of professional knowledge, which grantee
overall analysis and to figure out the root cause of the malfunctions.
——提供者：贵州通程 Dealer: Gui Zhou Tong Cheng

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19、挖掘机降动臂过程异常 Boom down operation is abnormal
故障现象: SY230C-8 液压挖掘机在动臂下落的过程中，系统压力变化太大，且伴随

着先导手柄的向前移动过程中，动臂没有下落的迹象，当手柄的移动的幅
度超过一半时，动臂直接掉下来可以把车身撑起来，其他正常。
Symptom: SY230C-8 system pressure varied obviously during the boom down operation. When the pilot
control lever is pushed forward, the boom does not drop. When the pilot lever is pushed more than half
stroke, the boom falls down rapidly and jacks up the machine. Other actions are normal.
故障分析：1、液压油太脏，存在阀卡现象；
2、支路安全阀存在泄压的情况；
3、泵压传感器不灵敏；
4、先导系统存在故障。
Failure analysis:
1. Hydraulic oil is contaminated by foreign materials and causes valve spool seized.
2. Internal leakage in the line relief valve.
3. Pump pressure sensor is insensitive;
4. Malfunction of pilot system.
故障原因：先导手柄阀芯卡死。此前客户自己更换了一根从先导滤清器到液压接通
电磁阀的先导管，换了以后就在这种现象；
Root c ause of t he f ailure: Pilot valve s pool i s s eized. Failure phe nomenon i s de tected a fter c ustomer
replacing the pilot hose from the pilot oil filter to the accumulator.
排故方法；1、液压油不干净更换液压油；
2、通过试车我们发现其他动作都正常，只有动臂下落这一个动作存在故
障，我们将动臂下落的支路安全阀和铲斗的支路安全阀调了一下，
故障仍存在；
3、把泵压传感器调换，泵压传感器正常；
4、检查先导，我们把动臂下落的先导和铲斗的调换一下，同样的问题出
现在铲斗上，由此确认先导手柄坏，打开发现阀芯卡住，拨正以后故
障消除。
- 46 -
Troubleshooting:
1. Replace the dirty hydraulic oil.
2. Tested and found other operations are normal except the boom down. Interchange the boom down line
relief valve with the bucket line relief valve, tested and proved problem still existed.
3. Interchange pump pressure sensors, tested and proved they are normal.
4. Check the pilot circuit. Interchange the boom down pilot hose with the bucket pilot hose. Tested and
found t he s ame m alfunction ha ppens t o t he buc ket while the boom dow n ope ration i s nor mal. It i s
sure that root cause of the failure is the pilot valve failed. Dismantle the pilot valve and found that the
boom down pilot valve spool is seized. Repair and clean the pilot valve, tested and proved problem
solved.
排故体会：同样的情况出现在另一台 230C-8 的机器上，很快能排除，这就需要积

累一定的工作经验很重要。
Experiences: The same failure happens to another SY230C-8 and it shall be solved quickly.
Accumulation of working experiences is very important.
——提供者：张汝昌 Service engineer: Zhang Ru Chang
- 47 -
20、挖掘机正常工作时转速异常 Engine speed is abnormal when the machine is working
故障现象：SY135C8B 挖掘机在工地正常工作时发动机突然掉速，工作一段时间后又
恢复正常，故障反复发生。
Symptom: SY135C8B excavator’s e ngine s peed drops suddenly du ring the normal w ork. Continue t o
work for a period of time, engine speed restored automatically. This malfunction happens repeatedly.
故障分析：
1、挖掘机为了减少发动机的油耗设定了自动怠速功能，如果压力开关或控制
电路出现故障就会引起自动怠速无法解除，产生发动机掉转速和工作速度
慢的故障现象；
2、挖掘机动作停止 5 秒左右，控制器检测先导无压力输出，控制发动机转速
降到 1400rpm/min 左右,从而达到降低燃油消耗的目的；
3、如果先导压力开关损坏，使自动怠速无法自动解除，引起发动机无自动怠
速功能、掉转速或转速不稳定故障。
Failure analysis:
1. In order to reduce fuel consumption, the excavator is designed to have auto idle speed function. The
malfunction of pressure switch or electric control circuit may lead to automatic idle function abnormal.
And the engine speed’s abrupt decline and slow working speed may happen.
2. If the ex cavator h as n o action for more t han 5senconds, t he c ontroller detects no pilot o il pressure.
Engine speed will drop to 1400rpm to reduce fuel consumption.
3. If the pilot pressure switch is damaged, the automatic idler cannot be activated, which may cause the
malfunction of no auto idle function, speed drop or unstable speed.
故障原因：行走先导压力开关损坏引起故障。
Root cause of the failure: Travel pilot pressure switch is failed.
排故方法：
1、启动发动机，将自动怠速功能在监控面板上面取消，在工作过程中故障消
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失，判断为自动怠速控制系统故障。
2、按下自动怠速开关，将行走先导压力开关接头拔下，发动机最高转速达到
2200rpm/min,短接两接头发动机转速降到 1400rpm/min,可以判定电路方
Travel pilot
面没有故障。 switch
3、更换行走先导压力开关，故障排除。
Troubleshooting:
1. Start the engine and cancel the auto idle function on the monitor. After the cancellation, the excavator
works normally. It means that the auto idle control function is abnormal.
2. Press the automatic idle switch. Pull open the travel pilot pressure switch and the engine highest speed
reaches t o 220r pm/min. short t he t wo w ires of t he t ravel pr essure s witch, the s peed r educes to
1400rpm. The electric problems shall be got rid of.
3. Replace pilot pressure switch, tested and proved excavator works normally. Problem solved.
排故体会：由于先导压力开关有很小的阻尼孔， Orifice inside

should not be
如果先导油不干净的话容易产生堵塞， blocked
导致机器工作异常，所以保证液压油
的清洁，就能够防止绝大多数液压系
统故障的发生。
Experience: There is small orifice inside the pilot pressure switch. If the hydraulic oil is contaminated by
the foreign material, these small orifices will be blocked which cause the machine malfunction. Keep the
hydraulic oil free from pollution will help to avoid most of the failures occurred.
——提供者：王晓军 Service engineer: Wang Xiao Jun
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21、 SY135行走跑偏 SY135 has excessive travel offset
故障现象：一台09年SY135C挖掘机出现行走跑偏故障。
Symptom: SY135C made in 2009 has excessive travel offset.
故障分析：1、转换为液控方式时故障是否消除，电气元件出现故障；
2、负压传感器损坏；
3、因为左侧先导操纵阀及先导压力，阀芯发卡时，研磨处理；弹簧折断
时更换；管路堵塞问题引起两侧行走阀芯最大先导压力不相等；
4、主泵负压调节弹簧损坏。
Failure analysis:
1. Transformed i nto h ydraulic m ethod, c heck w hether t he f ault i s cl eared. Malfunction o f e lectric
elements.
2. Negative pressure sensor is damaged.
3. Because of t he l eft pi lot c ontrol va lve a nd pi lot pr essure, t he va lve c ore i s c hoked a nd pol ishing.
Replace the broken spring. The block of pipes lead to unequal max pilot pressure of both side travel
valve cores.
4. Main pump negative pressure adjusting spring is damaged.
故障原因：1、电器元件出现故障；
2、负压传感器损坏；
3、两侧行走阀芯最大先导压力不相等；
4、主泵负压调节弹簧损坏。
Probable cause of the failure:
1. Malfunction of electric elements;
2. Negative pressure sensor is damaged;
3. Unequal max pilot pressure of both side travel valve cores;
4. Main pump negative pressure adjusting spring is damaged.
排故方法：1、判断标准：发动机转速：1800rpm,行走高速，如下图将行走手柄拉到
底，行走 20 米以上，按下图检测 L 值；
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当：L＞200mm 时，不正常；当：L＜200 mm 时，正常
2、检查主泵负压调节弹簧，发现弹簧需要调节；
3、调节弹簧。
Troubleshooting:
1. Judgment s tandard: t he engine s peed:1800rpm, at high speed. Push the travel handler to the end
position. Travel more than 20 meters, check the L value as per the pictures followed.
Abnormal: L>200M Normal: L<200M
2. Check the main pump negative adjusting spring and the spring needs adjusting.
3. Adjust the spring.
排故体会：1、定期做好挖机保养维护工作；
2、依据标准，判定挖机工作正常与否。
Experiences:
1. Maintenances should be done regularly.
2. Check whether the excavator works normally or not according to the standard.
——提供者：周书良 Service engineer: Zhou Shu Liang
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22、挖掘机整车无动作 Excavator has no action
故障现象：一台 SY65C 挖掘机在工地满负荷工作时突然发生整车无动作故障。

Symptom: One unit of SY65C suddenly has no actions during the full load working.
故障分析：1、电器方面的问题:如果先导电磁阀控制电路故障会引起整车没有动作；
2、液压方面的问题：先导压力过低或主压力过低、泵的排量过小或液压
系统内泄过大也会引起整车没有动作或动作过慢；
3、机械方面：发动机的功率没有传输到泵上面，机械能没有转化为液压
能，使整车没有动作。
Gear is loosed Engagement of pump
and shifted and engine is too small
Failure analysis:
1. Electric aspects: If the pilot solenoid or its wire circuit is failed, excavator will have no action.
2. Hydraulic aspects: the fault shall be caused by low pressure of pilot or main pump, little displacement
of pump, big leakage inside the hydraulic system;
3. Mechanic aspects: The engine power is not delivered to the pump. Mechanical energy is not
transferred into hydraulic energy.
故障原因：联轴器传动齿轮移位使发动机能量无法传递到主泵上。
Root c ause of t he failure: the di splacement of coupling dr ive gear c auses t he r esult t hat t he e ngine’s
power cannot be delivered to the main pump.
排故方法：
1、启动发动机，机器启动正常，先导控制开关电路正常。
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2、进入监控面板，检查先导电磁阀的通断正常，可
以排除先导电磁阀的问题。
3、检查系统压力，读取数值都为 0MPa；判断为发动
机功率没有传递到主泵上，确定为联轴器故障。
4、取下主泵，发现传动齿轮移位，从新固定传动齿轮位置，机器工作正常。
Troubleshooting:
1. Engine can be started normally. It means that the pilot control switch electric circuit is normal.
2. Checked and found in the monitor that the pilot solenoid valve is normal.
3. Checked and f ound the hydraulic system pressure is 0M pa. It i s sure t hat t he engine power is n ot
delivered to the main pump. It is suspected that the coupling is damaged.
4. Remove t he m ain pum p. T he d rive gear i s di splaced. A djust a nd f asten the dr ive gear t o t he r ight
position. And the excavator shall work normally.
排故体会：挖掘机的动力是通过联轴器传递到主泵的，从而实现机械能与液压能之
间的转换，同时联轴器还起到减震的作用。当机器的负载忽然增大时，联轴
器受到很大的反作用力，如果联轴器与传动齿轮的连接面积过小很容易引起
联轴器与传动齿轮之间动力传输中断，使整车没有动作。在发动机和主泵震
动的作用力下，传动齿轮也容易移位脱离联轴器啮合面，引起故障。
Experiences:
The engine power i s delivered t o t he m ain pum p b y coupling, which realizes t he en ergy t ransfers f rom
mechanic to h ydraulic energy. And the coupling has the function of shock absorption. When the load is
enlarged suddenly, the coupling receives big reaction force. If the connecting area between the coupling
and drive gear is too small, it is easily happened that the power delivery shall be suspended, which cause
the whole excavator’s no action. Under the force of engine and main pump shock, the drive gear shall be
separated from the coupling mesh area, resulting in malfunction.
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23、行走马达不工作 Travel motor failed to work
故障现象：SY75工作时候行走马达没动作，马达有异常响声。
Symptom: SY75 excavator has the failure of travel motors do not work with abnormal noise.
故障分析（附图）：
1、先导压力异常，无法打开主阀阀芯；
2、直线行走阀故障；
3、行走马达阀芯卡死；
4、减速机齿轮损坏。
Failure analysis:
1. Abnormal pilot pressure; the main valve core cannot be opened.
2. Straight travel valve failed.
3. The travel motor valve core is choked.
4. Gear of the final drive is damaged.
故障原因：
1、检查液压先导，在显示器里可以看到压力和信号反馈。
2、行走马达减速机或者马达损坏。
Root cause of the failure:
1. Check the hydraulic pilot. The pressure signal can be seen on the screen.
2. Travelling motor damaged or its speed reducer damaged.
排故方法（附照片）：
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1、起机做行走动作，查看显示器反馈情况正常；
2、动作时候异常声音检查，用工具插在马达上听声音是从马达上发出，打
开马达发现减速机齿轮无损坏，再起机做右行走动作，发现马达传动轴
没动作，测压正常，证明马达损坏，更换马达总成后工作正常。故障排
除。
Troubleshooting:
1. Start the engine and try to make it travel. The signal feedback in the monitor is normal.
2. Check the abnormal noise by putting a screwdriver onto the motor. The noise comes from the motor.
Remove the cover of the final drive and found the gears of final drive are normal. Start the engine and
do the right travel operation. It was found that the output shaft of the travel motor is failed to run. At
the same time , the measured pressure is normal. It is sure that the right travel motor is da maged.
Replace t he failed tr avel motor, t ested a nd pr oved the ex cavator could t ravel n ormally. Problem
solved.
排故体会：
先检查损坏故障点，再一步步判断，不一定是减速机构齿轮，也许是液压
故障马达。
Experiences:
Check the fault point and figure the reason out step by step. Root cause of the failure should be the failed
final drive gears or the failed hydraulic motor.
——提供者:童斌纲 Service engineer: Tong Bin Gang
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24、行走跑偏故障 Failure of exessive travel offset
故障现象：一台SY215C-8正流量型挖掘机，行走时低速向右偏行，高速向左偏行。机
器做行走动作时从显示屏读得的数据，低速时：前泵压力60-70公斤，
后泵压力35公斤，高速时：前泵压力90-100公斤，后泵压力50公斤。
Symptom: SY215C-8 positive flow SANY excavator skews to the right at low travel speed while to the
left at high speed. The date displayed on the LCD as follows: when the machine traveled tt low speed, the
front pump pressure is 60-70kgf and the rear pump pressure is 35kgf. When the machine traveled at high
speed, the front pump pressure is 90-100kgf and the rear pump pressure is 50kgf.
故障分析：造成行走低速向左偏行，高速向右偏行：
1、行走低压传感器：行走高低速操作时传感器反馈电压信号（200、201号
线）是否0.6—4.4V；
2、主泵电磁比例阀行走操作时电流值是否350--750mA。
3、先导压力是否为40公斤；
4、操作手柄至行走左右主阀芯先导压力是否一致，主阀芯是否切换到位；
5、回转中心接头是否内泄；
6、行走高低速电磁阀是否正常，到行走变速阀芯先导压力是否1致；
7、行走变速阀芯是否卡滞；
8、行走马达斜盘高低速伺服活塞是否卡滞；
9、行走马达斜盘是否磨损。
Failure analysis: (Probable cause of the failure)
1. Travel low pressure sensor: when the travel speed is shifted between low and high speed, whether the
feedback signal tested on wire 200 and wire 201is between 0.6-4.4V?
2. Whether the current of main pump proportional solenoid valve is between 350-750mA?
3. Whether the pilot pressure is 40kgf?
4. Whether the pilot pressure of the right and left main valve core are the same? The main valve core is
switched correctly?
- 56 -
5. Does the swivel joint have internal leakage?
6. High / low speed travel solenoid valve is normal? Pilot pressure to the motor is the same?
7. Whether the valve core of the high / low speed shift is choked?
8. Whether the travel motor swashplate’s servo piston is choked?
9. Whether the travel motor swashplate is worn or not?
故障原因：左行走马达斜盘高低速伺服活塞卡滞。
Root cause of the failure: Servo piston of the left travel motor swash plate is choked
排故方法：1、首先检测先导压力，测得先导压力为40公斤--正常。
Servo piston of
the left travel
swashplate is
choked.
High / lo w speed
shift valve
2、检测左右行走低压传感器，在做行走高低速动作时反馈电压信号为4.4V--
正常；
High / low speed
3、检测主泵电磁比例阀电流值为670mA--正常；
servo piston is choked
4、检测操作手柄至行走左右主阀芯先导
压力为40公斤--正常，拆检左右行走
主阀芯无卡滞--能切换到位.
5、分别检测低速时左右行走马达过载溢
流压力---360公斤--正常，排除回转中
心接头内泄导致的行走偏行；
6、检测行走高低速电磁阀至行走变速阀
芯先导压力为39公斤--正常，拆检左右行走马达变速阀芯--正常。
7、将液压主泵的两根高压出油管颠倒试车，依就低速向左偏行，高速向
- 57 -
右偏行，可以判断液压主泵工作正常；
8、通过上述的检查可以判断故障在行走马达，拆检行走马达，发现左行走马
达斜盘高低速伺服活塞卡滞，造成斜盘在低速回不到位，高速时到不了位。
更换损坏的伺服活塞后，试车一切正常，行走偏行故障排除。
Troubleshooting:
1. Check the pilot pressure, which is 40, normal.
2. Check the left and right travel low pressure sensor. The feedback signal is 4.4V, which is normal.
3. Check the main pump proportional solenoid valve’s current, which is 670mA, normal.
4. Pilot oil pressure to the left and right main valve core is 40kgf, normal. Check the right and left travel
main valve spool, which is not choked and can be switched to the right position.
5. Check the left and right travel motor’s pressure, which is 360kgf, normal. So it is sure that the fault
caused by internal leakage of the swivel joint is got rid of.
6. Pilot oil pressure to the left and right high-low speed shift valve is 39kgf, normal. Checked the high /
low speed shift valve core of both left and right travel motor, which is not choked.
7. Interchange the two high-pressure oil outlet hose of the main pumps. The failure phenomena are the
same. It is sure that the hydraulic main pump could works normally.
8. According to the analysis and troubleshooting above, it is judged that the travel motor is failed.
Dismantle the t ravel motor and found that t he left t ravel motor swashplate high-low speed servo
piston is choked, which causes t the swash plate could not returned to the correct position at low or
high travel speed. Replace the failed servo piston, tested and proved problem solved.
排故体会：在维修时，不管是什么故障，必须思路清晰，逐步把问题缩小，从简到
难的排除故障。
Experiences: No matter what kinds of fault is encountered, keep the mind clear and figure out the root
cause step by step from simple to complex.
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25、SY330 热车时憋车、冒黑烟 Engine speed drops and heavy black smoke
故障现象：一台 SY330 挖掘机，冷车时其工作正常，热车时其憋车、冒黑烟。

Symptom: SY330 works normally when it is cold, emits black smoke and stalled after warmed up.
故障分析： 1、电气故障、油路故障和液压故障都会造成憋车；2、涡轮增压器
故障也会造成憋车和冒黑烟。
Failure analysis:
1. Electric, oil circuit and hydraulic malfunctions will cause engine stalled.
2. Malfunction of turbocharger will cause engine stalled and heavy black smoke.
故障原因：液压泵磨损。
Root cause of the failure: Main hydraulic pump is worn.
排故方法： 1、工作时会一直存在，不分冷车、热车，所以首先排除电气和涡轮增
压器的原因。
2、液压泵和柴油高压泵磨损
都会引起挖掘机热车时其憋车。
试车，在挖机工作 1 个小时后其
出现憋车，检查油路并用凉水对图:含有杂质的滤芯 Picture: Filter with impurities
高压泵进行降温，故障仍存在，但故障现象不明显，建议客户校泵，校
泵后，挖掘机故障仍存在，确定为液压泵磨损造成憋车。更换液压泵并
将先导滤芯、回油滤芯、吸油滤芯及液压油后，故障排除。
Troubleshooting:
1. The f ault ex ists n o m atter w hen t he ex cavator i s co ld o r warmed up. T hus t he el ectric and
turbocharger malfunction shall be got rid of.
2. The fault shall be caused by severe worn of hydraulic pump and engine fuel injection pump. Start the
engine and it stalled after working one hour. Check the fuel circuit and cool the fuel injection pump
by the cold water. The fault still exists, but the symptom is not obvious. Suggest the end user to
- 59 -
rebuild the fuel pump. After fuel pump repair, checked and found the fault still exists. And it is sure
that the fault is caused by worn of hydraulic pump. Replace the hydraulic pump, replace pilot oil
filter, oil return filter, oil suction screen and replace hydraulic oil. Tested and proved excavator works
normally. Problem solved.
排故体会：针对故障现象要将问题考虑全面，在看到故障现象后，要将可能引起该
现象的全因素全部考虑进去，并由简单到复杂逐一排除。
Experiences: Once the malfunctions happen, take all the related reasons into consideration. Get rid of the
malfunctions from simple to complex and step by step.
——提供者：宋传博 Service engineer: Song Chuan Bo
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26、SY360 不能行走 SY360 failed to travel
故障现象：1 台 08SY360 挖掘机不能行走，其他正常。

Symptom: SY360 excavator cannot travel with other actions normal.
故障分析：1、没有先导压力，打不开阀芯所致；2、行走马达损坏；3、行走减速机
损坏；4、中央回转接头损坏。
Failure analysis:
1. The valve core cannot be opened without pilot oil pressure.
2. Travelling motor damaged.
3. Final drive damaged.
4. Swivel joint damaged.
故障原因：行走减速机构总成损坏。
Root cause of the failure: Final drive failed.
排除方法： 1、.检查行走先导控制油路有无额定压力，压力值正常；
2、检查行走二级溢流阀，完好；
3、马达进油口压力是否建立，有压力.
4、拆开行走减速机构总成，发现其磨损严重、开裂，更换
Troubleshooting：
1. Check the travel pilot oil pressure, which is normal.
2. Check travel line relief valve, which is normal.
3. Check the oil inlet pressure of hydraulic motor(s), which is normal.
4. Dismantle f inal drive unit, it is f ound t hat the inner part is heavily worn an d cracked. Replace t he
failed parts, tested and proved excavator could travel normally.
排故体会：必须先从容易到复杂, 一步步分析。
Experiences: Troubleshooting from simple to complex step by step.
——提供者：马弼杰 Service engineer: Ma Bi Jie

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27、SY215 工作无力 SY215 has insufficient power to work
故障现象：08SY20311139工作时候复合动作缓慢，冒黑烟，尤其大臂提升慢，油耗
较每小时大约19升，工作时间1040小时。
Symptom: When the excavator (08SY20311139, worked for 1040 hours) carries out combined actions, it
works slowly and emits black smoke, especially boom up operation. Fuel consumption is 19 L/H.
故障分析：
1、保养不及时，油路不畅，发动机高速运转时候不能正常工作；
2、主压力或者先导压力太低引起；
3、转速不正确，和额定转速相差较大或者位置传感器电压不对控制器不能让液
压泵正常输出值功率。
Failure analysis:
1. Maintenance is n ot time ly; f uel c ircuit is d irty or r estricted. T he ex cavator can not w ork normally
when the engine runs at high speed.
2. The main oil pressure or the pilot oil pressure is too low.
3. The engine speed is incorrect, excessive engine speed difference or the incorrect voltage of the
position sensor will cause the hydraulic pump output incorrect power.
排故原因：
1、咨询客户保养是否按照要求在规定时间定时保养；
2、是否系统压力过低；
3、油门拉线是否松动使转速是否过低；
4、位置传感器电压是否在要求范围3.7V；
5、主阀上各先导传感器是否完好。
1. Whether regular maintenances are carried out in specified time?
2. Whether the hydraulic system pressure is lower than specification?
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3. Whether the throttle cable is loosed and cause the speed lower than the specification?
4. Whether the voltage of position sensor is at 3.7V or not?
5. Whether all the pilot sensors on the main valve work normally?
排故方法：
1、咨询过保养都是按照要求完成；
2、检查主压力在345KG左右,先导压力32KG,调节先导压力到38KG；
3、转速在S模式下能达到2100转,位置传感器电压3.58V.
4、重新标定转速,位置传感器电压标定到3.7V，试车检查,机器工作正常.
Trouble Shooting:
1. All the maintenances have been carried out as required.
2. Checked and found the main oil pressure is 345kgf while the pilot pressure is 32kgf. Adjust the pilot
oil pressure to 38kgf.
3. Engine speed reaches 2100 rpm at “S” mode. Voltage of position sensor is 3.58V.
4. Calibrate the engine speed to the specified value. Checked and found the voltage of position sensor is
3.7V. Tested and proved machined works normally. Problem solved.
排故体会：
1、在工作到1000小时后要检查位置传感器电压和先导压力.
2、建议各分公司都备有一个转速标定器,及时解决故障；
3、现在很多挖机在工作一段时间后都有反映动作变慢,应检查发动机转速，必要
时进行标定。
Experiences:
1. Check the voltage of position sensor and pilot pressure after using 1000 hours.
2. Suggest each branch has a speed setter for engine speed calibration timely.
3. Feedback information indicates that engine speed will lower than specification after a long time using,
check / calibrate engine speed as required.
——报告人:高红强 Service engineer: Gao Hong Qiang

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28、SY215 行走跑偏 SY215 has excessive travel offset
故障现象：一台 SY215 直线前行时会向左转弯,有跑偏现象。

Symptom: SY215 turns left while it travels forward in a straight line.
故障分析：1、液压泵内泄过大；
2、行走马达内泄严重；
3、中央回转机构内油封损坏；
4、行走主控阀阀芯工作异常；
5、行走操作阀和行走先导压力传感器故障；
6、行走马达平衡阀故障。
Failure analysis:
1. Excessive internal leakage of the hydraulic pump.
2. Excessive internal leakage of the travel motor.
3. Seals of the swivel joint damage.
4. Travel main valve core works abnormally.
5. Malfunction of travel pilot valve and pilot pressure sensor.
6. Malfunction of travel motor balance valve.
故障原因：行走节流阀节流口有堵塞现象：
Root cause of the failure: orifice of the travel motor balance valve is blocked
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排故方法：1、反复前进和后退直行测试，发现只有前行时才有左行走无力导致向左
转弯现象，故主泵和行走马达内泄故障基本排除；
2、进入显示屏运行参数查询，检查前后泵主压力均正常,先后互换行走
伺服阀先导控制管路和左右行走主阀芯及中央回转接头左右行走油管后
跑偏方向还没有变化；
3、再次进入显示屏参数查询,发现前后主泵主泵比例阀电流正常,以上分
析基本确定为行走马达部分出现故障；
4、检查行走马达发现平衡阀的进油节流口有堵塞,拆解后进行清洗,安装
后正常。
Troubleshooting:
1. Drive the excavator back and forth repeatedly in a straight line. It is found that the machine turns to
the left only when it travels forward. It means main pump and travel valve has no internal leakage.
2. Checked in the monitor and found the main oil pressure of front and rear pump is normal.
Interchange the pilot hose to the travel valves, travel main valve spools, and the hoses to two motors
at swivel joint. Tested and found the travel offset phenomena not changed.
3. Checked and found in the monitor, the current of front and rear pumps’ proportional valve is normal.
As per the analysis mentioned above, travel motor is suspected to be failed.
4. Checked and found the oil inlet orifice of the balance valve is blocked. Remove the valve and clean.
Tested and proved machine travels normally. Problem solved.
排故体会：在排故的过程中，应用了互换的方法（先导控制管、主阀芯等）这样能
够快速的找出故障的部位，提高了处理故障的速度。
Experiences:
The method of parts-interchange is used (interchange of pilot hoses, main valve cores, and so on), which
could help figure out the specific malfunctions and improve our efficiency.
——提供者：高红强 Service engineer: Gao Hong Qiang
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29、铲斗动作非常慢 Bucket operation is very slow
故障现象：设备工作时铲斗挖土无力；铲斗收回后会自动下落。
Symptom: Excavator has a poor performance during soil digging. Bucket opens automatically after it is
closed.
故障分析：此类故障1般是从液压方面着手，如：油缸油封是否损坏；过载阀有没有
问题；主溢流阀是否有问题等方面。
Failure a nalysis: This kind of m alfunction shall be diagnosed from hydraulic elements, for instance,
oil seal, line relief valve, main relief valve, etc.
排故方法：1、铲斗动作非常慢，并且挖土无力溢流压力，后泵只有200K，低于正常
溢流压力330K，根据故障现象，初步判断铲斗动作回路有内泄现象，
问题可能出在铲斗阀芯、过载溢流阀或铲斗油缸。
2、将铲斗阀芯拔出检查，没有发现异常；再将过载溢流阀与其它回路的
过载溢流阀互换后试车，故障依然存在，说明与其无关。
3、检查回油滤芯发现有非金属杂质，于是拆检铲斗油缸，发现铲斗油缸
活塞油封破损.更换铲斗油缸的油封，试机正常。
Cylinder seals
failed cause t he
internal leakage
Troubleshooting:
1. The bucket works slowly with insufficent digging force. It is found that the rear pump oil pressure is
200kgf, lower t han t he normal va lue 330 kgf. A ccording t o t he s ymptom, it is s uspected t hat t he
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bucket circuit has internal leakage. Malfunction may happen in bucket valve core, bucket line relief
valve, or bucket cylinder.
2. Pull out t he buc ket valve core, checked an d f ound i t i s normal. Interchange t he bu cket line relief
valve with the one of other circuit, malfunction still exists. It means the bucket valve core and bucket
line relief valve are normal.
3. Check the return oil filter, non metallic imp urities a re f ound. Dismantle the bucket cylinder, it w as
found t hat t he pi ston s eal is d amaged. Replace the failed s eals, t ested a nd pr oved buc ket works
故障原因：铲斗油缸油封破损后，压力内泄，导致装备工作时铲斗挖土无力，斗收
回后会自动下落，更换油封后试车正常OK。
Root cause of the failure: The damage of oil seal causes internal leakage. Thus the bucket works slowly
with small digging force. The machine could work normally after oil seal is replaced.
排故体会：此类故障要从液压和电气方面区分开来，处理起来就相对比较简单一些，
要凭平时经验的积累。
Experiences:
This kind of malfunction could be resolved easily and quickly, which should be separated from t he
electrical ones. The accumulation of usual experiences is of quite importance.
---- 提供者：陈国 Service engineer: Chen Guo
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30、行走跑偏 Excessive travel offset
故障现象：一台 SY230 挖掘机行走严重跑偏，在脚踏先导阀同样行程时，行走时转
圈，无法正常工作。
Symptom: S Y230 ex cavator d eviates severely. The ex cavator m oves i n a ci rcular t rack w hile t he t wo
pilot valves are pushed to the same stroke.
故障分析:行走跑偏的主要原因为左右行走马达压力不同，或履带紧张度不同致使左
右行走马达转速不同，最终导致行走跑偏。
Failure analysis:
The different pressure of travel motor on bot h sides and different track tension results in different travel
speed, which causes the deviation
故障原因：
1、履带张进度不同；
2、P1、P2 泵压力不同；
3、中央回转接头油封损坏；
4、行走马达平衡阀损坏；
5、行走马达主要安全阀损坏或发卡；
6、单边行走马达损坏。
1. Different track tension
2. Pressure of the front pump and the rear pump is different.
3. Swivel joint seals are failed.
4. Balance valve of the travel motor is failed.
5. Line relief valve of the travel motor is failed or seized.
6. One of the travel motor is failed.
排故方法：
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1、检查履带：测量左右两侧履带长度一样，
排除履带故障；复合动作同样跑偏，排除主液
压泵故障。
2、前进后退往同一方向跑偏，排除中央回转接
头油封故障。
3、测量两侧行走马达压力，一侧压力为 28Mpa,另一侧为 34Mpa,即可排除单边单
边行走马达故障，此时怀疑单边安全阀故障，调安全阀使两侧压力相同后，设
备运转一切恢复正常。
Troubleshooting:
1. Check the t racks: t racks on both s ides have the same length, w hich m eans tracks are normal. The
excavator suffers from deviation during t he combined ope ration, w hich means t he main h ydraulic
pump works normally.
2. Travels forward and backward, the machine deviates at the same direction, which means the oil seals
of the swivel joint works normally.
3. Measure the two travel motors’ pressure, one side is 28Mpa while the other is 34Mpa, which means
both travel motors work normally. It is suspected th at the travel lin e relief valve has an incorrect
setting. Adjust the pressure of line relief valves to the same v alue, tested and proved the ex cavator
works normally. Problem solved.
排故体会：超载阀中的弹簧在使用过程中吸收液压油温度，导致弹簧温度升高、弹
力下降，致使行走马达原设定的压力下降，阀门自动打开，导致挖机行
走跑偏。
Experiences:
The spring inside line relief valve shall lose some elastic force after it absorbs certain hydraulic
temperature, then the decline of travelling motor pressure set initially causes the travel deviance.
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31、SY230 机器无动作 SY230 excavator has no action
故障现象：该机器为五十铃 6BG1 发动机、EC-7 控制器，整车无动作。

Symptom: The excavator SY230 is equipped with Isuzu engine（6BG1）and EC-7 controller. The
excavator has no actions.
故障分析：
1、先导锁打开后无动作；
2、显示屏显示数据正常；
3、发动机可以升降速、熄火。
Failure analysis:
1. Excavator has no action after the hydraulic activation control lever is unlocked.
2. The data displayed on the monitor is normal;
3. The engine can be accelerated, decelerated, and shut down normally.
排故思路：
1、检查先导锁是否完好；
2、检查先导电磁阀是否正常；
3、检查先导泵是否正常；
4、检查主泵是否工作正常。
1. Hydraulic activation control lever is failed.
2. Pilot solenoid valve is failed.
3. Pilot pump is failed.
4. Main hydraulic pump is failed.
排故过程：
1、发动机工作正常，仪表显示数据正常，先导继电器工作正常。
2、打开先导锁，用螺丝刀检查先导电磁阀线圈吸力正常。
3、拆下先导电磁阀阀芯，插入线圈检查阀芯开闭正常。
4、打开主泵侧边门，检查先导泵出油口胶管，无液压脉冲，打开油管无液压
油流出，先导泵不工作。
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5、检查主泵无工作，拆下主泵发现连轴器损坏，更换连轴器，挖机工作正常。
Troubleshooting:
1. Checked and found engine works normally. Data displayed on on the monitor is normal, and the pilot
relay works normally.
2. Uncover the pilot lock and check the suction of solenoid valve coils by the usage of screwdriver. It is
found that the suction is normal;
3. Remove the pilot valve spool and insert coil. The opening and closing of valve spool are normal.
4. Open the pump compartment service door. Check the oil outlet hose of pilot pum p. No hydraulic
pulse. Open oil hose and no hydraulic oil flows out. Pilot pump does not work.
5. Checked and found the main pump does not work. Remove the main pump and fouond the coupling is
damaged. Replace the coupling, tested and proved excavator could work normally. Problem solved.
排故体会：由简到复杂的过程是最行之有效的。
Experiences: Diagnosis from simple to complex is quite effective.
----提供者：卞干彪 Service engineer: Bian Gan Biao
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32、斗杆油缸无法完全升出和缩回 Stick cylinder can’t be operated in full stroke
故障现象：SY230斗杆油缸无法完全升出和缩回。
Symptom: SY230 Stick Cylinder cannot be Extended or Retracted Fully.
故障分析：1.主泵故障；
2.主阀阀芯发卡；
3.过载溢流阀发卡；
4.油缸活塞脱落。
Failure analysis:
1. Malfunction of main pump;
2. Malfunction of main valve spool;
3. Malfunction of the line relief valve;
4. Cylinder piston comes off.
故障原因：斗杆油缸活塞杆螺纹损坏导致活塞脱落。
Root cause of the failure: The screw thread of the cylinder rod is worn causes the piston drops.
排故方法：1.挖机其他动作正常，说明主泵完好；
2.检查主阀阀芯，将斗杆1、斗杆2阀芯拔出，未发现发卡现象；
3.检查油口过载溢流阀，将斗杆阀芯过载溢流阀与其他阀芯过载溢流阀
调换，试机故障未消除；
4.将斗杆油缸拆检，斗杆油缸活塞杆螺纹损坏，活塞脱落卡在缸筒内；
5.更换斗杆油缸，故障消除。
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Troubleshooting:
1. Other actions could be done, which means the main pump works well;
2. Check main valve spool. Extract spools of Stick 1 and Stick 2. No malfunction occurs.
3. Check t he ove rload r elief va lve. Interchange t he stick’s ove rload r elief v alve w ith ot her one s. T he
malfunction is not figured out.
4. Uncover t he s tick c ylinder. The s crew t hread on stick cylinder pi ston rod is worn, which c auses t he
drop of piston to the cylinder tube.
5. Replace the stick cylinder and the stick shall work normally.
排故体会：排故过程中对故障现象仔细分析推敲，可以少走弯路，对故障排除可以
达到一步到位。
Experiences: Carefully analysis during the troubleshooting is quite necessary.
——提供者：卞干彪 Service engineer: Bian Gan Biao
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33、左边履带不能行走 Left track can not travel
故障现象：一台 SY330 负流量挖机左边履带前后均不能行走，右边履带行走以及其它
动作都正常。
Symptom: One uni t of S Y330 NFC excavator’s l eft t rack c an not t ravel f orward and backward. T he
righe track travels normally and other actions shall be done normally.
故障分析：查看行走管路是否有漏油严重的地方，造成履带单边不能行走，一般为行
走马达故障或减速机故障；
Failure a nalysis: Check t he travelling hoses to f ind o ut w hether o il l eakage o ccurs. G enerally,
malfunction of one-side track is caused by failure of travel motor or final drive.
故障原因：1、左边行走先导管路故障；
2、左边行走先导脚踏阀故障；
3、左边行走马达故障；
4、左边行走马达减速机故障。
1. Malfunction of the left travel pilot circuit.
2. Malfunction of the left travel pilot valve.
3. Malfunction of the left travel motor.
4. Malfunction of the left final drive.
排故方法：1、检查左边行走先导管路是否松动造成漏油严重或油管脱落；
2、将行走脚踏阀左右先导管路交换，启机后操作行走排除先导脚踏阀
故障；
3、用挖机铲斗侧方向将左边履带顶起，单独操作左边行走动作，查看
行走马达有无异常响声，如有则表示行走马达正常，如没有则表示
马达故障以及刹车片不释放；
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4、根据第 3 点判定，马达正常且有联接轴转动的声音，则判定为马达
减速机故障，打开减速机外壳，查看行星齿轮，判定减速机故障。
Troubleshooting:
1. Check the left travel pilot circuit, the loose of which may cause serious oil leakage or dropping of oil
hose.
2. Interchange right and left pilot hose on foot pilot valve. Tested and found the same malfunction still
exists, which means the travel pilot valve is normal.
3. Raise the left track by the usage of the bucket. Only operate the left track to check whether any noise
could be he ard f rom t he t ravel m otor. If t he noi se c an be he ard, t he m otor w orks w ell; i f no t, t he
motor may breakdown or the brake does not release.
4. As pe r t he j udgment m entioned i n N o.3, t he m otor w orks w ell a nd t he r unning s ound of c oupling
could be he ard. T hus t he m alfunction of reducer i s en sured. U ncover t he r educer t o check t he
Planetary Gear and figure out the specific failure.
排故体会：根据客户反映的情况检查, 认真对待每一个细节, 想到可能发生的一切。

Experiences: According to customer’s reflection, careful check and analysis is of very importance.
——提供者：胡志杰 Service engineer: Hu Zhi Jie
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34、机器热机出现抖动 Machine vibrated after it is warmed up
故障现象：SY230C6B挖机热机时出现抖动。
Symptom: one unit of SY230 shakes while it is warmed up.
故障分析：1、热机时抖动说明与油温有关系,（液压油温、水温）；
2、热机时检查发动机转速是否正常；
Rear pump PRV
3、更改为液控后检查是否还出现抖现象；
4、是否所有动作都抖动； Front pump PRV
5、是否各节流阀卡滞；
6、液压油温度传感器故障；
7、电控转液控故障现象是否消除。
Failure analysis:
1. The shake during warm up has something to do with oil temperature.
2. Engine speed is abnormal.
3. Whether the shake still exists under hydraulic control style?
4. Whether the shake occurs while all the actions are done?
5. Whether the throttle is choked?
6. Malfunction of hydraulic oil temperature sensor?
7. Whether the shake still exists after changed to Hydraulic control?
故障原因：前后泵电磁比例阀O型圈损坏。
Root cause of the failure: O-ring seal of the front and rear pump solenoid proportional valves is failed.
排故方法：1、热机时检查发动机转速正常；
2、检查液压油温度传感器正常（模拟电阻2K）；
3、电比例阀电流正常，S模式10档憋车470mA；
4、KCM控制器正常；
5、检查传感器电压信号正常；
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6、将电控改液控后抖动故障现象消除；
7、拆下电比例阀阀芯,发现阀芯O型圈损坏；
8、更换O型圈,抖动现象消除。
Troubleshooting:
1. The engine speed is normal while warm up the machine;
2. Hydraulic oil temperature sensor is normal(Imitation Resistance 2K )
3. Current of the proportional solenoid valve is normal. The excavator is stalled at 10th (S model) and
the current is 470mA.
4. KCM controller is normal;
5. Sensor’s voltage is normal;
6. Changed to Hydraulic Control Module and shake disappears.
7. Remove the proportional solenoid valve spool, and find that the O-ring is damaged.
8. Replace the failed O-ring, tested and proved shake disappears. Problem solved.
排故体会：电磁比例阀O型圈损坏，热机时，液压油温度高，液压油变稀，导致内
泄大。
Experiences: The damage on the O-ring of solenoid proportional valve causes the oil becomes thin
internal leakage increase.
——提供者：颜礼平 Service engineer: Yan Li Pin
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35、斗杆自动下降 Stick drops automatically
故障现象：一台 SY65 型小挖机，各动作工作正常，斗杆回收到底，操作手柄中位，
斗杆自动快速下落。
Symptom: Here i s one unit of S Y65. A ll the actions can be done no rmally. But w hen t he s tick in is
complete and release the joystick to the neutral position, the stick will fall automatically.
故障分析：1、先导是否内泄；
2、斗杆油缸分配器过载遗流阀是否好用；
3、阀块内泄。
Failure analysis:
1. Internal leakage in the pilot circuit.
2. Does the stick cylinder line relief valve work well?
3. Valve internal leakage.
故障原因：主控制阀阀芯磨损，系统压力内泄。
Root c ause of the failure: Abrasion on the main control valve spool causes the internal leakage and
pressure lost.
排故方法：1、首先把斗杆油路接到铲斗油缸上，故障点转到铲斗油缸上，现象是铲
斗挖土时出现油缸回收现象；
Arm
Relief valve
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2、过载溢流阀互换现象没有改变；
3、更换阀块后故障得到排除。
Troubleshooting:
1. Connect the stick oil hose to stick cylinder, which changes the malfunction point to the bucket
cylinder. By this mean, the bucket cylinder will be retracted while digging.
2. Interchange the line relief valve, malfunction still existed.
3. Replace the valve and the stick works well.
排故体会：排除法确认阀块内泄。
Experiences: Elimination is employed to ensure valve internal leakage.
----提供者：王新伟 Service engineer: Wang Xin Wei
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36、SY230C8B 挖掘机整机发抖 Machine vibrated obviously
故障现象：一台工作 1800 小时的 SY230C8B 挖机出现整机发抖故障。

Symptom: One unit of SY230C8B shakes while working (working hour: 1800hr)
故障分析： 1、先导控制系统传感器电源 50#电源线供电异常；
2、控制器问题；
3、油门马达故障；
4、主泵调节机构故障。
Failure analysis:
1. 50# power supply wire of the pilot sensors works abnormal.
2. Malfunction of controller.
3. Malfunction of throttle motor.
4. Malfunction of main pump adjustment mechanism.
故障原因：后泵调节器故障。
Root cause of the failure: Malfunction of rear pump adjuster.
排故方法：1、现场操作挖掘机发现：在电控模式，冷机状态挖机各个动作没有任何
问题，热机后（两个小时）5-11 档油门工作所有动作发抖，但发动机转
速没有没有明显变化，通过观察显示屏发动机参数转速跳动范围在 40 转
-90 转之间，属于正常现象；
2、在液控状态下冷机和热机状态挖机正常均工作，发动机转速稳定，检
查从控制器出来的 50#电源线，检查显示电压为 5 伏，说明控制器电源模
块正常，检查先导过渡块上各个传感器电压正常，说明线路无故障；
3、通过单独检查左右行走马达转数的方法，检测出左右行走马达的转速
误差在 1/5 以内，判断排量没有问题；在热机时抖动越来越厉害；通过单
独做左行走动作，发现前泵主压稳定；通过单独做右行走动作，发现后
- 80 -
泵主压稳定；但作任意动作加作动臂提升动作时，发现后泵主压力不稳，
因此可以判定是后泵调节器故障，更换后泵调节器后，故障排除，机器一
Schematic Rear pump adjuster
切正常；
Troubleshooting:
1. Operate the excavator in working site: By electric control mode, the excavator works normally
with a ll a ctions i n c old condition. In t he he at c ondition ( working for 2 h ours), s hake oc curs a t t he
stall 5-11 while doing all the actions with the engine speed normal. The engine speed date displayed
is among 40rpm-90rpm, which is normal.
2. By h ydraulic control m ode, t he excavator works well i n bot h cold and heat conditions. The engine
speed is normal. The voltage of the 50# power code is 5V, which means the controller’s power supply
module works normally. And check the pilot transition valve, the voltage of all the sensors is normal ,
which means the power cords are normal;
3. Check the travel m otor speed individually and the speed discrepancy is within 1/ 5, which m eans
displacement is normal. The shake becomes much more serious; Do r ight and left travel actions
individually, t he f ront a nd r ear pum p m ain pr essure a re nor mal. B ut t he rear pum p pr essure i s not
stable w hile a ll t he a ctions a re done , which m eans t hat t he m alfunction of r ear pum p r egulator is
ensured. Replace the regulator, the excavator works well.
排故体会：应用显示屏上的参数，由简到繁，一步一步通过排除法排除故障。
Experiences: As per the operation data displayed, from simple to complex, figure out the malfunctions
step by step.
—— 提供者：王万军 Service engineer: Wang Wan Jun
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37、SY210C 发动机工作中熄火 SY210C engine shutoff automatically during the work
故障现象：一台SY210设备冷机时动作慢，工作3-5分钟后动作时熄火。
Symptom: SY210 works slowly initially and the engine stops after working for 3-5mins.
故障分析： 1、燃油系统堵塞或进空气；
2、燃油高压油泵工作不正常，喷射压力不够；
3、液压先导系统压力异常，工作时主控阀阀芯未完全打开；
4、液压回油油路故障、背压高导致憋熄火。
Failure analysis:
1. Fuel system is blocked or air enters.
2. Abnormality of fuel high-pressure oil pump. The spurting pressure is not enough.
3. Abnormality of hydraulic pilot system pressure. The main control pump spool cannot be opened fully
while working;
4. The hydraulic oil return pipe is blocked and high back-pressure causes engine’s stop.
故障原因：先导泵故障引起先导压力过低，导致比例电磁阀无法调节斜盘摆角，负
载时会出现动作慢或熄火。先导泵损坏
Root c ause of t he failure: Malfunction of pi lot pum p c auses
low pilot pr essure. A nd the pr oportional s olenoid va lve c annot
adjust swashplate tilt angle. When loaded, t he excavator will
work slowly or the engine stops running.
排故方法： 1、首先向该设备操作手了解和询问机
器使用情况，特别是故障发生的前
后对比及故障发生的详细情况.
2、启动机器并试机，发现冷机时机器虽然各项动作均有，但明显比正
常动作偏慢；
3、进入显示屏界面，未发现有异常情况；
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4、检查燃油系统，未发现有堵塞和进空气情况；
5、检查发动机高压油泵，喷油高度正常；
6、检查测量主泵及先导压力，发现主压力正常，先导压力偏低；
7、拆检先导泵，发现调压阀阀芯锥部磨损严重，液压油泄漏严重导致
先导压力不够；
8、更换先导泵后试机，设备工作恢复正常。
Troubleshooting:
1． Ask the operator for operating information, especially the contrast of the working conditions before
and after the malfunction and the specific malfunctions;
2． Start the excavator; it works a little slowly than the normal condition;
3． Check the LCD display, and no abnormality can found out;
4． Check the fuel system, and it is not block or no air enters either;
5． Check the engine high-pressure oil pump, the spurting height is normal;
6． Measure the main pump and pilot pressure. The main pressure is normal while the pilot pressure is a
little lower than the normal value.
7． Remove t he pi lot pum p a nd t he s erver a brasion on t he r egulator va lve spool s hall be s een. Severe
leakage of hydraulic oil causes low pilot pressure.
8． Replace the pilot pump and the excavator works normally.
排故体会：用排除法对液压、发动机、电气来分析故障点出现在哪大类上，再进行
细致分析，可更快、更方便用于排除故障。
Experiences: The method of elimination is employed on hydraulic system, engine, and electrical system.
Careful inspection and professional analysis ensure quick and efficient troubleshooting.
——提供者：贵州通程兄弟 Dealer: Gui Zhou Tong Cheng Brother
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38、SY230 冷机动作不协调 SY230 has a delay response before machine is warmed up
故障现象：一台 SY230C5 老式挖掘机在冷机时操作时，手柄要到行程末端时相应的
执行元件才有动作，而手柄回到中位后，该动作还会延续 1-2 秒钟，机
器液压油温度达上升到 45 度左右，机器恢复正常。
Symptom: Here is one unit of SY230C5 old model excavator. Only when the operation handler reaches
at t he e nd, r elative a ctuator s tarts t o w ork. W hen t he ha ndler r eturns t o t he m id-position, t he working
action will last for 1 -2 seconds. After the hydraulic oil temperature reaches at 45 degree, and the
excavator could work normally.
故障分析：1、先导泵故障，导致先导压力异常；
2、先导操纵阀故障，先导操纵阀阀芯卡滞，加上冷机时液压油温度低、
凝度高，导致操纵阀芯开启或关闭不及时；
3、排除各种内泄可能，因为如果内泄热机后同样存在该故障现象。
Failure analysis:
1. Malfunction of pilot pump causes abnormality of pilot pressure;
2. Malfunction of pilot control valve, whose valve spool is choked. The corkage together with low oil
temperature, high condensation lead to untimely opening or closing of controlling valve spool.
3. Eliminating all kinds of internal leakage because if leakage exists, the same malfunction will occur
when the excavator is heated.
故障原因：1、由于操作阀内阀芯有轻微卡滞现象，加上冷机时液压油粘度大而卡滞
造成半行程时阀芯开启慢；
2、阀内计量弹簧疲软回位滞后，造成手柄回到中位后而该动作还会延后
1-2 秒。
Reasons:
1. Malfunction of pilot control valve, whose valve spool is a little choked. The corkage together with
low oil temperature, high condensation lead to untimely opening or closing of controlling va lve
spool.
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2. The loosen spring inside the valve returns to the mid-position slowly, resulting the working actions
last for another 1-2 seconds after the hander returns to the mid-position.
排故方法：1、冷机时检查发现，在操作手
柄半行程时测得一级先导压力为
39Kg/c ㎡,测得二次先导压力为
0.8-1Kg/c ㎡；
2、热机后测量发现，在操作手
柄半行程时测得一级先导压力为
39KG/C ㎡,测得二次先导压力为
39KG/C ㎡；
3、更换操作阀、液压油及相关滤
芯，清洗液压系统，调整全车液压系统压力，机器恢复正常。
Troubleshooting:
1. In cold working condition, when the handle stop in the mid-position, the first-class pilot pressure is
39Kg/c ㎡ while the second-class is 0.8-1Kg/c ㎡;
2. In heated working condition, when the hander stop in the mid-position, the first-class pilot pressure is
39Kg/c ㎡ while the second-class is 39KG/C ㎡;
3. Replace h andler, h ydraulic o il an d f ilters; cl eanse t he h ydraulic s ystem, adjust t he whole excavator
pressure and then the excavator works normally.
排故体会：面对该种软性故障时冷静分析，掌握机器各部件的结构与工作原理，一步
一步的排查，就能找到问题所在。
Experiences: Be car efully analysis an d f amiliar w ith al l t he el ements an d t heir w orking p rinciples. To
figure out the reasons and find out effective methods step by step.
———提供者：王学辉 Service engineer: Wang Xue Hui
- 85 -
39、SY360 无法启动 SY360 can not be started
故障现象：一台 SY360 出现启动时发动机冒黑烟，发动机不爆发，无法启动故障。

Symptom: Here is one unit of SY360, whose engine fails to be started with heavy black smoke.
故障分析： 1、发动机柴油油路供不上、堵塞；
2、发动机进气系统堵塞或不畅；
3、由于环境温度过低导致发动机启动阻力过大；
4、发动机手油泵故障、高压油泵故障、发动机本身故障；
5、液压系统发生故障,阀芯卡滞导致负载过大；
6、启动马达故障。
Failure analysis:
1. The fuel pipe is blocked;
2. The engine’s air inlet pipe is blocked;
3. Low surrounding temperature;
4. Malfunction of hand pump, high-pressure pump or the engine itself;
5. Malfunction of hydraulic system. The choke of valve spool leads to overload.
6. Malfunction of start motor.
故障原因：备用阀阀芯卡滞，导致启动时负载过大。
Root cause of the failure: The choke of stand-by valve spool leads to overload while starting.
排故方法：1、检查发动机机油粘度、油路、气路均正常；
2、启动时通过显示屏参数检查前后泵主压力，发现前泵主压异常偏高，
但在启动时系统压力将近 260KG 压力时整车无动作，判定备用阀杆或铲
合流阀杆卡滞导致启动时负载过大而无法启动。检查备用阀杆时，用手
无法将其抽出，借助工具将阀杆抽出、清洗重新安装后试车启动正常。
- 86 -
Abnormal Spare valve spool
pressure
displayed
Troubleshooting:
1. The lubricating oil, oil pipe and air pipe are all normal;
2. As per the data displayed on the LCD, the pressure of the front and rear pumps is a little higher than
the normal. But when started, the excavator does not work with the system pressure reaching
260KG.It is presumed that the choke of stand-by valve spool leads to overload while starting. Check
the s tand-by va lve r od, t he r od cannot b y extracted. P ull t he r od out b y t ools a nd c leanse i t. A fter
installation of the clean rod, the excavator works normally.
排故体会：对于无法启动故障平时需积累发动机油路、气路发生故障时的故障现象，
故障出现时能较快的判断故障原因，要善于观察，针对故障现象要全面的分析，找
出故障原因，快速排除故障。
Experiences: In terms of failure to start, it is necessary to accumulate the symptoms about malfunctions
of oil pip and air pipe. When the malfunction occurs, it is if very importance to inspect carefully, analyze
wholly and then figure out the reasons quickly and efficiently.
——提供者：邵锏波 Service engineer: Shao Jian Bo
- 87 -
40、发动机无法启动 Engine can not be started
故障现象：一台SY360负流量型挖掘机，在工作一段时间后停机，再次去启动发动机
时发动机无法启动。在启动时发动机冒大量黑烟。将主流溢阀拧松后发动
机能启动。
Symptom: Here is one unit of SY360 negative flow excavator, which will stop working after working for
a cer tain t ime. T he en gine can not b e s tarted an ymore w ith h eavy b lack s moke. Loose t he m ain r elief
valve and then the engine can be started.
故障分析：根据故障现象可以排除因发动机自身故障造成的无法启动。造成发动机
不能启动的原因：
1、电气方面原因：（1）发动机在启动时主泵电磁比例阀电流值是否在
450--1000mA，（2）比例电磁阀阀芯是否卡滞在泵最大排量位置。使
发动机带负荷。
2、液压方面：（1）主泵调节器是否
卡滞在泵最大排量位置；（2）主控制
阀各动作阀芯是否卡滞在常通位置；
（3）主控制阀备用阀芯是否动作卡滞
在常通位置；(4)负控制溢流阀是否损
坏，建立不起负控制压力（正常压力：
2-40公斤），使发动机带负荷启动。
Analysis： According to symptoms, the malfunction caused by engine itself shall be got rid of. Reasons
for the engine’s failure to be started are as follows.
1. Electrical aspects:
(1) Whether the current of main pump solenoid proportional valve is between 450--1000mA?
(2) Whether the proportional solenoid valve spool is choked at the position of pump’s maximum
displacement.
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2. Hydraulic aspects:
(1) Whether the main pump regulator is choked at the position of pump’s maximum displacement?
(2) Whether all the valve sloops of main control valve are choked at the connected position?
(3) Whether the standby valve sloop of main control valve is choked at the connected position?
(4) Whether the negative control relief valve is damaged. If damaged, it causes the pressure smaller than
the normal value (2-40KG). The engine cannot be started with load.
故障原因：主控制阀备用阀芯动作卡滞在常通位置。
Root c ause of t he failure: T he s tandby v alve spool of m ain c ontrol va lve i s c hoked at t he c onnected
position.
排故方法：1、首先检测主泵电磁比例阀电流值，在发动机启动时电流值为550mA左
右--正常，排除此处故障。
2、将主流溢阀拧松后发动机能启动，放下先导锁定阀，操作大臂、小臂、
回转、铲斗、左右行走各动作是否工作正常--正常，排除以上阀芯
卡滞造成的故障。
3、根据故障现象及上述的检
测可以判断故障点不在主泵
调节器、负控制溢流阀。
故障可能为备用阀芯动作
卡滞在常通位置。
4、拆检主控制阀备用阀芯，
发现备用阀芯下沉2cm并卡
滞在主控制阀体上，造成主 Spare valve s pool

seized in t he m ain
泵排量增大。备用阀芯将液 control valve
压油堵死，液压油不能流动，使发动机带较大负荷造成不能启动。后
- 89 -
将备用阀芯取出，进行打磨修复重新安装，试车发动机能正常启动，
无法启动故障排除。
Troubleshooting:
1. Firstly, check the main pump solenoid proportional valve current. When the engine is started, current
is 550mA，which is normal.
2. Loosen t he m ain r elief v alve and t hen s tart t he engine, put t he pi lot lock down. Operate t he boom ,
stick, rotary, bucket and left & right travel motor. All these actions shall be done normally;
3. According to the symptom and inspection mentioned above, the m alfunction is not at main pu mp
regulator or negative control relief valve. It is presumed that the standby valve sloop is choked at the
connected position.
4. Uncover the standby valve sloop, which is found to have dropped 2 cm and choked at the main
control valve, causing main pump displacement enlarged. The standby valve spool blocked hydraulic
oil, resulting in the engine’s no start with load. Extract the valve spool. After polishing, install it. And
the excavator works normally.
排故体会：在维修处理故障时，根据操作人员反映的历史故障及现场故障现象，思
路清晰的逐步把问题缩小，从简到难的排除故障。
Experiences: During the diagnosis, it is necessary to know well the symptom reflected by the operators
and present. Keep the mind clear and figure out the malfunction little by little from simple to complex.
- 90 -
41、回转无力 Swing operation performs poorly
故障现象：一台 SY215C8 型机器，在做回转单独动作、回转复合动作时回转动作均
动作慢无力，其它动作正常。
Symptom: Here i s one unit of S Y215C8, w hose r otation a ction i s
slow and weak when it rotates separately or does compound actions.
故障分析：造成回转动作慢无力原因。
电气方面：1、回转低压传感器损坏，反馈电压值不在正常范围内（正常反馈电压值：
手柄中立时 0.4-0.5V,手柄全程操作时不超过 4.5V）。
2、前泵电磁比例阀电流值是否在标准范围内（电
流值：350 - 750mA）。
液压方面：1、回转先导二次压力是否在正常范围内（正常先导压力 35 公斤以上）

。
2、回转主阀芯是否切换到位，回转阀芯回
位弹簧是否断裂。
3、回转溢流阀损坏，回转溢流压力是否在
正常范围内（溢流压力：280 公斤）。
4、配流盘磨损损坏，造成回转马达内泄。
Swing motor
5、回转马达泵体与柱塞磨损损坏，造成马达内泄。
6、只有回转动作慢其它动作正常，可以排除液压主泵、主溢流阀故障。
Failure analysis: Reasons for the weak rotation
A. Electrical reasons:
1. Rotary low pressure sensor is broken. The pressure feedback is abnormal. (the normal
pressure feedback value: 0.4 -0.5V with handler at mid-position; less than 4.5V with
handler at full position );
2. Whether the current of electromagnetic proportional valve is normal(350—750mA);
B. Hydraulic reasons:
- 91 -
1. Whether the rotary pilot sub-pressure is abnormal (normal value: above 35KG);
2. Whether the rotary main valve core is switched to the right position. Whether the spring of
valve core is broken or not?
3. Swing relief valve is damaged causing the relief pressure abnormal. (280KG)
4. Hydraulic pressure allocation plate is damaged, causing the internal leakage of rotary.
5. Rotary motor pump body and rotary pillar are worn, causing the internal leakage of motor.
6. Other working actions are normal except the rotary’ slow working, which cannot be caused
by malfunction of hydraulic main pump and main relief valve.
故障原因：回转马达配流盘与泵体接触面磨损损坏，造成马达内泄。
Root cause of the failure: Rotary motor is worn, causing the internal leakage of motor.
排故方法：1、首先检查回转操作二次压力 39 公斤--正常。
2、检测回转低压传感器反馈电压值：操作手柄中立时 0.5V,手柄全程操
作时 4.3V--正常。
3、测量回转全程操作时前泵电磁比
例阀电流值为 550mA 左右--正常。
4、测量回转溢流压力为 195 公斤--
不正常。调整溢流阀压力无变化。
5、测量主溢流阀压力为 348 公斤--

Motor worn severely,
正常，排除液压主泵、主溢流阀故障。 internal leakage occurs
6、拆解回转马达溢流阀，未发现溢流阀内部损坏--溢流阀工作正常。
7、拆检主阀上回转阀芯，阀芯活动自如，回位弹簧未断裂--阀芯工作
正常。
8、拆解回转马达，发现配流盘与柱塞泵体接触面磨损严重，回转马达内
部泄漏，使回转液压系统压力过低，造成回转动作无力慢。
9、将磨损严重的配流盘更换，回转马达重新装配好后，试车回转工作正
- 92 -
常，故障排除。
Troubleshooting:
1. Check the rotary pilot sub-pressure, 39KG, which is normal;
2. Check t he pr essure feedback b y the p ressure s ensor: pr essure i s 0.5 V with ha ndler a t m id-position
while it is 4.3V with handler at full position ;
3. Measure t he r otary f ull a ction ope ration f ront p ump e lectromagnetic proportional c urrent i s a round
550mA.
4. Measure the rotary relief pressure, 195KG, which is abnormal. Adjust the relief valve pressure, which
cannot be changed.
5. Measure t he m ain r elief va lve pr essure, 348 KG, w hich i s nor mal. H ydraulic m ain pum p a nd r elief
valve can work normally.
6. Remove t he r otary m otor r elief va lve, w hose pa rts i nside a re f ound t o be nor mal, w hich m ean t he
relief valve is normal.
7. Remove the main pump valve core, which can move normally and the spring is not broken. Thus the
valve core can work normally.
8. Remove the swing motor, it is found that hydraulic pressure allocation plate and rotary pillar are
heavily worn, causing t he i nternal l eakage of m otor, which causes t he h ydraulic s ystem pr essure i s
low. Thus the excavator rotates slowly.
9. Replace the worn hydraulic pressure allocation plate, and install the rotary motor. Start the machine
and it can work normally.
排故心得：回转马达内部磨损后造成密封不严液压油泄漏，致使回转无力动作慢，
在处理液压系统时根据“压力取绝于负载、流量决定速度”的原理，进行
由简到繁，由外到里分析处理故障。
Experiences: Internal a brasion i nside t he r otary m otor h as caused l eakage o f h ydraulic o il b ecause o f
loosened seal. And the excavator rotates slowly. Based on the principal of “ Pressure d etermined b y
working l oad a nd s peed determined by f low”, c heck t he hydraulic system from simple to complex and
from outside to inside.
------提供者刘志刚 Service engineer: Liu Zhi Gang
- 93 -
42、SY75 小臂回收时动作速度慢 SY75 stick in operation has a long cycle time
故障现象：一台 SY75 挖机工作时，小臂回收时动作速度慢。

Symptom: slow speed for one SY75’s stick withdraw.
故障分析：1、小臂回收系统压力阀压力低；
2、手柄控制小臂回收动作卡；
3、控制阀上的合流阀卡死；
Arm cylinder he ad
4、小臂油缸油封损坏，导致内泻； end hose leaks oil
5、主油管供油低。
Failure analysit:
1. Low pressure for pressure valve when withdraw the stick.
2. Stuck of the stick when the joystick moves.
3. Stuck interflow valve on the control vale.
4. Damage of the o-ring in the stick cylinder.
5. Low oil supply in the main horse.
故障原因：小臂油缸无杆腔进油管漏油。
Root cause of the failure: Main oil hose of the stick cylinder head end leaks oil.
故障排除：1.检测先导压力系统压力一切正常；
2.检查油路发现小臂油缸无杆腔油管漏油，更换胶管，动作恢复正常。
Troubleshooting:
1. Check the pilot system pressure
2. Check the stick cylinder oil leaking, and change the o-ring, the performance is ok.
排故体会：本故障是一个特例，平时遇到这种情况的概率较低。
Experience: This is a special fault, and with low rate suffered.
——提供者：龙振国 Service engineer: Long Zheng Guo
- 94 -
43、SY360-8 全车动作迟缓无力 SY360 has long cycle time for all actions
故障现象：一台川崎控制器 SY360-8 挖掘机全车动作迟缓无力。

Symptom: Slow performance of one SY360-8 which with KPM controller.
故障分析： 1、液压油箱油位不足；
2、主泵内泄严重导致供油不足；
3、伺服压力过低；
4、系统安全阀压力过低；
5、发动机转速过低；
6、液压油滤清器堵塞；
7、发动机滤清器堵塞。
Failure analysis:
1. Not enough hydraulic oil in the tank.
2. Not enough oil supply in the main pump Fuel is dirty.
Filter blocked
3. Low pilot pressure
4. Low pressure on the safe valve
5. Low engine speed
6. Hyd. Oil filter stuck
7. Engine filter stuck
故障原因：发动机燃油脏导致滤清器堵塞。
Root cause of the failure: Desiel fuel is dirty and cause the fuel filter blocked.
排故方法： 1、测量该机器主压力正常 35MPa；
2、测量该机器先导压力正常 3.9MPa；
3、检查液压油位标尺，液压油油量正常；
4、检查发动机转速正常，H 模式 11 档 2230 转；
5、检查前后泵比例阀电流异常 400mA 左右，检查燃油滤清器，发现滤

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清器堵塞，由于川崎控制器有失速保护功能，当发动机功率下降，控
制器会将主泵排量减少，导致动作缓慢无力。
Troubleshooting:
1. Check the main pressure is 35 MPa or not
2. Check the pilot pressure at 3.9 MPa or not
3. Check the hyd oil enough or not
4. Check the engine speed from H model to 11 at 2230
5. Check the electric at about 400mA, check the oil filter, and found the stuck of the filter. As the KPM
controller w ith t he l osing s peed p rotect s ystem, which r educe t he m ain pump f low a nd c ausing the
slow performance.
排故体会：了解川崎控制器这一特性，对排故有一定帮助。

Experience: knowing well about KPM controller will be helpfue to the troubleshooting.
——提供者：颜礼平 Service engineer: Yan Li Ping
- 96 -
44、斗杆自动伸展 Stick extends out automatically after engine is started
故障现象：一台 SY210 挖掘机出现启动后斗杆自动伸展，当斗杆伸展到最大位置，挖
掘机自动熄火。
Symptom: Stick extends out automatically after engine is started. Engine shut down automatically when
the stick reaches the max stroke.
故障分析：由于此故障与斗杆伸出的动作相关，根据故障现象，基本可以排除电气
故障、亦可以排除先导系统的故障，所以可以从以下几方面分析：
1、液压油脏，导致斗杆阀芯发卡；
2、主阀阀内壁拉伤，斗杆卡死在某一位置，而造成主阀芯不能归位。
Failure analysis: According to the failure phenomena, it is sure that failure has nothing to do with the
electrical system and also the pilot system.
1. Hydraulic oil is contaminated and cause the stick valve spool seized.
2. Stick valve spool scratched and can not operated in the main control valve.
故障原因：斗杆阀芯 1 因有脏东西，造成阀芯发卡。
Root cause of the failure: Stick 1 valve spool is seized in the main ctrl valve due to contanmination.
排故方法：1、先查看液压油是否脏——液压油正常；
2、检查斗杆阀芯 1：斗杆阀芯 2：是否卡死；在拔斗杆阀芯 1 时感觉有
点紧，于是拔出斗杆阀芯 1 及斗杆阀芯 2 ，分别清洗； Stick 1

valve spool
- 97 -
3、清洗阀芯后，机器工作正常，证明故障点就是斗杆阀芯 1 发卡造成；
4、为防止类似故障再发生，为客户更换了液压油滤芯及先导滤芯。
Troubleshooting:
1. Checked and found the hydraulic oil is not contaminated. It is normal.
2. Check t he s tick 1 a nd s tick 2 va lve s pools. It i s found t hat s tick 1 va lve s pool can not m ove i n t he
main control valve freely. Remove these two valve spools and clean them, then restore them.
3. Tested and proved machine works normally problem solved.
4. Suggest the end user to replace the hydraulic oil, pilot oil filter, and return oil filter.
排故体会：在对三一液压分布及工作原理了解的基础上，合理的由简单直观现象缩小
故障范围，找到故障源，最短最快排除故障。
Experience: Knowing the components location well, understanding the system operation well, figure out
the root cause of the failure according to the failure phenomena as fast as possible.
——提供者：陈国 Service engineer: Chen Guo
- 98 -
45、左右回转刹车漂移量大 Overswing when the swing operation is stopped
故障现象:一台 SY230 挖掘机工作 700 小时，工作中突然出现回转漂移量大，其他工
作正常。
Symptom: SY230 excavator has 700H working hours. All the actions are normal except the overswing.
故障分析：1、回转漂移量大主要是刹车性能不好引起；
2、引起刹车性能不好的原因只有高压泄油所致；
3、引起高压泄油的原因有：补油单向阀卡滞；溢流阀压力过低；阀杆回
位慢；马达内泄严重。
Failure analysis:
1. Overswing is usually caused by the poor performance of brake system.
2. Internal leakage will cause poor brake performance.
3. Probable cause of internal leakage: makeup valve seized, line relief valve pressure setting is too low,
pilot valve return to neutral position slowly, case drain of the swing motor is severe, etc.
故障原因：先导分配阀块通往回转控制阀杆的油口内部装有节流阀，由于滤网堵塞
造成先导油通路不畅而形成的动作滞后并刹车回位滞后，清洗后正常。
Root cause of the failure: There is oil screen in the pilot oil port of the main valve spool. This screen is
blocked, pi lot oi l can no t return t o t he t ank qui ckly after t he pi lot valve returns t o t he neutral po sition.
Clean the small screen, overswing problem solved.
Location of the
orifice and screen.
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排故过程：1、观察驾驶员操作过程，无违章作业现象；
2、上车操作，回转漂移确实很大，但明显的感觉动作滞后，先导手柄
推出一半的位置回转才开始动作，证明控制阀杆回位慢所致；
3 、排查先导油管，发现先导分配阀块通往回转控制阀杆的油口内部装
有节流阀并设有滤网.
4、由于滤网堵塞造成先导油通路不畅而形成的动作滞后并刹车回位滞
后，清洗后正常。
Troubleshooting:
1. Checked and found failure has nothing to do with the user’s operation.
2. It is sure that the overswing is excessive. It is obvious to found the late response. Machine starts to
swing when the swing pilot valve is pushed about half stroke.
3. Check the pilot hose to the swing valve spool, orifice and small screen are found in the pilot oil port
of the swing main valve spool.
4. Checked and found the small screen is blocked which cause the late response and overswing. Clean
the screen, tested and proved problem solved.
排故体会：作为服务工程师应该熟练操作，并细心观察，听取驾驶员的故障描述往
往很重要，自己亲自操作，快速解决故障。
Experience: To be a s ervice e ngineer, i t i s i mportant t o ope rate t he m achine e xpertly a nd obs erve t he
failure p henomena carefully. Listen t o t he o perator car efully an d record t he failure phenomena de tailly.
Figure out the root cause and solve the problem quickly.
---提供者：卞干彪 Service engineer: Bian Gan Biao
- 100 -
46、SY200 动作慢、无力 SY200 has a long cycle time
故障现象：一台SY200负流量挖机动作慢，无力，负载增加时更明显，发动机转速正
常，不掉速。
Symptom: NFC excavator SY200 has slow operation speed, especially with load increased. Engine speed
is normal.
故障分析：在发动机转速正常情况下，动作慢，无力一般可从以下几方面分析：
1、系统压力内泄；使挖机在挖掘时的压力达不到设定值；
2、先导压力过低：使主阀芯开度不到位，从而导致动作慢，无力。
Failure analysis: Machine has a cycle time while the engine speed is normal. Possible cause:
1. Internal leakage cause the working pressure lower than the specification.
2. Pilot oil pressure is too low to open the main valve spool completely which cause slow speed.
故障原因：主溢流阀内部有杂质，造成提动头无法复位，工作时主溢流阀产生内泄。
Root cause of the failure: Main relief valve seized to open status due to impurity, part of main oil
returns to the hydraulic tank directly.
Armature
seized
Main relief
valve
排故方法：1、先测量先导压力,测得先导压力为39公斤--正常；
2、测量主控制阀至主泵调节器负反馈压力,测量前后泵负反馈压力，操
- 101 -
作手柄中立时为38公斤,全行程操作手柄时为4公斤左右--正常；
3、测量主溢流阀溢流压力为255公斤,溢流压力--不正常。因为正常主溢
流压力为330公斤，由此判断压力不正常需要调整；
4、调整主溢流阀时,将主溢流阀调整螺钉顺时针旋紧1圈后，测量溢流压
力无变化，这时可以判断主溢流阀故障；
5、拆检主溢流阀发现内部有杂质,造成提动头无法完全复位,从而产生系
统压力内泄。清洗、调整主溢流阀压力到330公斤,试车一切正常,故障
排除。
Troubleshooting:
1. Measured pilot oil pressusre is 39kgf which is normal.
2. Measured negative feedback pressure to the main pump is 38kgf when the pilot valves are all in
neutral position and 4kgf when pilot valve is operated. Normal.
3. Measured main oil relief pressure is 255kgf which is lower than specification 330kgf.
4. Adjust the main relief valve pressure setting. Screw in the adjust screw of the main relief valve
clockwise, measured pressure has no change. It is sure that the main relief valve is failed.
5. Dismantle the main relief valve, checked and found the impurity in the main relief valve which causes
the armature of the main relief valve can not reset fully and internal leakage existed. Clean the main
relief valve and adjust it the the specified setting, tested and proved machine works normally. Problem
solved.
排故体会：主溢流阀故障，使系统压力达不到设定值，就会导致正常挖掘时动作无
力的故障。
Experience: Main relief valve is malfunctioned, will cause the hydraulic system pressure lower than the
specification. Usually, customer will complain about machine has insufficient power.
——提供者：陈侃侃 Service engineer: Chen Kan Kan
- 102 -
47、SY215C8 挖机动作慢 SY215C8 has a long cycle time
故障现象: 川崎控制器、三菱发动机，整机动作慢，但改液控后，机器工作正常。

Symptom: KCM controller, 6D34 engine. Slow action speed but normal under hydraulic mode.
故障分析：1、从动力输出方面分析：
A、发动机动力不足，发动机本身出现故障；
B、发动机转速异常，转速未达到标准转速；
C、主泵等液压系统异常；
2、从电气方面分析：
A、主压力传感器异常或电压异常；
B、各动作信号压力传感器异常或电压异常；
C、前后泵比例电磁阀异常或电流异常；
D、 KCM 控制器异常；
E、发动机转速标定出现异常。
Failure analysis:
1. Power aspects:
A. Engine output power is insufficient. Do troubleshooting for engine.
B. Engine speed is lower than specification. Do the speed calibration.
C. Main hydraulic pump malfunction.
2. Electric aspects:
A. Output pressure sensor or its voltage is abnormal.
B. Pilot pressure sensor or its voltage is abnormal.
C. Proportional solenoid valve or its current of the pump is abnormal.
D. KCM controller is abnormal.
E. Engine speed calibration is abnormal.
故障原因：主泵调节器异常，清洗后正常。
- 103 -
Root cause of the failure: Main pump adjuster is seized by impurity.
排故方法：1、到达现场后发现该机动作很慢，大臂提升约 6~8 秒，先检查发动机
转速正常，确定发动机转速符合公司标准；
2 、检测先导压力为 3.9MPa，主压力为 35MPa，压力正常；
3 、显示屏各参数显示均正常，各压力信号传感器反馈数据均正常，KCM
控制器各 5V 输出电压正常；
4 、S 模式 10 档憋压时发现前后泵比例电磁阀电流正常为 470mA~500mA
由于 S 模式 10 档憋压时发现前后泵比例电磁阀电流正常，KCM
之间，
控制器电比例阀电流输出正常，由此可以判断为主泵输出功率过小，
且之前更换了油门电机、标定了转速，在改液控情况下正常可以判定
为调节器异常；
5 、将调节器，拆下清洗后，机器工作正常，故障排除。
Setting
screw
Troubleshooting:
1. Checked in the jobsite the operation speed is very slow, 6 to 8 s econds for boom up. Engine speed is
within the specification. It is normal.
2. Measured pilot oil pressure is 3.9Mpa and the main oil pressure is 35Mpa. Both are normal.
3. Checked in the monitor, all the parameters are normal. Feedback data of all the pressure sensors are
normal. KCM output 5V voltage to each sensor.
4. Do the est at 10th throttle under S mode to let the main relief valve open, it is found that the current to
the proportional s olenoid va lve of front a nd rear pum p a re w ithin 470mA~500mA. It i s nor mal.
- 104 -
Before this failure occurs, governor actuator is replaced and the engine speed is calibrated. Checked
and found that the machine is normal under hydraulic control mode. All of these information indicates
that the pump adjuster is suspected to be abnormal.
5. Remove pump adjuster and clean it, tested and proved machine works normally. Problem solved.
排故体会：调节正流量螺钉（负控系统的我们习惯叫负流量螺钉），该螺钉为调节先
导压力和输出排量曲线的螺钉，没有把握的情况下不建议调节，在调节前做好记号，
在调节后可能出现不能调回初始状态，必须拆下分解重新清洗安装（负控的往里面
调节为在恒定压力下增加排量）
。
Experience: Adjust the PFC setting screw to adjust the pump output horsepower. If you are not
professional engineer or not grasp t he h ydraulic pump expertly, s uggest never adjust t his s crew. Before
this s cew i s adjusted, m ake a m ark on the screw and t he pum p hous ing, make a ve ry s mall adjustment
each time and then do the performance test to see whether the machine performance is improved or not. If
the pump is failed to output after adjusting this screw, try to remove the adjuster and clean it.
-----提供者：龙振国 Service engineer: Long Zhen Guo
- 105 -
48、SY215 挖机铲斗油缸抖动 Bucket cylinder of SY215 vibrated
故障现象:铲斗油缸在伸出超过一半时油缸活塞杆发生抖动。
Symptom: Bucket cylinder rod shakes when it extends out over half stroke.
故障分析：1、铲斗油缸主阀芯卡滞；
2、油缸活塞杆变形；
3、油缸活塞拉缸筒；
4、连杆装置等发生变形。
Failure analysis:
1. Bucket valve spool seized.
2. Bucket cylinder rod bended.
3. Bucket cylinder has a distortion.
4. Bucket linkage has a distortion.
故障原因：连杆装置之间，斗杆和铲斗之间活动间隙过小，造成做铲斗动作时，运
动阻力过大，造成活塞杆抖动。
Root cause of the failure: clearance among the linkage, the stick, and the bucket are too small to let the
bucket cylinder rod extends out freely which cause the cylinder rod shakes.
Clearance
is too small
排故方法：1、检查系统压力 340Kg，正常；
2、现场检查油缸没有碰撞等情况，正常；
3、检查发现摇摆部分间隙过小，动作时，有明显的受力，且拌有异响；
- 106 -
4、间隙压盘增加一块 2mm 调整垫片后，活塞杆工作正常。
Troubleshooting:
1. Measured hydraulic system pressure is 340kgf which is normal.
2. Checked and found there is not impact evidence on the bucket cylinder or the cylinder rod.
3. Checked and found the clearance in the bucket l inkage section is very s mall, and abnormal noise is
detected when the bucket is operated.
4. Insert a 2 mm s him t o ad just t he cl earance b etween the linkage a nd t he buc ket, t ested a nd pr oved
machine works normally. Problem solved.
排故体会：排除故障，可以先用眼观外表的方法，往往会事半功倍的效果。
Experience: Visual inspection is always a very important method used in the troubleshooting. You may
get twice the result and half the effort.
----提供者：龙振国 Service engineer: Long Zhen Guo
- 107 -
49、SY230 动作慢，偶尔憋车 SY230 has a long cycle time ans stalled sometime
故障现象：一台 SY230 因主阀上斗杆软管破裂后，造成液压油大量泄漏，修复后产生
个别动作偶尔慢，偶尔憋车熄车的现象。
Symptom: Hydraulic oil sprayed out after the stick cylinder hose ruptured. Machine has action slow and
engine stall occasionally after repairing the failed stick cylinder hose.
故障分析：1、考虑到之前的动作是正常，此现象只因漏油后液压系统缺油工况下机
器运转造成的，所液压系统可能是因缺油运转发生了问题；
2、影响动作慢的因素有：
主泵功率不足；主阀开口不够；系统内泄严重；
3、影响憋车熄火的因素有：
发动机功率不足；主泵功率超负荷；
4、因为是偶尔动作慢故考虑到因缺油磨损造成液压系统污染使主阀芯发
卡造成动作慢可能性最大；
5、泵功率太大造成发动机憋车。那么造成泵功率大的问题有控制器对电
磁比例阀无效；电磁比例阀问题；功率调节器内部损坏；
6、液压系统如果先导压力不正常，会造成主阀开口不足导致动作慢，同
时先导压力不足也会导致调节器中的先导压力不足造成主泵排量不能改
变，导致憋车熄火。
Troubleshooting:
1. Machine w orks nor mally before the stick c ylinder hos e r uptured. It is s uspected th at th is f ailure is
caused by machine operated with insufficient hydraulic oil.
2. Probable c ause of the slow action includes main pump insufficient power, main valve spool not
opened completely, and severe internal leakage of the hydraulic system.
3. Probable cause of engine stalls includes engine power insufficient and main pump overloaded.
4. Since the slow action failure just only occurs occasionally, it is suspected that abrasion due to lack of
- 108 -
hydraulic oil occurred and valve spool is seized occasionally by the impurity.
5. Probable cause of the engine stalls should be hydraulic pump is srized at maximum output horsepower
caused by the pump adjuster.
6. If the pilot oil pressure is lower than specification excessively, the main valve spool will not be opened
completely. Also t hat pilot oil t o the pump adjuster is too low to let pum p output nor mal horsepower.
This will cause the engine stalled.
故障原因：1、先导系统问题，因缺油时造成先导泵磨损，压力不足，先导油滤芯发
堵，压力供应不正常，先导溢流阀发卡。
2、泵调节器问题。
Probable root cause of the failure:
1. Pilot pump is worn due to lack of hydraulic oil in the former failure. Pilot relief valve is seized to the
open position or the pilot filter is blocked causes the low pilot oil pressure.
2. Pump adjuster has a malfunction.
排故方法：1、观察显示屏机器运行状况中的泵 1、泵 2 电磁比例阀电流在全动作变
化过程中，电流变化正常介于 300mA-700mA 之间。说明控制器没有问
题。
2、检查电磁比例阀绕阻线圈电阻为 18 欧母，说明电磁比例阀没有损坏。
3、更换先导油滤芯，试车半小时，未发现动作慢现象，但偶尔熄火憋车
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现象仍在。
4、更换先导泵，试车一小时，未发现憋车现象。隔天工作也未发现。
Troubleshooting:
1. Check the current to the proportional solenoid valve of bot h f ront and rear pum p. It is w ithin the
normal range 300mA – 700mA. It means that the machine controller works normally.
2. Checked and found the resistance of the proportional solenoid valve is 18 ohm which is normal.
3. Replace the pilot oil filter, tested for more than half an hour. The slow action problem solved. But the
failure of engine stall occasionally is still existed.
4. Replace the pilot pump. Tested and proved engine stall phenomena disappeared. Problem solved.
排故体会：熟悉液压原理图，先简单后复杂的排故思维不能忘。
Experience: Familiar with the hydraulic drawing and the system operation. Troubleshoot from simple to
complex step by step.
——提供者：韩晓锋 Service engineer: Han Xiao Feng
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50、SY75C 行走无力 SY75C travel operation performed poorly
故障现象：一台 SY75C，10 年新车，工作时间：42 小时，左行走无动作，右行走时
有时无且无力。
Symptom: SY75C m ade i n 2010 w ith 42 working hou rs. Left tr avel mo tor f ails to w ork a nd th e r ight
travel motor has no action intermittently.
故障分析：行走无动作，可能主压不够；先导压力异常；行走先导阀故障；马达平
衡阀卡滞；单向阀卡死；溢流阀卡滞。
Failure analysis: No travel operation may be caused by insufficient main pressure, abnormal pilot
pressure, travel pilot valve, balance valve of travel motor seized, check valve seized, relief valve seized.
排故方法：1、检查主压力正常，先导压力正常；行走马达压力只有 13MPa 左右；
2、检查先导阀、行走马达平衡阀、单向阀、溢流阀都正常。
3、检查马达內泄，起车怠速时內泄管即有液压油喷出，判断马达故障，
更换两个行走马达后正常。
Troubleshooting:
1. Measure pilot pressure and main pressure are normal.
Travel motor relief pressure is only 13Mpa.
2. Checked and found pilot valve, balance valve, check valve, and relief valve are normal.
3. Measure the case drain of the travel motor. Internal leakage oil sprayed out when engine is running at
low idle speed. It is abnormal. Replace two travel motor, tested and proved problem solved.
排故体会：要熟悉液压原理，熟悉液压元件工作原理。
Experience: Service engineer should be familiar with the hydraulic system operation and the work
principle of each component.
——提供者：王宏斌 Service engineer: Wang Hong Bin
- 111 -
51、挖机右行走不工作 Right travel motor failed to work
故障现象：左行走工作正常，右行走不工作。附带破碎锤也不能工作。
Symptom: Left travel motor works normally. Right travel motor fails to work. Hydraulic hammer fails to
work also.
故障分析：1、泵损坏；
2、主阀阀芯发卡；
3、压力传感器损坏。
Failure analysis:
1. Main hydraulic pump failed.
2. Main control valve spool seized.
3. Pressure sensor failed.
故障原因：1、首先检查显示屏参数，看各传感器工作是否正常；
2、检查主泵的工作压力是否正常；
3、检查主阀是否有阀芯发卡现象。
Probable cause of failure:
1. Sensor is abnormal.
2. Main pump output pressure is abnormal.
3. Main valve spool seized.
排故方法：1、踩下右行走脚踏阀，观察显示屏，发现后泵的主压力不能升到正常值，
感觉油路上有东西堵。
2、反复操纵脚踏阀前进后退，突然右行走恢复正常。在右行走恢复正常
的同时，发现破碎锤没有反应了。
- 112 -
3、考虑到主阀阀芯发卡。拆下破碎锤阀芯阀盖，发现该阀芯已被卡死，
不能动。把阀芯拿出来的同时发现阀芯上有 O 型圈颗粒，卡在阀芯内。
4、查 O 型圈是怎么进入阀芯内的，拆开吸油滤芯发现吸油滤下的大 O 型
圈不见。说明是该 O 型圈进入系统。另外发现回油滤、吸油滤上都有
明显的橡胶粉沫。
5、更换所有液压油滤芯、更换液压油整车工作恢复正常。
Troubleshooting:
1. Operate th e r ight tr avel p ilot v alve to th e f ull s troke. Checked and f ound t he r ear pum p pr essure
displayed i n the monitor is lo wer th an s pecification. It s eems t here i s i mpurity bl ocked i n t he r ight
travel circuit.
2. Operate the right travel pilot valve back and forth repeatly. It is found that the right travel action is
restored suddenly. At the same time the hydraulic hammer fails to work.
3. Checked a nd f ound t he hammer m ain va lve s pool i s s eized i n t he m ain control va lve. Remove t he
hammder valve spool and found debris of o-ring seal on the valve spool.
4. Checked and found the o-ring seal at the bottom of the suction screen disappeared. It means this seal
is failed and enters into the hydraulic system. Further research found the debris of o-ring seal on the
return oil filter.
5. Replace all the filters of the hydraulic system. Replace the hydraulic oil. Tested and proved machine
works normally. Problem solved.
排故体会：提醒广大的售后服务人员，挖机保养很重要。一定要认真仔细，一定要全
面检查。
Experience: Kindly remind all the service engineers to pay more attention to the excavator maintenance.
It should be carried out carefully and inspect completely.
——提供者：王超 Service engineer: Wang Chao
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52、SY210C 铲斗动作慢并且挖掘无力 Bucket operation is poor and failed to load
故障现象：装备工作时铲斗挖土无力，铲斗收回后会自动下落。
Symptom: Bucket in operation is failed. Bucket drops automatically when pilot valve is not operated.
故障分析：1.溢流压力，后泵只有200K，低于正常溢流压力330K，根据故障现象，
初步判断铲斗动作回路有内泄现象，问题可能出在铲斗阀芯、过载溢流
阀或铲斗油缸。
2、将铲斗阀芯拔出检查，没有发现异常；再将过载溢流阀与其它回路的
过载溢流阀互换后试车，故障依然存在，说明与其无关。
3、检查回油滤芯发现有非金属杂质，于是拆检铲斗油缸，发现铲斗油缸
活塞油封破损，从而导致上述故障。
Failure analysis:
1. Measured t he rear pum p relief pressure i s 200k gf which i s l ower t han s pecified 330k gf. S usptected
the bucket circuit has internal leakage caused by bucket valve spool, line relief valve or cylinder.
2. Checked and found the bucket valve spool is normal. Interchange the line relief valve with the one of
other circuits, checked and found the problem still existed. Line relief valve has no failure.
3. Checked and found the nonmetal impurity in the return oil filter. Dismantle the bucket cylinder and
found the cylinder seal is damaged.
故障原因：铲斗油缸油封破损后，压力内泄，导致装备工作时铲斗挖土无力，斗收
回后会自动下落。
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Root cause of the failure: Seals of bucket cylinder are failed. Severe internal leakage occurred. Bucket in
operation is failed and bucket drops automatically when after stick in operation.
排故方法：更换油封后试车正常。
Troubleshooting: Repalce the bucket seals, tested and proved problem solved.
排故体会：按照 SY210C 液压原理图逐步分析，排除每一个环节点是否正常。

Experience: Analysis according to the SY210C hydraulic schematic, figure out t he root cause of the
failure as per the road sign.
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53、动作无力缓慢 Machine has a long cycle time
故障现象：一台 SY235-8 挖机动作缓慢无力。

Symptom: SY235-8 excavator has a long cycle time and insufficient power.
故障分析：根据挖机动作缓慢无力，但发动机转速正常这一现象，基本可以排除发
动机及柴油油路的问题，主要考虑电气及液压方面的故障:
1、主泵磨损，造成系统压力低；
2、主溢流阀卡滞、损坏或磨损严重，造成各液压系统压力偏低；
3、先导压力低；
4、比例电磁阀故障、主压传感器故障、线路故障；
5、控制器故障。
Failure analysis: Since the engine speed is normal, no need to suspect engine or fuel system. We should
care about the electrical and hydraulic system.
1. Main pump is worn and caused the low system pressure.
2. Main relief valve is seized, worn or damaged which cause the low system pressure.
3. Pilot oil pressure is lower than specification.
4. Malfunctions of proportional solenoid valve, pump outpur pressure sensor or electric circuits.
5. Machine controller has malfunction.
故障原因：先导泵磨损,造成先导压力低，从而使整机动作慢。
Root cause of failure: Pilot pump is worn causes the low pilot oil pressure and machine slow action.
Pilot pump
Pilot relief valve

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排故方法：1、进入显示屏内部菜单查看各模式下发动机转速分别为：H=2220; S=2110;
L=1920; A/I=1300 通过以上数据说明发动机转速正常，可以排除发动机
转速与泵的功率不匹配的故障。
2、通过监控器查看系统压力为34MPa，可以排除主泵、主溢流阀的故障；
3、主泵比例电磁阀电流值在操作手柄中立时电流为350mA，全程操作手柄
时电流为750mA，故可以排除主泵比例电磁阀电流值的故障。
4、先导压力传感器反馈电压值是否在标准范围内（0.5—4.5V）。检测各先
导压力传感器，在操作手柄中位时电压为0.5V,全程操作手柄时电压为
3.2V，证明故障点为先导压力过低；
5、调整先导压力后，故障依旧，更换先导泵后故障解决。
Troubleshooting:
1. Checked and found engine speed is normal at each working mode. Engine is not suspected.
2. Measured hydraulic system pressure is 34Mpa. Main pump and main relief valve are not suspected.
3. Measured current to the pump solenoid is 350mA when all the pilot valves are in neutral position and
750mA when pilot valve is operated. It is normal.
4. Measure voltage of the pilot pressure sensor is 0.5V when pilot valve is in neutral. And 3.2V when the
pilot valve is at full stroke which is lower than specified 4.5V. It means pilot pressure is lower than
specification.
5. Adjust the pilot pressure, problem still existed. Replace the pilot pump, problem solved.
排故体会：当出现正流量动作缓慢的故障时，通常要检查完发动机转速后，再作其
它检查。先导压力传感器的输入电压正常时,要检查反馈电压是否正常。
Experience: Troubleshooting on the failure of long cycle time should be started from checking engine
speed, and then other inspection. If the power voltage of the pilot sensors is correct, the signal voltage of
the pilot sensors should be checked.
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54、SY230C6B 热机时出现抖动 Vibrates excessively after the machine is warmed up
故障现象： SY230C6B挖机热机时出现抖动。
Symptom: SY230C6B vibrates after the machine is warmed up.
故障分析：1、热机时抖动说明与油温有关系（液压油温、水温）；
2、热机时检查发动机转速是否正常；
Rear pum p proportional
3、更改为液控后检查是否还出现抖现象； solenoid valve
4、是否所有动作都抖动；
5、是否各节流阀卡滞；
Front pump PSV
6、液压油温度传感器故障；
7、电控转液控故障现象是否消除。
8、KCM控制器正常；
Failure analysis:
1. Failure is relative to the temperature, such as hydraulic oil temperature and coolant temperature.
2. Whether the engine speed is normal after the machine is warm up.
3. Does the machine vibrate under the hydraulic control mode?
4. Does the machine vibrate during all the actions?
5. Is there orifice or throttle valve choked?
6. Hydraulic oil temperature sensor is failed or not.
7. Does the failure phenomenon disappear when the pump is under hydraulic control mode?
8. Is the KCM controller normal?
故障原因：前后泵电磁比例阀O型圈损坏。
Root cause of the failure: O-ring seal of both the front and rear pump
proportional solenoid is damaged.
Location of
the O-ring seal
- 118 -
排故方法：1、热机时检查发动机转速正常；
2、检查液压油温度传感器正常；（模拟电阻2K）
3、电比例阀电流正常，S模式10档憋车470mA；
4、检查传感器电压信号正常；
5、将电控改液控后抖动故障现象消除；
6、拆下电比例阀阀芯,发现阀芯O型圈损坏；
7、更换O型圈,抖动现象消除。
Troubleshooting:
1. Checked and found the engine speed after machine is warmed up is normal.
2. Checked and found the hydraulic oil temperature sensor is normal.
3. Current to the proportional solenoid valve is normal. It is 470mA at 10th dial position under S mode.
4. Checked and found the sensor voltage is normal.
5. Tested and found machine does not vibrate when the hydraulic pump is under hydraulic ctrl mode.
6. Remove the proportional solenoid valve and find its o-ring seal is damaged.
7. Replace the failed o-ring seal, tested and proved machine works normal. Problem solved.
排故体会：电磁比例阀O型圈损坏，热机时，液压油温度高，液压油变稀，导致内
泄大。
Experience: After the machine is warmed up, the hydraulic oil temperature is high and oil viscosity
decreased. If the o-ring seal of the proportional solenoid valve is damaged. Internal leakage is much more
severe.
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55、左侧履带不能行走 Left track can not travel
故障现象：一台 SY330 负流量挖机左边履带前后均不能行走，右边履带行走以及其它
动作都正常。
Symptom: An NFC excavator SY330, has the failure of left track can not travel. Right track and all other
actions are normal.
故障分析：查看行走管路是否有漏油严重的地方，造成履带单边不能行走，一般为行
走马达故障或减速器故障。
Failure analysis: Check if there is severe oil leakage in the travel circuit. Usually, the root cause of one
track fails to work is the travel motor or final drive failed.
故障原因：1、左边行走先导管路故障；
2、左边行走先导脚踏阀故障；
3、左边行走马达故障；
4、左边行走马达减速器故障。
1. Pilot circuit of the left travel has failure occurred.
2. Pilot valve of the left travel has failure occurred.
3. Left travel motor is failed.
4. Left final drive is failed.
排故方法：1、检查左边行走先导管路是否松动造成漏油严重或油管脱落；
2、将行走脚踏阀左右先导管路交换，启机后操作行走排除先导脚踏阀
故障；
3、用挖机铲斗侧方向将左边履带顶起，单独操作左边行走动作，查看
行走马达有无异常响声，如有则表示行走马达不正常；
4、根据第 3 点判定，马达正常且有联接轴转动的声音。判定为马达减
速机故障，打开减速机外壳，查看行星齿轮，判定减速机故障；
- 120 -
5、更换行星架、行星齿、减速齿及太阳齿后试机正常。
Metal debris from the grear New gear group installed.
Troubleshooting:
1. Checked found pilot circuit of the left travel has no oil leakage and tightened properly.
2. Interchange the left travel pilot hose with the right travel pilot hose. Tested and proved problem still
existed. It means the pilot valve has no failure.
3. Swing the machine to put the bucket to the left side of the machine and jack up the left track. Push the
left t ravel pi lot va lve t o c heck w hether t he l eft t ravel m otor ha s a bnormal noi se or not . If t here is
abnormal noise from the left travel motor, the left travel motor should be suspected.
4. Tested and found the left motor is normal and the running sound of the motor output shaft can be
detected. Now the final drive is suspected. Dismantle the final drive, a large amount of metal chip can
be found and gears are damaged.
5. Replace the failed gears and related parts, tested and proved left track travels normally. Problem
solved.
排故体会：根据客户反映的情况检查, 认真对待每个细节, 想到可能发生的一切。
Experience: According to the failure phenomena the customer complained, take care to each details, list
out each probable cause of the failure, and then troubleshoot step by step.
- 121 -
56、发动机无法启动 Engine can not be started
故障现象：设备无法正常启动。
Symptom: Machine can not be started normally.
故障分析：1、检查电瓶电压是否正常；
2、检查燃油箱、滤芯是否堵塞；
3、检查各燃油管堵塞或泄露；
4、检查启动机是否工作正常；
5、分开主泵和发动机,看发动机能否启动,如能启动,说明发动机本身一
切正常,而是液压起动时带负荷。
1. Battery voltage is normal or not.
2. Check the fuel tank and the fuel filter to see whether the fuel is blocked or not.
3. Check the fuel circuit for fuel hose collapse or fuel leakage.
4. Starting motor works normally or not.
5. Separate the main pump from the engine to see whether the engine can be started or not. If the engine
can be started, it means there is heavy hydraulic load during the engine cranking.
故障原因：前泵斜盘及伺服活塞发卡。
Root cause of the failure: Swashplate and servo piston of the front pump is seized.
Clean the valve spool to make it move freely. Install the yoke properly to fix with the piston
- 122 -
Plugers Swashplate
排故方法：1、检查电瓶电压 24V 正常；
2、检查燃油箱，更换燃油滤芯；
3、燃油管无堵塞和泄露；
4、分开主泵和发动机, 起动发动机,能起动证明发动机本身一切正常,可
以推断是由于起动时负荷过高；
5、分解主泵,检查发现主泵斜盘及伺服活塞有发卡现象；
6、清洗伺服阀芯，更换损坏件，试车正常。
Troubleshooting:
1. Checked and found the battery voltage is 24V which is normal.
2. Inspect the fuel tank and replace the fuel filter.
3. Fuel circuit is normal. No collapse and no fuel leakage.
4. Separate hydraulic pump from the engine, engine can be started normally. It is suspected that engine
take a heavy load during cranking.
5. Dismantle the main pump, it is found that the servo piston and the swashplate are seized.
6. Clean the servo valve, replace the failed parts, tested and proved engine can be started normally.
Problem solved.
排故体会：针对故障现象的特点，应仔细分析，一一排除。
Experience: Troubleshoot carefully as per the fault phenomena. Figure out the root cause step by step.
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57、SY215C8M 回转无力 Swing operation is poor
故障现象：一台加装破碎锤的 SY215C8M 在使用 2000 小时后出现回转无力现象，其他
正常。
Symptom: SY215C8M hydraulic hammer with 2000H working hours, has the failure of poor swing
operation, other actions are normal.
故障分析：1、泵 1 出现内泄增加或调节器故障时都会出现回转无力；
2、回转先导压力传感器或线路故障；
3、回转马达故障；
4、回转控制阀芯不到位或阀芯断裂。
Failure analysis:
1. If the front pump has severe internal leakage or its adjuster is failed, swing operation will be poor.
2. Swing pilot pressure sensor or its circuit has a failure occurred.
3. Swing motor is failed.
4. Swing valve spool is abnormal.
故障原因：回转马达柱塞及配流盘磨损严重。
Root cause of the failure: Plungers and the port plate are worn severely.
排故方法：1、启动机器，操作其他动作都正常，尤其是左侧单边行走也正常，可排
除泵 1 或其调节器故障；
2、操作回转，由显示屏观察回转信号指示正常，可排除回转压力传感器
或其线路故障；
3、拆出回转阀芯，发现阀芯无卡制或断裂故障。
4、拆解回转马达，发现柱塞及配流盘磨损比较严重，造成回转马达内泄
较大。更换相应配件后，故障排除。
- 124 -
Port plate is worn Swing motor
Troubleshooting:
1. Tested and found the left side operations are all normal, especially the left travel. It means the front
pump and its adjuster work normally.
2. Check the parameters of the swing pilot pressure sensor in the monitor and found they are normal.
Swing pilot pressure sensor should not be suspected.
3. Checked and found the swing valve spool is not seized, it is normal.
4. Dismantle the swing motor, it is found that the port plate and the plungers are worn severely which
cause the severe internal leakage.
5. Replace the failed parts to rebuid the swing motor, tested and proved problem solved.
排故心得：由于客户加装破碎锤，造成液压油污染及老化都比较快，更需要及时维
护保养，以免造成液压元件的异常磨损。
Experience: Since the hydraulic hammer is installed by the end user, hydraulic oil and hydraulic filters
have a shorten maintenance interval. End user should do the maintenance timely to prevent the abnormal
wear.
----提供者：李宏伟 Service engineer: Li Hong Wei
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58、泵输出压力不稳定 Pump output pressure is unstable
故障现象：一台 SY65C 挖掘机，Rexroth 系统。泵震动较大，压力输出不稳定。发动
机转速正常。挖掘机做任何动作时均出现上述症状。
Symptom: SY65C excavator with Rexroth hydraulic system, vibrates excessively. When any operation is
performed, it is found that engine speed is normal while the pump output pressure is unstable.
故障分析：由装配工艺和液压原理图分析：
1、主泵和发动机联接问题，主泵发动机同心度超出公差，产生振动。
2、是否软管产生扭曲，管路较长且未安装管卡。
3、溢流阀是否磨损，造成压力不稳定，产生振动。
4、油液中是否有空气，产生气蚀。
5、油液污染严重，造成异响、振动、压力不稳定。
6、主泵问题。
Failure analysis:
1. Pump is not aligned with the crankshaft, which cause the vibration.
2. Hose is twisted or a long hose installed without clamps to support.
3. Main relief valve is abnormal.
4. Air enters into the hydraulic oil.
5. Hydraulic oil is contaminated severely.
6. Main pump works abnormally.
故障原因：主泵问题。
Root cause of the failure: Main pump failure.
排故方法：1、首先检查主泵主轴安装同心度及联轴器，均无问题。也无软管过长和
严重扭曲的现象。用替代法加装新溢流阀，排除溢流阀故障。打开油
箱检查，采取油样品检查，也未发生有油污染严重超标。同时油箱内
只有微量气泡，用手摸高压管路，也无气蚀造成的气泡爆裂的不规则
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爆裂振动。最后将故障元件定位于主泵。
2、拆检主泵，检查内部元件，发现内部元件只有缸体配油盘有较明显磨
损，更换缸体配油盘，装配上去后，故障现象仍存在。
3、检查调节螺钉，未发生调动现象。故将问题定位于调节弹簧和阻尼孔。
发现阻尼孔堵塞，将阻尼孔清洗疏通后，故障仍不能排除。
4、用替代法分别检查各弹簧，发现更换压力切断阀弹簧后故障排除。
Troubleshooting:
1. Checked and f ound e ngine i s a ligned w ith the hydraulic pum p p roperly. The coupling be tween the
hydraulic pump and the engine is normal. Hoses are supported properly. Main relief valve is also ok
by using method of interchange. No proof of hydraulic oil contamination can be found. Touching the
main oil hose with hand, and no irregular air blast feeling can be detected. Main hydraulic pump is
suspected.
2. Dismantle the main hydraulic pump, it is found that port plate is worn obviously. Replace the failed
port plate, tested and found the pump output pressure is still unstable.
3. Checked and found the adjusting screw is not adjusted. Orifice hole is plugged. Clean the orifice but
the problem still existed.
4. Interchange the spring of pressure cut valve, tested and proved problem solved.
排故体会：排故时，最常使用的方法即为替代法和排除法，本次排故优先使用排除
法，并结合替代法进行排除，多种方法合理结合，以便达到更快的排故
速度。
Experience: Interchange and elimination are the methods used most frequently in the troubleshooting. In
this failure case, elimination method is used priority. Of course, interchange method is combined to figure
out the root cause of the failure.
——排故者：墨凯 Service engineer: Mo Kai
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59、单边行走无力，单独回转无力 One track travel/Swing performs poorly
故障现象：一台 SY205C8M 挖掘机，平地单独左行走或右行走无力，单独回转也无
力, 以上三种工况显示器显示压力只有 100bar 左右。其他动作及全部复
合动作均正常,复合动作时压力均正常为 350bar。
Symptom: SY205C8M has a poor performance during the single task operation of swing, left track travel,
and the right travel. The pressure displayed in the monitor is only 100bar. Other single task operation
a nd c ombined ope rations are nor mal. Oil pr essure i s 350ba r w hen t he combined operation is carried out.
故障分析：由故障现象推断主溢流阀、主泵、行走回转马达均无问题。将问题定位
在主阀上。由液压原理图分析：
1、在单独左行走时主阀上 P1 口进入高压油后，在流入左行走换向阀
前，分为四道油路，经过 TS 阀油路和经过 LCs 的和 LCa1 的分油
路均为截止油路。故分析故障油路可能为通过 CMR1 单向阀油路
（油路流经 CMR1 后分为截止于单向阀 CMR2 和通过主溢流 MR
两条油路）和截止于 Csp 单向阀的油路。
2、假若 CMR2 或 Csp 两单向阀坏损的情况，符合单独左行走和单独回
转无力的故障现象。
3、同理分析单独右行走时行走无力，后泵单独供油，此时如若 CMR1
坏损，逆向思维分析符合右行走无力。
Troubleshooting: Since the combined operations are normal, main relief valve, main pump, swing motor,
and travel motors should not be suspected. It is suspected the main valve has malfunction.
1. In single task operation of left travel, main oil divided into four branchs.
A. Oil supplied to swing motor pass through Ts and LCs valve is blocked.
B. Oil supplied to stick 1 valve pass through Ts and LCa1 is blocked.
C. Oil returns to tank through Csp check valve boom 2 valve.
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D. Oil goes through CMR1 check valve to the main relief valve. This oil has another circuit which
could go through CMR2 check valve and then goes to oil tank through rear pump circuit.
2. In the four oil branchs of the front pump, if the check valve Csp or CMR2 has malfunction, part of
pressure oil will return to the oil t ank and cause single track traveling or swing operation a poor
performance.
3. As the single right track travels poorly, the Csp or CMR1 check valve is suspected.
故障原因：CMR1、CMR2 两单向阀磨损。
Root cause of the failure: CMR1 and CMR2 check valve are worn.
排故方法：拆检 CMR1、CMR2 和 Csp3 单向阀，发现 CMR1 和 CMR2 均有较严重
的磨损，Csp 单向阀无异常。更换两新单向阀后故障排除。
Troubleshooting: Remove t he C MR1, C MR2 and C sp check valve. It i s found t hat C MR1 and CMR2
check valves are worn severely. Replace the failed two check valve, tested and proved problem solved.
排故体会：理论和实践相结合，用理论指导实践，用实践验证并丰富理论。
Experience: Grasp the system operation expertly and use it in the troubleshooting. At the same time get a
further understanding of the system operation.
——排故者：墨凯 Service engineer: Mo Kai
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60、高速行走严重跑偏 High speed travel has an excessive offset
故障现象：一台 SY205C8M 挖掘机，低速行走时一切正常。高速时前进后退均向左
严重跑偏。检查压力显示在高速行驶时，主泵前泵压力只有 250bar 左右。
不能达到规定的 350bar。后泵压力正常。单独左行走高速变化也达不到
规定速度，且左行走马达发热。
Failure phenomena: SY215C8M travels normally at low speed. Both the forward and backward travel at
high s peed, m achine h as an ex cessive offset. Measured at hi gh s peed t ravel, t he front pum p pressure i s
250bar which is lower than the specification and the rear pump pressure is 350bar which is normal. Travel
speed is lower than specification when only the left track is travelling. Left travel motor is hot.
故障分析：由故障现象推断主溢流阀、主泵、主阀均无问题。将问题定位在左行走
马达和中央回转接头上。
1、马达刹车片有些许接触，造成较大的发热损失，造成高速行走速度降
低和输出功率降低。
2、控制高低速的直接控制机构即为变量活塞，分析直接原因，即变量活
塞变量不到位，拆检发现变量活塞配合公差因磨损的原因超出设定公
差，形成较大的配合间隙，造成泄漏。
Failure analysis: As per the phenomena describe, main pump, main valve, and main relief are normal.
Swivel joint and travel motor should be suspected.
1. Travel brake is not release completely. Motor become hotter and travel speed decreased.
2. High / Low speed servo piston is worn which makes the swashplate can not be shift to the high speed
travel completely.
故障原因：变量活塞阀芯和阀套因磨损造成配合间隙过大。
Root cause of the failure: High / Low speed servo piston is worn and causing internal leakage.
排故方法：据统计液压故障中有 75%的液压故障是由于油液污染造成，产生本故障
的原因可能是由于高低速变化较频繁，且变量活塞内有清洁度不达标，
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造成变量活塞过快磨损。拆检变量活塞，发现阀芯磨损较严重，阀套有
轻微磨损，且有黑色污染油滴少许，清洗阀套，更换新阀芯，测量配合
间隙略有增大，但仍在规定范围内，装配后试车故障排除。
Troubleshooting: According to the statistic data, more t han 7 5% o f hydraulic f ailure is caused by the
contamination of the hydraulic oil. In t his f ailure c ase, servo piston is worn due to contraminated oil.
Dismantle the servo piston and found that the piston is worn severely. Replace the failed parts, replace the
hydraulic filters and hydraulic oil, tested and proved problem solved.
排故体会：此次排故完全依靠表面现象和理论分析图纸，分析时要将问题先定位
于几个故障的大方向，但故障现象可能为多元件故障累计造成，分析思路
须明确。
Experience: Do the troubleshooting according to the failure phenomena and the system operation. List all
probable cause of the failure. Troubleshoot step by step to figure out the root cause clearly.
—
—排故者：墨凯 Service engineer: Mo Kai
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61、SY215C8 机斗杆掉臂 SY215C8 stick drops severely
故障现象：斗杆油缸掉臂，30 分钟内斗杆活塞杆下掉约 8 厘米。

Symptom: Stick cylinder has an excessive drift, about 8 cm within half an hour.
故障分析：1、因斗杆工作油路中在斗杆主阀芯前安装有防下降保持阀，只要斗杆保
持阀正常的话，就能将回油在保持阀处堵住，因此不要考虑主阀芯原
因引起的斗杆掉臂。
2、按液压原理图分析，引起斗杆掉臂的原因有：A 斗杆活塞头上导向密
封环磨损内泄；B 斗杆保持阀泄露；C 斗杆过载安全阀（油口溢流阀）
泄露；D 斗杆补油单向阀泄露。
Troubleshooting:
1. As the cylinder drift is measured when the machine is shut down. Stick drop has nothing to do with
the main relief valve.
2. As per the hydraulic drawing of SY215C8, probable cause of the failure is listed below:
A. Seal ring of the stick cylinder is worn which cause the internal leakage.
B. Stick holding valve has internal leakage.
C. Line relief valve of the stick circuit.
D. Makeup check valve of the stick circuit has internal leakage.
故障原因：斗杆过载安全阀密封上有油垢，由于密封不严引起内泄，致使斗杆掉臂。
Root cause o f t he failure: Impurity i s found on t he s eal o f t he s tick l ine relief valve, which c ause t he
internal leakage and the excessive stick drift.
排故方法：1、检查斗杆油缸是否有内泄：将斗杆油缸活塞杆全部伸出，拆下斗杆油
缸有杆腔端进油管，将进油端油口封住，启机后做斗杆挖掘溢流动作，
如有油可判断是斗杆油缸内密封环内泄，无油则斗杆油缸正常。经检
查斗杆油缸工作正常。
2、检查斗杆保持阀：检查保持阀无磨损现象，清洗
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或更换斗杆保持阀，不能排除掉臂故障，可排除保持阀原因。
3、检查发现斗杆补油单向阀无磨损现象，排除补油单向阀故障原因。
4、检查斗杆过载安全阀：检查发现过载安全阀芯密封接触面上一圈液压
油污垢，有少许杂物，将安全阀清洗干净后试机，斗杆油缸无掉臂现象，
故障排除。
Troubleshooting:
1. Check the internal leakage of the stick cylinder. Extends the stick c ylinder rod completely. Remove
the inlet oil hose of the stick cylinder rod end. Start engine and perform stick in operation. If oil leaks
out from the open port, stick cylinder has internal leakage. Or vice versa.
2. Checked and found the stick holding valve spool is normal. It is not worn.
3. Checked and found the check valve of the stick circuit is not worn. It is normal.
4. Remove the stick line relief valve. It is found that impurity on t he o-ring seal of the line relief valve.
Clean the line relief valve and replace its o-ring seal. Tested and proved problem solved.
排故体会：根据液压原理图和部件工作原理来分析故障原因，再加以逐步排除法，
能比较快速的找出故障原因。
Experience: Grasp the hydraulic drawing and system operation to do the troubleshooting. Using th e
elimination method can figure out root cause of the failure quickly.
——提供者：严旭强 Service engineer: Yan Xu Qiang
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62、SY215 回转无刹车 Swing operation is hard to stop
故障现象：右回转启动较迟缓，左回转先导阀停止操作时，约7秒旋转停止。
Symptom: Left swing stops 7 seconds after pilot valve returns to neutral. Right swing has a late response
when the operation is started.
故障分析：根据现象,可以确定故障定位在回转马达刹车制动部分。
Failure analysis: as per the failure phenomena, swing brake control valve is suspected.
故障原因: 经拆卸左旋转先导油路，发现信号控制阀上阻尼阀截流口堵塞；经过处
理阻尼阀的截流孔，后重新安装，试机后恢复正常。
Root cause of the failure: orifice in swing pilot circuit is blocked. Clean the orifice, problem solved.
排故方法：1、调换左右回转先导管，无变化；调换左右回转溢流阀，无变化；
2、左、右旋转，先导压力35KG，主泵压力350KG；右旋转先导阀停止操
作时，先导压力、主泵压力立即为0；左旋转先导阀停止操作时，先
导压力、主泵压力缓慢下降，约7秒为0。
Troubleshooting:
1. Interchange left swing pilot hose with righ swing. Problem still exist. Interchange the left swing line
relief valve with the right swing. Problem still exist.
2. Pilot pr essure of l eft a nd r ight s wing i s 35k gf and m ain pr essure i s 350kgf. When righ s wing pi lot
valve returns to neutral, both main and pilot pressure drop to 0. When left swing pilot valve returns to
neutral, both pilot and main pressure drops to 0 slowly, about 7 seconds later.
排故体会：不管故障大小，都要认真检查排故。
Experience: Whether the failure is hard or not, do the troubleshooting carefully.
—— 提供者：合肥湘元 Dealer: He Fei Xiang Yuan
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63、行走阀杆回中位后，左行走停不下来 Pilot valve in neutral, left travel can not be stopped
故障现象：一台SY360-8挖掘机，同时操作两行走阀杆回中位后，左行走仍继续缓慢
行走，如加任何一复合动作或将档位降至4档以下，左行走即停止。此时先
导脚踏阀回到中位检查后泵压力在85bar左右，其他动作正常。
Symptom: SY360-8 excavator has the failure of left track can not stop when two travel pilot valves
returns to the neutral position. If any of other operation is combined, both the left and the right track will
stop immediately once the pilot valve returns to the neutral position. Rear pump pressure is 85bar when
travel pilot valve is in neutral. Other actions are normal.
故障分析：因为操纵阀回中位后，左行走仍然继续行走；
1、液压方面：
（1）可能有先导压力推开左行走主阀芯移动；
（2）先导单向节流阀是否堵塞；
（3）左行走主阀芯是否发卡；
（4）主阀是否内泄。
(5)液压泵流量调节机构故障。
2、电气方面：电磁阀线圈短路断路故障，自主控制器流量控制电流过小使
液压泵流量增大故障，导线有断路故障。
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Failure analysis: Left track continue to travel when the left travel pilot valve returns to neutral:
1. Hydraulic aspects:
A. There is pilot pressure oil acts on the left travel valve spool.
B. Orifice in the pilot circuit is blocked.
C. Left travel valve spool is seized and can not return to the neutral position.
D. Left travel valve spool has internal leakage.
E. Pump adjuster has malfunction
2. Electric aspects: Solenoid coil has malfunction which cause the cu rrent to the proportional solenoid
valve is the minmum and the pump output flow is the maximum.
故障原因：由于液压油脏后泵调节器内部阀芯有卡带现象，使后泵流
量增大，由于流量的增大左行走阀芯弹簧无法使阀芯完全推回原位，使
得有少量液压油通过左行走阀芯供给左行马达形成回路缓慢旋转。
Root cause of the failure: Metal chip in the hydraulic oil cause the valve spool of pump adjuster seized.
Pump out put oi l f low i ncreased w hich m akes t he left t ravel va lve s pool f ailed t o pus h t he v alve s pool
back to neutral position timely.
排故方法：1、检查电磁阀电阻在 17.5Ω--正常；
2、检查控制器输出电流--正常；
3、用万能表检查电磁阀导线 702,703--无故障；
4、检查左行走阀芯无卡带下沉磨损现象；
5、将先导锁打到关闭状态拆卸左行走先导管路无油流出；
6、加上其他动作或转速下降左行走停止，故判断控制阀无内泄现象；
7、将行走截流阀拆解无发现堵塞情况，将脚塌阀两行走先导管进行互换
故障依旧；
8、将转速降至 4 档以下左行走停止检查后泵压力时发现压力在 85bar 左
右，而正常压力在 40bar，判断不正常.
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9、将主泵调节器互换后左行走工作正常，判断调节器有故障，将调节器
分解清洗安装后行走工作正常。
Troubleshooting:
1. Measured resistance of the solenoid is 17.5 ohm which is normal.
2. Current output from the controller is normal
3. Wire 702 and wire 703 of the solenoid have no circuit problem.
4. Checked and found the left travel valve spool has no wear and seizure phenomena. It is normal.
5. Push the hydraulic activation control lever to the lock position. Remove the pilot hose of left travel
and found no pilot oil flows out.
6. Combined w ith a ny ot her ope ration, bot h t he l eft a nd r ight t ravel s tops onc e t he t ravel pi lot va lves
return to the neutral position. It means the travel valve spool has no internal leakage.
7. Checked and found the orifice in the travel pilot circuit is not blocked. Interchange the left travel pilot
hose with the right travel pilot hose, but the problem still existed.
8. Put the throttle position lower than 4 th, measured rear pump pressure when the left travel stopped is
85bar which is higher than specified 40bar. It is abnormal.
9. Interchange t he a djuster of t he f ront pum p a nd rear pum p. Tested a nd proved left t ravel is nor mal.
While the right travel has the former failure of the left travel. Clean t he pump a djuster, replace the
failed parts, tested and proved problem solved.
现象的全部因素考虑进去，并由简单到复杂逐一排除。
Experience: Consider all the aspects of the failure, listed out the probable cause of the failure, and then
troubleshoot step by step and from simple to conflex.
——提供者：时宏国 Servcie engineer: Shi Hong Guo
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64、发动机正常熄火次日不着车 Engine is shutoff normally, can’t be started next day
故障现象: 一台SY200 挖掘机工作 3000 小时，工作正常熄火后第二天发动机无法着
车，发动机有灰色烟排出，启动机器吃力，感觉小臂有轻微抬起动作。
Symptom: SY200 with 3000 working hours, is shutdown normally but can not be started next day.
During the cranking, grey smoke emits out and the stick has a slight action.
故障分析：
1、发动机有灰色烟排出证明供油系统正常；
2、小臂有轻微抬起动作应该是小臂控制阀杆Ⅰ或Ⅱ没有回到中位，发动机负
载过大所致；
3 、小臂阀杆卡滞应是液压油脏所致。
Stick 1
valve
Failure analysis:
1. Engine emits grey smoke during the cranking, it means fuel supply is normal.
2. Stick has a slight action, it means the stick valve spool is not in neutral position. Engine is overloaded.
3. Root cause of the stick valve spool seized should be the hydraulic oil contaminated.
排故过程：
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1、抽出小臂阀杆Ⅱ，清洗，后试机，故障现象依旧；
2、抽出小臂阀杆Ⅰ，清洗，后试机，可以正常启机，故障排除；
3、但是小臂自落严重；
4、拆出液压油回油滤芯观察，有大量的铁屑胶木屑，初步分析原因应该为小
臂油缸活塞的密封圈损坏所致；
5、更换油缸密封并更换液压油及液压油吸油滤芯，回油滤芯、先导滤芯后正
常。
Troubleshooting:
1. Pull out stick 2 valve spool and clean it, tested and proved problem still existed.
2. Pull out stick 1 valve spool and clean it, tested and proved engine can be started. Problem solved.
3. But the stick drops severely.
4. Checked and found there are a large amount of metal chip and rubber chip in the return oil filter. It is
suspected that stick cylinder seals is damaged.
5. Replace the failed seals, hydraulic oil, all the hydraulic filters, tested and proved problem solved.
排故体会：排故要注意先易后难，循序排除，讲究方式方法，遵循故障发生的规律，
多了解车辆的工作原理，而后为之，就没有排除不了的故障。
Experience: Troubleshoot f rom easy t o difficult and step by step. Using the correct method, along t he
road sign and understand the system operation well to figure out the root cause of the failure.
---提供者：宋红星 Service engineer: Song Hong Xing
- 139 -
65、手柄回中位后，动臂仍缓慢上升 Pilot valve returns to neutral, boom up continued
故障现象：一台 SY210 挖机工作中，动臂提升操纵手柄回到中位后，动臂仍缓慢自动
上升，直到提升行程到达末端后才停止，其它动作均正常。
Symptom: SY210 boom up a utomatically until the full stroke after the pilot valve returns to the neutral
position. Other operations are normal.
故障分析：可以从主油路和先导油路方面分析:
1、主油路方面：因为手柄回中位后，动臂仍然自动上升，证明主泵有负载，
仍有主油路通过主阀到执行元件（动臂油缸）：
1、动臂主阀芯Ⅰ仍然处在开启位置；
2、动臂主阀芯Ⅱ仍然处在开启位置；
3、主阀内部窜油。
二、先导油路方面：因为手柄回中位后，动臂仍然自动上升，证明仍然有先
导油推开主阀芯： Check valve & orifice
1、液压先导手柄阀芯发卡；
2、液压先导手柄阀内泄；
3、先导油路上单向节流阀发
- 140 -
卡或堵塞导致主阀芯回位过慢，从而仍有动力油至油缸。
Failure analysis: maybe pilot system or main hydraulic oil system has malfunction.
1. Main oil circuit: Boom up automatically after boom pilot valve returns to neutral position. It means
still has main oil enters into boom cylinder.
A. Boom 1 valve spool not return to neutral position.
B. Boom 2 valve spool not return to neutral position.
C. Internal leakage occurred withing the main valve spool.
2. Pilot circuit: Boom up a utomatically after boom pilot valve returns to neutral position. It means still
has pilot oil to push the main valve spool and makes it opened.
A. Pilot valve spool seized and not return to neutral position.
B. Pilot valve spool has internal leakage.
C. Check valve and orifice is blocked which cause the pilot oil return to tank very slowly.
故障原因：动臂主阀芯Ⅱ的先导油路上单向节流阀局部堵塞，从而先导油经过节流
口的流速变慢,造成手柄回中位后,先导油经过单向节流阀回油的速度过
慢,造成动臂主阀Ⅱ回位滞后,从而主泵仍有负载,有动力油经过主阀至
执行元件(油缸),所以手柄回中位后,动臂仍然可以自动上升。
Check valve
and orifice
- 141 -
Root cause of the failure: There is an orifice in the boom2 pilot circuit which is blocked partially. Return
pilot oi l f rom t his or ifice i s restricted a nd cause the boom up ope ration continued after the boo m pi lot
valve returns to the neutral position.
排故方法: 因为其它动作正常，基本可以排除系统主压力和先导系统压力的问题:
1、将动臂主阀芯Ⅰ、Ⅱ更换后，故障现象依旧，证明主阀芯没有问题；
2、更换液压先导阀总成，故障现象依旧，排除先导阀内泄；
3、更换主阀总成，故障现象依旧，排除主阀内部窜油的问题；
4、拆除先导油路上单向节流阀，试机故障解决。
Troubleshooting: Since other operations are normal, main oil pressure and pilot oil pressure should not
be suspected.
1. Replace the boom1 and boom2 valve spool, problem still existed. It means boom1 and boom2 valve
spools are normal.
2. Replace the pilot valve assembly, problem still existed. It means pilot valve is normal.
3. Replace the main control valve group, problem s till e xisted. It means main control valve has no
internal leakage.
4. Remove and clean the check valve & orifice, tested and proved problem solved.
排故体会：节流阀在液压回路中，对通过的流量起限制作用，因此通过节流阀可以
调速，挖机复合动作时可以提高协调性能，因节流阀出油口滤网密集也很
容易造成油路阻塞，直径设计过小也会造成阻碍油的流速。
Experience: The function of the orifice in the hydraulic circuit is to restrick the oil flow. And make the
operation smooth during the combined operation. If the hydraulic oil is contaminated, the screen at the
orifice would be blocked and failures occurred.
- 142 -
66、新安装的破碎器,不击锤 Newly installed hammer failed to work
故障现象：挖掘机安装破碎器后,试车时出现不击锤现象。
Symptom: Newly installed hydraulic hammer fails to work.
故障分析：
1、该故障出现前曾更换过备用阀块,但故障依然未解。
2、在破碎器的主控阀上(备用阀),下端连接先导油路,上端阀盖用堵头堵死。
Failure analysis:
1. Before this failure occurred, the spare valve has been replaced, but problem still existed.
2. A pilot hose is connected to the bottom of hammer main valve spool while the top end of the hammer
main valve spool is plugged.
故障原因：安装新锤连接管路时侧阀盖少接一根回油管。
Root c ause of t he f ailure: A pi lot hose connects to the top end of the hammer main valve spool is
uninstalled when the hydraulic hammer is installed.
排故方法：
- 143 -
1、当出现故障时,测量备用阀先导压力为 39 ㎏/c ㎡(正常)；
2、测量破碎器工作压力为 10 ㎏/c ㎡(不正常,正常为 160-180 ㎏/c ㎡)；
3、将截止阀关闭后测量破碎器二级溢流压力为 180 ㎏/c ㎡(正常)；
4、用流量计测量破碎器的流量为 30L/min(不正常，正常为 120L/min)；
5、将备用阀上盖堵头拆开,有液压油流出,堵头不安装时,破碎器工作正常；
6、当把堵头再次安装上时,故障再次出现；
7、将阀体上侧阀盖增加一根回油管路,故障排除。
Troubleshooting:
1. Measured pilot oil pressure is 39kg/cm2 which is normal.
2. Working pressure of the hammer is 10 kg/cm2 which is lower than normal 160-180 kg/cm2.
3. Measured line relief pressure is 180 kg/cm2 which is normal.
4. Measure oil flow is 30 L/min which is lower than 120 L/m.
5. Remove the plug on the top end of the hammer main valve spool, hydraulic oil flows out and hammer
works normally.
6. Intall the top end plug, failure repeats again.
7. Connect a pilot hose from the pilot valve to the hammer main valve spool top end. Tested and proved
problem solved.
排故体会：破碎器出现故障时,首先应检查破碎器安装是否正确,然后再检查系统的
压力和流量等。
Experience: When the hammer has failure occurred, check the oil circuit is connected correctly o r not.
Then measure system pressure and oil flow.
- 144 -
67、行走马达上液压油管破裂 Hydraulic hose of travel motor cracked
故障现象：行走马达上液压油管破裂,导致液压油大量泄漏。
Symptom: Hydraulic hose of travel motor cracked , cause a large amount of hydraulic oil sprayed out.
故障分析：同时爆两根或多根油管的原因一般分为：
1、是否系统压力过高；
2、或者机器的使用时间过久，管路有老化的现象；
3、是否有摩擦的现象；
4、其它特殊情况。
Failure analysis: The probable cause of the two or more hoses cracked at the same time listed below:
1. System pressure setting is above the specification.
2. Working hours of the machine is very long, hoses is aged.
3. Hose scratched each other ot scratched with other components.
4. Other reasons.
故障原因：由于固定马达的固定螺栓松动、折断从而造成马达总成的窜动，由于管
路的长度是固定的，所以管路在最薄弱的地方拉断掉了。
Root cause of the failure: Installing bolts of the travel motor group is loosed and broken which cause the
motor moved back and forth. The fixed hoses suffered impact force and fatigue fracture occurred.
- 145 -
排故方法：服务人员现场检查:
1、打开行走马达盖板,看到四根液压油管中有两根已从头部断开,另两根
从头部扭断，更换掉新的油管；
2、检查固定马达的 18 颗粒螺栓,有 13 颗脱落,其中的 5 颗已折断,没有松动
的 5 颗螺栓也已松动.
3、将液压油清理干净，并用丝攻清理螺纹，更换所有的螺栓。试机正常。
Troubleshooting:
1. Open t he cover and a ccess t o the t ravel m otor. It is found that two hydraulic hoses a re broken and
another two hoses are twisted.
2. 13 of 18 motor mounting bolts have been dropped down. 5 of 13 bolts have been broken. The renaubed
5 bolts are loosed。
3. Replace the failed parts, carry out necessary repair. Tested and proved problem solved.
排故体会：螺栓紧固部位应做好紧固标记，上好标准扭矩。
Experience: Apply correct torque to each bolt and make mark on each bolt after the it is torque properly.
- 146 -
68、往前行走速度慢，后退正常 Backward travel is normal while forward slowly
故障现象：该机工作 258 小时，行走过程中往前行走速度慢，后退正常。

Symptom: SMU is 258 hours. Excavator travels forward slowly, backward is normal.
故障分析：可以从以下方面检查：
1、主阀芯是否发卡；
2、先导压力是否正常。
Failure analysis:
1. Travel main valve spool is seized or not.
2. Pilot oil pressure is normal or not.
故障原因：行走 PPC 阀故障，更换行走 PPC 阀总成后，试机工作恢复正常。

Root cause of the failure: Travel pilot valve has malfunction.
排故方法：现场检查操纵行走操纵杆；机器往前行走速度很慢，且行走无力，变换
行走速度档位无变化；机器后退正常；
1、清洗，检查主阀芯，正常；
2、检查行走 PPC 阀的行程正常；
3、将行走 PPC 阀控制前进和后退的油管对调，操纵行走操纵杆，故障现
- 147 -
象变为相反。
4、更换 PPC 阀，故障排除。

Troubleshooting: Do the operation test on t he j obsite. It is found that forward travel performed poorly
under both high speed travel and low speed travel. Backward travel operation is normal.
1. Checked and found the travel main valve spool is normal.
2. The stroke of the travel pilot valve control lever is normal.
3. Interchange t he f orward t ravel pi lot hos es w ith the ba ckward t ravel pi lot hos es. Tested a nd pr oved
failure phenomena reversed. The forward travel is normal while the backward travel is slowly.
4. Replace the failed travel pilot valve, tested and proved problem solved.
排故体会：处理机械上有两个相对方向运动的部件故障时，可以利用机械本身，转
换或对调方向，让故障进一步明显化。
Experience: If the machine has failure in one direction but normal in the reverse direction, using
interchange method to do the troubleshooting and figure out root cause of the failure.
——提供者：尚建波 Service engineer: Shang Jian Bo
- 148 -
69、工作中上部车体缓慢左回转 Uper structure left swing slowly during the work
故障现象：工作过程中上部车体缓慢左回转。
Symptom: Uper structure left swing slowly during the work.
故障分析：工作中上部车体缓慢回转通常有：
1、回转马达的刹车机构有问题（如刹车片，制动缸，制动活塞等）；
2、停车制动阀有问题，卡死在常开的位置，有一定的先导压力油流动，
始终打开刹车；
3、安全阀有问题，卡死在常通位置；
4、补油单向阀有问题，泄露严重；
5、防摆阀有问题；
6、回转支承有问题（里面的轴承间隙过大，磨损严重）；
7、减速机严重磨损。
Failure analysis: probable root cause of the failure listed below.
1. Swing brake has malfunction. (disc, cylinder, piston,etc)
2. Swing brake control valve has malfunction. Valve spool is seized and cause brake released always.
3. Swing line relief valve has malfunction.
4. Makeup check valve has malfunction, internal leakage.
5. Anti-swing valve failed.
6. Swing bearing worn severely and cause excessive clearance.
7. Swing drive worn severely.
故障原因：压力补偿阀油封老化，造成泄露。
Root cause of the failure: Seal of the pressure compensation valve failed and cause oil leakage.
- 149 -
排故方法：
1、将左右两边的安全阀调换故障依旧，证明安全阀无问题；
2、检查先导压力（39KG）及制动阀块均正常；
3、将左右防摆阀互换，故障依旧，证明防摆阀是好的；
4、拆检右回转单向阀未发现异常，拆检左回转补油单向阀时发现补偿阀内部
油封损坏，更换该油封后故障消失。
Troubleshooting:
1. Interchange the two swing line relief valve, problem still existed. It means line relief valve is ok.
2. Measured pilot pressure is 39kgf which is normal. Checked and found swing brake ctrl valve is ok.
3. Interchange the anti-swing valves, problem still existed. Anti-swing valve should not be suspected.
4. Inspect the right swing makeup check valve and it is normal. Remove the right swing makeup check
valve and found its seal is damaged. Replace the failed seal, tested and proved problem solved.
排故体会：回转、小臂、挖斗和大臂之中的任何一个动作都会使回转刹车释放。

Experience: Swing, stick, bucket, and boom is operated, swing brake will be released.
——提供者：姜箭 Service engineer: Jiang Jiang
- 150 -
70、SY200 回转启动时有异响 Abnormal noise is detected when swing operation begins
故障现象: 一台 SY200C 型挖掘机，工作时间 180h,每次在启动回转动作时都会发出
“咣”的一声异响，当回转启动后工作正常。
Symptom: SY200C excavator with 180H working hours, has abnormal noise when the swing operation
begin. The swing operation is normal once it is started.
故障分析：1、回转减速器故障；
2、回转支承故障；
3、回转马达制动无法解除。
Analysis:
1. Swing drive has a malfunction.
2. Swing bearing failure.
3. Swing brake can not be released.
故障原因：发现制动解除阀芯卡滞。
Root cause of the failure: Swing brake release valve spool seized.
Swing brake
release valve
排故方法：
1、试机左、右回转启动时均有异响，基本可以排除回转马达安全阀、防反转
- 151 -
阀、补油单向阀故障；
2、启动回转时,站在回转马达处听异响发生部位在回转马达上部,基本可以排
除回转支承和回转减速器的可能,重点部位在回转马达驻车制动部位；
3、检查回转马达制动解除信号 SH 油压 3.8Mpa（正常）。
4、拆检回转制动释放阀，发现阀芯发卡。清洗回转制动释放阀，故障排除。
Troubleshooting:
1. Tested and found abnormal noise can be detected when both left and right right swing starts. It is sure
that swing line relief valves, anti-swing valve, and makeup check valve have no problem.
2. Further research found that the abnormal noise comes from the top section of the swing motor. Swing
bearing and swing drive have no problem. Swing brake release valve is suspected.
3. Measure the pilot oil pressure at SH port is 3.8 Mpa which is normal.
4. Dismantle the swing brake release valve and found its valve spool seized. Clean the swing brake
release valve, tested and proved problem solved.
排故体会: 回转马达制动解除阀芯发卡，不能灵活动作。所有在在回转开始的瞬间发
出异响。
Experience: Swing brake release valve seized, and can not move smoothly. So the abnormal noise is
detected when the swing operation begins.
—— 提供者：卞干彪 Service engineer: Bian Gan Biao
- 152 -
71、SY215C 挖机工作时小臂回收突然无动作 Stick in operation failed suddenly
故障现象： SY215C 挖机工作时突然小臂回收无动作，其它工况正常。

Symptom: SY215C excavator, stick in ope raton failed suddenly dur ing the work. Other operations a re
normal.
故障分析：1、小臂的阀杆卡滞；
2、小臂阀杆所连接油管堵塞；
3、小臂阀杆断裂；
4、电磁阀故障或卡滞；
5、先导手柄内部阀芯卡滞。
Failure analysis:
1. Stick valve spool seized.
2. Hose connects to the stick valve spool blocked.
3. Stick valve spool fractured.
4. Solenoid valve seized or has a malfunction.
5. Stick pilot valve spool seized.
故障原因：发现液压油中有铁屑,液压油太脏把阀芯或阀杆卡住；
Root cause of the failure: Iron chip is found in the hydraulic oil. The stick valve spool is seized by the
contaminated hydraulic oil.
排故方法：1、先根据先导油的来油情况，确定阀杆是否卡滞，拆小臂阀杆来油管小
臂外扬不来油；
2、拆开先导手柄，小臂外伸油管不来油；
3、整个先导手柄拆开，发现小臂回收油管所连接的手柄操纵阀芯卡死；
4.清洗先导手柄，摘掉异物，故障排除。
- 153 -
Pilot vale group Seized valve spool
Troubleshooting:
1. Determine whether valve spool is seized according to the pilot oil. Disconnect the stick out pilot hose
from the main control valve. No pilot oil flows out when the stick out operation is performed.
2. Disconnect the stick out pilot hose from the stick pilot valve. No pilot oil flows out when the stick out
operation is performed.
3. Dismantle the pilot valve, and find the pilot valve spool seized in the valve body. Clean the pilot valve,
tested and proved stick operation is normal. Problem solved.
排故体会：先根据先导油的来油情况，进一步判断是哪里的故障，方可检查。
Experience: According to the pilot oil conditions, determine Pilot circuit or main oil circuit has a failure.
Then do the trouble step by step.
——提供者：张志辉 Service engineer: Zhang Zhi Hui
- 154 -
72、SY215C挖机发动机启动困难 Engine is hard to start
故障现象：该机停机后，不能正常启动，必须手油泵排气才能启动。
Symptom: Engine can not be started normally after shut down. Engine can only be started after using the
priming pump to bleed air.
故障分析：因为停车后，需要排气才能启动，明显证明系统进了空气。
1、检查管路连接处是否有松动现象；
2、检查油水分离器有无漏气现象；
3、更换柴油滤芯；
4、拆检柴油泵回油单向阀，看是否磨损。
Failure analysis: Air enters into fuel system and cause engine hard to start.
1. Fuel circuit has connector loose or not.
2. Fuel water separator has connector loose or not.
3. Fuel return check valve of the injection pump is worn or not.
故障原因：柴油管路堵塞；柴油泵回油单向阀磨损。
Root cause of the failure: Fuel circuit is blocked and fuel return check valve is worn.
排故方法：1、检查管路连接无松动现象；
2、油水分离器无漏气现象；
3、拆下柴油泵、回油单向阀，发现磨损严重，更换单向阀故障排除。
Troubleshooting:
1. Checked and found fuel circuit has no connector loosed.
2. Checked and found fuel water separator has no air leakage phenomenon.
3. Checked and found the fuel return check valve is worn severely. Replace the failed check valve, tested
and proved engine can be started normally. Problem solved.
排故体会：回油单向阀损坏，有时也会有憋车现象。
Experience: Mentioned check valve failed will also cause engine speed drops severely.
——提供者：高影辉 Service engineer: Gao Ying Hui
- 155 -
73、手柄重并有反弹力 Pilot lever is heavy and has a rebound force
故障现象：操作控制工作装置手柄时，感觉到手柄重并有反弹力。
Symptom: Joystick is heavy to operate and has a feeling of rebound force.
故障分析：
1、用户承认在深水中有过陷车情况,油品是否变质；
2、其它工作装置工作是否正常，先导压力是否正常；
3、先导阀芯是否堵塞。
Failure analysis:
1. Customer said that the machine sunk in deep water before. Hydraulic oil deteriorated?
2. Implement works normally or not. Pilot oil pressure is normal or not.
3. Pilot valve spool choked or not.
故障原因：液压油变质，先导调压阀发卡导致先导压力过高。
Root cause of the failure: Hydraulic oil is deteriorated. Pilot valve spool is seized and cause the pilot oil
pressure higher above normal.
排故方法：
1、检查液压油，发现颜色异常、粘度也异常。
2、检查自减压阀压力异常，87kg/cm²。标准值 38±2kg/cm²。
3、从以上检查结果判斷操作手柄重系先导系统压力过高所致
4、清洗液压油箱和自减压阀，加入清洁液压油操作所有工作装置 30 分钟，
排放液压油箱的油再次加入清洁液压油重复前次的工作 30 分钟，再次排放液
压油,加入清洁液压油并更换滤芯，试车检查压力正常,故障排除。
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Troubleshooting:
1. It is found that the hydraulic oil color and viscosity are abnormal.
2. Measure pilot oil relief pressure is 87 kg/cm² which are higher than the specification 38±2kg/cm².
3. As per the test result in the above step, the joystick is operated heavily should be caused by the
excessive high pilot oil pressure.
4. Replace with the clean hydraulic oil and clean the hydraulic oil tank. Replace the hydraulic oil filters
and run the machine for half an hour.
5. Repeat the 4 th step for three times. Tested and proved machine operation is normal and the pilot oil
pressure is normal. Problem solved.
排故体会：1、机器工作时水面不许超过托链轮中心线，如超过将对机器造成损害；
2、如机器陷入水中进行自救时要注意检查液压油箱通气管管口是否也在
水中，脱险后要对相关部位进行全面检查。
3、如果发动机燃烧室进水了，在将水从燃烧室排尽之前，切莫转动钥匙
试图启动发动机，否则连杆必然弯曲。
Experience:
1. Water level should not above the centerline of the carrier rollers. Otherwise, machine may be
damaged.
2. Once the machine sinks in deep water, make a thoroughly inspection to the machine after it is pull out
from the water. Also check whether the vent hose of the hydraulic tank sank in water or not.
3. If water enters into combustion chamber, never try to crank engine by turning the start switch to the
start position. Oterhwise, con-rod will be bending.
- 157 -
74、SY230 行走跑偏 SY230 has the excessive travel offset
故障现象：SY230 挖掘机在脚踏先导阀同样行程时，行走转圈。
Symptom: SY230 h as a s everely t ravel o ffset. It tr avels in a c ircuit w hen th e tw o p ilot v alve control
levers are pushed at the same stroke.
故障分析: 行走跑偏的主要原因为左右行走马达压力不同，或履带紧张度不同致使左
右行走马达转速不同，最终导致行走跑偏。
Failure an alysis: If t he t wo t ravel m otors have di fferent pressure, t wo t racks have di fferent t ension, or
have different travel speed, machine will have an obvious offset.
故障原因：
1、履带张紧度不同；
2、P1、P2 泵压力不同；
3、中央回转接头油封损坏；
4、行走马达平衡阀损坏；
5、行走马达主要安全阀损坏或发卡；
6、单边行走马达损坏。
Failure analysis:
1. Two tracks have different track tension.
2. Oil pressure of front pump and rear pump is different.
3. Seals of swivel joint are damaged.
4. Balance valve of travel motor is failed.
5. Travel line relief valve seized or damaged.
6. One travel motor failed.
排故方法：
1、检查履带：测量左右两侧履带长度一样，排除履带故障；
2、复合动作同样跑偏，排除主液压泵故障。
- 158 -
3、前进后退往同一方向跑偏，排除中央回转接头油封故障。
4、测量两侧行走马达压力，一侧压力为 28Mpa,另一侧为 34Mpa,即可排除单边单
边行走马达故障，此时怀疑单边主安全阀故障.
5、调主安全阀使两侧压力相同后，设备运转一切恢复正常。
Troubleshooting:
1. Checked and found two tracks have the same length and the same track tension.
2. Problem still exists when the combined operation of travel and other action is performed. Pump
should not be suspected.
3. Machine offsets in t he direction during bot h forward and backward travelling. It should not be the
caused by the failure of swivel joint seals.
4. Measured pressure of the two travel motors is different. One side is 28Mpa and another side is 32Mpa.
It is sure travel motor has no problem, and the travel line relief valve is suspected.
5. Adjust the pressure setting of the travel line relief valve and make them the same. Tested and proved
machine travel offset is within specification. Problem solved.
排故体会：主安全阀中的弹簧在使用过程中吸收液压油温度，导致弹簧温度升高、
弹力下降，致使行走马达原设定的压力下降，阀门自动打开，整个系统
压力下降，最终导致挖机行走跑偏。
Experience: Spring of the travel line relief valve suffers high oil temperature and cause its elasticity
reduces. Pressure setting of the travel line relief valve decreased which cause the machine travel offset.
- 159 -
75、整机突然无动作 Machine has no action suddenly
故障现象：该车在正常工作时,整机突然无动作。
Symptom: Machine has no action suddenly during the normal working.
故障分析：
1、该机使用破碎器，累计 3000 小时未更换液压油,检查液压油，发现油污染
严重，怀疑是液压油过脏造成；
2、更换液压油和滤芯后,全车动作仍然时有时无,而且还出现了全车动作慢、
无回转等现象。
3、经检查油液仍有污染,而且吸油滤芯上附有大量毛絮、清洗回转锁定电磁
阀后,回转正常;
4、清洗比例电磁阀后,动作慢现象消失;测试先导压力,发现压力波动较大、
不稳定且偏低；再次证明液压系统有杂质,造成“阀堵”现象。
Failure analysis:
1. Hydraulic hammer is equipped and used for 3000 hours without changing hydraulic oil. Checked and
found the hydraulic oil is contaminated severely.
2. Replace the hydraulic oil a nd hydraulic oil filters, it is found machine has no action intermittently.
Machine can not swing and other action has a long cycle time.
3. Checked a nd found hydraulic o il is s till contaminated. A lot o f impurity is found on the suction screen
Clean the swing solenoid, tested and proved machin can swing normally.
4. Clean the proportional solenoid valve, tested and proved all the operations have the normal cycle time.
Measured pilot speed is unstable and lower than the specification. It is sure the hydraulic system has
contaminations and cause valve seizure.
故障原因：液压油过脏，导致液压系统主溢流阀和比例电磁阀发卡。
Root cause of the failure: Hydraulic oil is contaminated which cause the proportional solenoid valve and
the main relief valve seized.
- 160 -
排故方法：
1、再次清洗液压油箱，用和好的面粘净油箱中的杂质并更换液压油及滤芯；
2、清洗液压油散热器，用柴油冲洗然后用气泵吹净；
3、清洗主溢流阀和比例电磁阀；
4、清洗管路。
Troubleshooting:
1. Clean the hydraulic tank thoroughly. Replace the hydraulic oil and hydraulic oil fitlers.
2. Clean the hydraulic oil cooler with clean fuel and use the compressed air to blow it dry.
3. Clean the main relief valve and the proportional solenoid valve.
4. Clean the hoses.
排故体会：
。
1、挖掘机使用破碎器时,必须按照保养要求进行保养（液压油和滤芯）
2、清洗液压系统时，必须按照要求进行清洗（禁止使用抹布）。
Experience:
1. Maintenance must be performed according to the maintenance interval. Especially the hydraulic
hammer is used.
2. Do not use cloth to clean the hydraulic system to prevent fibre stick on t he parts and enters into the
hydraulic oil.
- 161 -
76、油缸漏油 Hydraulic cylinder leaks oil
故障现象：液压油缸油封漏油，污染严重。
Symptom: Hydraulic cylinder leaks oil and contaminated severely.
故障分析：1、油封黑焦，失去弹性，炭化严重；
2、油封有1道或几道划口，从该划口处漏油；
3、油封周圈大面积的损坏，油缸杆划伤严重。
Failure analysis:
1. Cylinder seal is aged, has no elasticity, and failed.
2. Cracks are found on the seal which cause the oil leakage.
3. Oil seal damaged severely. Cylinder rod is scratched.
故障原因：1、在高温下长期使用，导致油封炭化；
2、油缸内有杂物颗粒，将油封以及油缸杆划伤；
3、由于油缸杆的严重划伤，导致油封的损坏。
1. Cylinder seal is used long time under the high oil temperature, and gets brittle.
2. Foreign material in the cylinder causes the cylinder rod scratched.
3. The scratched rod causes the seal damaged.
排故方法：更换油封和油缸杆；更换液压油，更换液压滤芯空车运行将油缸内空气
排放净；
Troubleshooting: Replace the cylinder rod and damaged seals. Replace the hydraulic oil and h ydraulic
oil filters. Operate the machine softly to bleed air from the hydraulic system. Tested and proved problem
sovled.
排故体会：更换油封一定要保证液压油的油品质量，保证液压系统的干净。
Experience: After replace the cylinder seal and cylinder rod, make sure the hydraulic oil quality and the
hydraulic system is clean.
- 162 -
77、SY360C 机大臂下降动作失控 Boom down operation is out of control
故障现象：操作先导手柄做大臂下降动作时，大臂猛地下降到底，不受控制。
Symptom: Boom down operation is out of control. Boom drops to the ground rapidly.
故障分析：1、先导手柄阀阀芯发卡，先导阀芯弹簧断裂或弹力过弱；
2、大臂下降阀芯发卡，阀芯回位弹簧断裂或弹力过弱。
Failure analysis:
1． Pilot valve spool seized, pilot valve spring broken or too soft.
2． Boom valve spool seized, boom valve spring broken or too soft.
故障原因：动臂下降先导阀芯弹簧断裂。
Root cause of the failure: Boom pilot valve spring is broken.
排故方法： 1、经检查动臂下降阀芯无发卡现象，回位弹簧无断裂和弹力过弱现象，
可排除主阀芯故障；
2、经检查动臂下降先导阀芯内回位弹簧断裂，阀芯无法回位, 一直向动
臂主阀芯提供先导压力，将动臂阀芯推开致使动臂下降动作失控。
3、更换阀芯回位弹簧后故障排除，机器恢复正常工作。
- 163 -
Troubleshooting:
1. Checked and found boom main valve spool is not seized. Its spring is normal. Not cracked, and the
elasticity is within specification.
2. Dismantle the boom pilot valve, and found that its valve spring is broken. When the boom pilot lever
is released and returns to the neutral position, the pilot valve spool can not return to the neutral
position. Pilot oil is supplied to the boom cylinder continually and causes the boom down operation
out of control.
3. Replace the failed spring, tested and proved machine works normally. Problem solved.
排故体会：根据故障现象由简到繁进行故障分析，是比较清晰的排故思路。
Experience: Troubleshoot f rom simple to conflex according to t he failure phenomena. This is a clear
troubleshooting logic.
----提供者：严旭强 Servcie engineer: Yan Xu Qiang
- 164 -
78、215C8 机型斗杆伸出发卡 Stick out operation has a restriction
故障现象：215C8 机型斗杆伸出发卡、斗杆不能完全伸开且在工作时自动收合，其余动作均正常。
Symptom: SY215C8 stick out operation has a restriction. Stick in automatically whenthe stick pilot valve
is released and returns to the neutral position. Other actions are normal.
故障分析：1、首先检查油缸外观是否发现磕碰现象；
2、油缸内泄，活塞杆大螺帽脱落等；
3、主控阀的回油弹簧是否损坏；斗杆阀芯是否发卡；
4、斗杆伸收压力是否正常；
5、斗杆溢流阀是否损坏。
Failure analysis:
1. Whether the cylinder is impacted, and causes a deformation.
2. Cylinder has internal leakage. The nut on the cylinder rod is loosed.
3. Return check valve spring of the main control valve is damaged or not. Stick valve is seized or not.
4. Pressure is normal or not when stick in and stick out is performed.
5. Line relief valve of stick operation is damaged or not.
故障原因：液压油污染，斗杆伸出端溢流阀损坏。
Root cause of the failure: Hydraulic oil is contaminated. Stick out line relief valve is failed.
排故方法：1、观察外观无磕碰现象此故障排除；
2、收斗杆时正常，油缸大螺帽脱落现象故可以排除；
3、斗杆阀芯拆卸未发现异常，此故障排除；
4、因其它动作均正常，故可排除回油弹簧损坏；
5、通过显示屏观察斗杆伸出压力为 13MPa，不正常；
6、拆检斗杆溢流阀时发现 O 形圈损坏.
7、更换 O 形圈后可以达到 34.3MPa 的系统工作压力,整机工作正常。
Troubleshooting:
1. Inspect the cylinder and rod, no impact vestige.
2. Stick in operation is normal, the rod nut should be in position.
3. Remove the stick valve spool and no abnormal could be found.
4. All other operations are normal. It means the return check valve spring is normal.
- 165 -
5. Measured main oil pressure is 13Mpa when the stick out operation is performed.
6. Removed the stick line relief valve and found the o-ring seal is damaged.
7. Replace the failed o-ring seal, tested and proved the system pressure is 34.3Mpa. machine works
排故体会：1、因安装破碎锤管路，客户没按规定时间更换液压油，操作手在进行铲斗与破碎锤相
互更换时不注意清洁，导致脏物进入液压系统，污染了液压油，使溢流阀磨损；
2、在平时服务的过程中一定要与客户解释，并交待清楚，安装破碎锤的挖掘机一定要
按时保养，及时更换液压油。
Experience:
1. Hydraulic hammer is installed and used. hydraulic oil not changed according to the maintenance
interval. Hydraulic oil is contaminated when the working tool is changed between hammer and the
bucket. Line relief valve is worn by the contaminated hydraulic oil.
2. During the new machine delivery and the service repair, service engineer should explain clearly to end
user that the periodic maintenance must be performed according to the maintenance interval.
——提供者：黄小协 Service engineer: Huang Xiao Xie
- 166 -
79、SY210C6 型挖机憋车 Engine stalled
故障现象：210C6 型挖机憋车、工作无力，发动机转速由 2000 转掉速直至熄火，显
示屏显示其它信息均正常。
Symptom: SY210C6 engine stalled. Engine speed drops from 2000rpm to zero. Others are normal.
故障分析：1、首先从发动机的动力来考虑如果动力不足，当增加负荷时必然发动机
转速会严重下降；
2、发动机的输出功率与主泵是否相匹配及主泵调器是否发卡等；
3、先导压力是否正常；
4、电磁比例阀，负压传感器如有问题从显示屏可以看到；
5、如果主控器损坏，其它动作正常，只有憋车，这种情况很小。
Failure analysis:
1. If the engine power is insufficient, when the load increased, the engine speed will be dropped.
2. Engine output power matches the hydraulic power or not. Pump adjuster seized or not.
4. Proportional solenoid valve and negative pressure sensor are normal or not.
5. All the actions are normal except the obvious speed drop. Controller should not be failed.
故障原因：1、油路供油不畅；
2、液压油脏污，调节器发卡。
1. Fuel supply circuit is blocked by the impurity.
2. Contamination in the hydraulic oil cause the pump adjuster
seized.
排故方法：1、我们更换了柴滤，油水分离器及
燃油油路的全面清洗，所以燃油系统
可以排除。
- 167 -
2、检查先导压力压力，发现正常；
3、把主泵流量调节螺栓向外调 360 度，发现没变化；
4、拆检，清洗前后泵调速器没发现异常，但故障排除。
Troubleshooting:
1. Replace the fuel filter and fuel water separator. Make sure the fuel supply circuit is free of impurity.
2. Measured pilot oil pressure is normal.
3. Screw out the pump adjuster setting screw one turn, tested and proved performance has no change.
4. Dismantle the pum p adjusters, and no damaged found. Clean the pump adjuster, tested and proved
machine works normally. Problem solved.
排故体会：虽然拆检清洗过程中没发现异常，但可以断定是主泵调节器发卡，从而
使前后泵流量在最大位置。
Experience: Although the pump adjuster has no damaged could be found. It is sure that the pump
adjuster is seized at maximum position.
——提供者：常英俊 Service engineer: Chang Ying Jun
- 168 -
第2节电气系统 electrical system
01、OPUS46 显示屏显示档位异常 Displayed throttle position on the monitor is abnormal
故障现象：SY360显示屏（OPUS显示屏）有时不能正确显示档位，发动机无法升速，
整机动作慢，挖掘无力作业效率低，发动机憋车，不能正常工作。
Symptom: Displayed throttle position is abnormal. Engine can’t be accelerated, can't work normally.
故障分析：
Failure analysis:
Fuse of wire 42 failed Y Wire 42 shorted Y Repair short circuit
Wire 42 has DC24V N Repair open circuit
Wire 50 has DC5V N SYTRU \SYHCU failed. Replace
Wire 506 has voltage N SYTRU \SYHCU failed. Replace
SYHCU\SYTR, COMMUNICATION, AND OTHER FIALURES
SYTRU \SYHCU failed Monitor or CAN failed Dial switch failed
- 169 -
故障原因： 1、控制器与OPUS德国屏通讯中断；
3、线路故障（主要指控制器24V电源及5V电源线路）。
1. Communication between the controller and the OPUS monitor is interrupted.
2. Controller has malfunction.
3. Circuit failure ( 24V power circuit and 5V circuit of the controller)
排故方法： 1、检查控制器电源42#号线电压正常（DC24V）；
2、测量控制器50#线电压正常（DC5V）；
3、油门档位显示异常时其它模拟数据也显示异常，确定自主控制器出
现与显示屏通讯中断现象，判定控制器损坏；
4、更换新的自主控制器（SYHCU、SYTRU），重新刷程序，标定发动机
转速，机器故障消除，工作正常。
HCU controller
TRU GPS module
Replaced SYHCU/SYTRU
Troubleshooting:
1. Measured voltage of wire 42# is 24VDC which is normal.
2. Measured voltage of wire 50# is 5VDC which is normal.
3. Other analog data is abnormal when the displayed throttle position is abnormal. Suspect the controller
has malfunction, and the communication between controller and monitor is interrupted.
- 170 -
4. Replace the controller (SYHCU、SYTRU), flash the software, and calibrate the engine speed. Tested
and proved machine works normally. Problem solved.
排故体会：自主控制器出现通讯中断后，会导致所有模拟数据显示不正常；如果只
有油门档位显示不正常，而其它模拟数据正常，则可排除控制器故障，
再检查油门旋扭、及线路故障。
Experience: When the communication of the controller is interrupted, all the analog d ata will be
displayed abnormally. If all the analog data are normal except the throttle position, controller should not
be suspected. Dial switch and wire circuit failure should be suspected.
——提供者：颜礼平 Serice engineer: Yan Li Ping
- 171 -
02、机器无法启动 Engine can not be started
故障现象： SY210C5挖机通电显示屏显示正常，但机器无法启动。
Symptom: Engine can not be started with parameters displayed normally.
故障分析 failure analysis：
Battery voltage lower than 22V Y Battery lack power Y Charge the battery
Wire 12# voltage is 24V Y Starting motor failed Replace starting motor
Wire 11 # voltage is 24V N Start switch failed Replace the start switch
Wire 602# voltage is 24V Y K3 start relay failed
N Wire 105# shorted or opened Y Repair wire 105#
Wire 42# voltage is 24V N Wire 42# shorted or opened Repair wire 42#
Wire 50# voltage is 5V EPEC controller failed Replace EPEC controller

Y
Transfer module failed Replace transfer module
- 172 -
故障原因：1、电瓶故障电量不足；
Transfer module
2、K3启动继电器故障；；
3、启动马达故障；
4、EPEC控制器故障；
EPEC contrller
5、转换板故障；
6、液压先导行程开关故障；
7、线路故障。
1. Battery has insufficient power.
2. K3 start relay failed.
3. Starting motor failed.
4. EPEC controller has malfunction.
5. Transfer module failed.
6. Hydraulic activation control switch failed.
7. Circuit failure.
排故方法：1、经检查电瓶电压充足（DC24V）；
2、启动状态下用万用表测量启动马达12#线无电压（正常为DC24V）；
3、启动状态下测量K3继电器线圈602#号线无电压（正常为DC24V）；
4、测量42#线对地电压为DC24V，说明控制器电源正常；
5、测量50#线对地电压为DC5V，说明转换板5V模块正常；
6、检查液压先导105号#线无断路现象；
7、判定EPEC控制器602#线启动输出点异常或烧坏；
8、更换EPEC控制器启动正常。
Troubleshooting:
1. Measured battery voltage is 24VDC which is normal.
- 173 -
2. Measured wire 12# of starting motor has no voltage when crank the engine. Normally, it should be
24VDC.
3. Measured wire 602# of K3 relay has no voltage. Normally, it should be 24VDC.
4. Measured wire 42# to ground is 24VDC which means controller power supply is normal.
5. Measured wire 50# to ground is 5VDC which means transfer module is normal.
6. Checked and found wire 105# of hydraulic activation control switch has no circuit failure.
7. Replace the EPEC controller, engine can be started normally. Problem solved.
排故体会： EPEC控制器50#线对地电压5V，液压先导为锁定状态，显示屏其它数据
显示正常，而602#线无启动信号，可判定EPEC控制器602#启动信号输出
节点故障，更换EPEC便可消除故障。
Experience: Voltage of wire 50# of the EPEC controller is 5VDC, hydraulic activation control lever is
locked, pa rameters di splayed i n t he m onitor a re nor mal, a nd t he w ire 602 # has no starting s ignal. It is
suspected controller fails to output starting signal to wire 602#. Replace the failed controller will solve the
problem.
- 174 -
03、行走高低速无法切换 High / Low travel speed can not be shifted
故障现象：SY230C1在显示屏上切换行走高低速时，不能实现高速行走。
Symptom: SY230C1 is shifted to high speed travel on the monitor, but travel speed not changed.
故障分析：
Failure analysis:
Button on monitor is normal N Monitor failure Y Replace monitor
Wire 607# of controller voltage is 24VDC N Controller failed Replace controller
Voltage of travel solenoid wire 607# is 24V N Wire 607# opened Repaire wire circuit
Solenoid valve spool has action Travel solenoid valve spool seized Replace valve spool
Y
Solenoid valve coil failed
Replace failed coil
- 175 -
故障原因：1、显示屏按键故障；
H/L speed shift solenoid
2、显示屏故障；
4、线路故障；
5、电磁阀线圈故障；
6、电磁阀卡滞。
1． Button on the monitor failed.
2． Monitor has malfunction.
3． Controller failed.
4． Circuit failure.
5． Solenoid valve coil failed.
6． Solenoid valve seized.
排故方法：1、按下高低速切换按钮,显示屏显示高低速已切换,说明按钮、显示屏，
控制器与显示屏通讯均正常；
2、检查控制607#线有DC24V输出；
3、检查电磁阀组V7续流二极管无导通、击穿现象；
4、行走高低速电磁阀处607#线对地电压为DC24V，说明线路无断路，短
路现象；
5、高低速切换时，高低速切换阀阀芯不动作，测量行走高低速电磁阀线
圈电阻异常，并且烫手，
6、判定行走高低速电磁阀线圈故障，更换线圈后正常。
Troubleshooting:
1. Checked and found the displayed travel speed can be shifted in the monitor by pushing button. It
means the button, the monitor and the communication from controller to monitor are normal.
- 176 -
2. Measured voltage of wire 607# at the controller, there is 24VDC output which is normal.
3. Checked and found the diode of travel speed solenoid is normal, not failed.
4. Measured voltage of wire 607# at the travel speed solenoid, it is 24VDC. Circuit has no problem.
5. When the high/low speed shift button is pushed on the monitor, valve spool of the travel speed
solenoid has no operation. Solenoid coil has abnormal resistance very hot.
6. Solenoid c oil i s s uspected t o be f ailed. Replace the f ailed s olenoid coil, t ested a nd p roved pr oblem
solved.
排故体会：特别说明V7续流二极管如果导通时，会降低607#线电压(DC24V)，会导致
行走高低速电磁阀无法进行切换。
Experience: Please notice that if the diode of the solenoid valve V7 is shorted, voltage of wire 607# will
decrease, and cause the travel speed can not be shifted.
——提供者：颜礼平 Service engnineer: Yan Li Ping
- 177 -
04、工作灯不亮 Working lamp failed to work
故障现象： SY210C1挖机整机大灯不亮。
Symptom: SY210C1 working lamps fail to work.
故障分析：
Failure analysis:
F4 fuse failed Y Replace 15A fuse
Wire 24# voltage is 24VDC N Wire 24# shorted or opened Repair wire circuit
Turn on switch S2
Wire 33# voltage is 24VDC N Switch S2 failed Replace switch S2
Relay K6 is normal N Replace relay K6
Wire 34# voltage is 24VDC N Wire 34# shorted or opened Repair wire circuit
Bulb failed
Replace bulb
- 178 -
故障原因：1、F4保险丝是否烧断；
2、灯光开关S2是否故障；
3、继电器K6是否故障；
4、线路是否故障；
5、工作灯灯泡故障。
1. Fuse F4 is damaged.
2. Lamp switch S2 failed.
3. Relay K6 failed.
4. Circuit failure.
5. Lamp bulb failed.
排故方法： 1、检查工作灯F4保险丝正常；检查24#线对
地电压正常(DC24V); SY210C1 working lamp circuit
2、检查33#对地电压正常(DC24V)；说明S2翘板开关及该线路正常；
3、K6继电器吸合,但测量34#线对地电压为0V,说明K6继电器常开触点断
路,检查发现该常开触点接触不良,更换K6继电器后,工作灯工作正
常。
Troubleshooting:
1. Measured fuse F4 is normal. Voltage of wire 24# is 24VDC which is normal.
2. Measured voltage of wire 33# is 24VDC which means switch S2 and its circuit is normal.
3. Relay K6 is engaged, but measured voltage of wire 34# is 0V. It means the normal open contact is
opened. Replace the failed relay K6, working lamp works normally. Problem solved.
排故体会：继电器经常工作,触点产生电弧,容易导致接触不良。
Experience: Contacts of the relay acts frequently which will cause the arc welding, and causes the
contacts failed intermittently.
- 179 -
05、发动机不能升速降速 Engine speed can not be accelerated and decelerated
故障现象：SY220C5发动机启动后,发动机无法升降速。
Symptom: SY220C5 engine speed can not be changed after starting up.
故障分析：Failure analysis:
Wire 42# voltage is 24VDC N F11 fuse failed or wire 42# circuit failure Replace F11 or repair circuit
Wire 29# voltage is 24VDC N F10 fuse failed or wire 29# circuit failure Replace F10 or repair circuit
Wire 5# voltage is 24VDC N EC-7 transfer module failed Replace EC-7 transfer module
Displayed throttle position is normal N Dial switch or circuit failed Replace dial switch / repair circuit
Y EPEC failure Replace EPEC controller
Wire 601#（24VDC）
，wire 701#（10-14VDC） N EPEC failure Replace EPEC controller
A+、A，B+、B- voltage is 24-28VAC N Governor actuator failed Replace governor actuator
Resistance A+ & A- ; B+ & B-（1-3ohm） N Governor actuator failed Replace governor actuator
Y Position sensor failed Y Replace throttle position sensor
N Governor actuator failed Replace governor actuator

- 180 -
故障原因：1、检查各保险丝是否正常；检 Sline failed
查油门旋扭是否正常；
2、检查控制器输出步进方向信
号601、步进脉冲信号701输
出电压是否正常；
3、步进电机驱动器输出A+与
A-,B+与B-之间电压正常否；
4、检查油门位置传感器是否正常；检查步进电机是否正常。
1. All the fuses are normal or not. Dial switch is normal or not.
2. Voltage of wire 601 and 701 output from the controller to governor actuator is normal or not.
3. Voltage between A- and A+ is normal or not. Voltage between B+ and B- is normal or not.
4. Governor actuator and the throttle position sensor are normal or not.
排故方法：1、检查42#号线、29#号线电压正常(DC24V)；
2、检查油门档位显示正常,说明油门旋扭正常；
3、检查控制器步进方向信号601,步进脉冲信号701输出电压正常,说明控
制器输出正常；
4、检查步进电机驱动器A+与A-,B+与B-，输出电压正常;(AC24-28V),说
明步进电机驱动器正常；
5、测量步进电机A+与A-,B+与B-之间电阻正常,用手拉动油门拉杆,发现
油门拉杆拉动困难 ,进一步检查发现电机传动花键与扇形齿轮之间卡
滞,花键损坏,更换油门马达后正常。
Troubleshooting:
1. Measured voltage to wire 29# and wire 42# is 24VDC which is normal.
- 181 -
2. Displayed dial switch can be changed. It means dial switch is normal.
3. Measured voltage to the wire 601# and wire 701# from the controller is normal. Controller is ok.
4. Measured voltage between A+ and A-, B+ and B- is normal. (24 – 28VAC).
5. Resistance b etween A + and A -, B + an d B - is n ormal. Pull the cable of t he governor actuator a nd
found the cable is hard to pull. Further research found the spline of the motor is damaged. Replace the
governor actuator. Tested and proved problem sovled.
排故体会：机器断电情况下先手动拉动油门拉杆,检测马达有无卡滞现象；再将设
备通电,手动拉动油门拉杆,可判定A+与A-,B+与B-有无电压输出，该方法
可排除是电器或是步进电机机械故障。
Experience: Pull the cable of the governor actuator when the machine is powered off to check whether
the cable is seized or not. Power on the machine and pull the cable again to determine whether there is
voltage between A+ and A-, also the voltage between B+ and B-. This method can be used to make sure
whether the governor actuator has a mechanical or electrical problem.
Dial switch Throttle position

sensor
changed
Throttle gear
EPEC controller Feedback signal Throttle position sensor

signal
Speed change
Motor rotate
A+
Driver of the A- Motor of governor
governor actuator B+ actuator
B-
- 182 -
06、OPUS46 显示屏无法断电 OPUS46 monitor can not be power off
故障现象:1、 SY215C8M 挖机工作中突然熄火；断电后显示屏亮，按
钮失灵.
2、整车动作慢，不能工作；显示屏多个报警。
Symptom:
1. SY215C8M shut off automatically. Monitor is lighted when the start switch is at off position.
2. All actions are very slow, can not work. Multiple faulty codes displayed on the monitor.
故障分析：综合以上各个故障，说明控制器工作不正常，显示屏不能正常工作导致
机器熄火，OPUS显示屏死屏多个故障代码等。
Failure analysis:
As per the failure phenomena, machine controller is suspected to be failed, which cause the monitor fails
to work and machine shut off automatically.
故障原因: 1、OPUS 显示屏出现故障；
2、控制器损坏；
- 183 -
3 、各压力信号传感器损坏；
4、线路故障。
1. OPUS46 monitor has a malfunction.
2. Machine controller has a malfunction.
3. Pressure sensors failed.
4. Circuit failure.
排故方法：1、测量各压力传感器的电压为 0.2V，控制器 50 号线也为 0.2V；
2 、通过观察控制器，发现代码： 17； 20；21；22；23；24；29；
3、将行走压力信号传感器拆下，该故障消除，显示屏能正常断电.
4、更换行走压力信号传感器后，机器工作正常。
Troubleshooting:
1. Measured voltage of the pressure sensors and controller wire 50# is 0.2V.
2. Displayed failure codes are: 17, 20, 21, 22, 23, 24, and 29.
3. Remove the travel pressure sensor, failure soved. Monitor can be powered off normally.
4. Replace the failed travel pressure sensor, tested and proved machine works normally.
排故体会：单个传感器内部出现短路故障，将导致机器整个 5V 电压下降，控制器
不能正常工作，出现多个故障代码；OPUS 显示屏出现多个（5 个或以上）
故障代码会导致显示屏死机，
Experience: One pressure sensor has a short circuit will cause the 5V voltage of the machine reduce.
Controller fails to work normally, and multiple faulty codes will be displayed. OPUS46 monitor will be
abnormal if more than five faulty codes displayed.
- 184 -
07、机器工作中自动熄火 Machine shut down automatically during the work
故障现象：SY230C6B工作中突然熄火，重新启动又正常，故障次数频繁。
Symptom: SY230C6B shut off suddenly during the work. Machine works normally after restarting. This
failure repeats frequently.
故障分析：先排除柴油油路的可能性分析，突然出现发动机熄火，
而重新启动后正常，说明线路接触不良或停车机构故
障，排除外排线路后再确定其它故障原因，确定是否
还有其它现象。
Failure analysis: Failure should not be caused by fuel system. Machine works
normally after restarting. It is suspected that circuit may be failed intermittently.
故障原因：1、停车继电器故障；
2、停车电磁阀故障；
Shut down circuit
3、传速传感器故障；
Signal amplifier
4、KCM控制器故障；
5、线路故障或停车电磁阀机械故障。
1. Shut down relay failed.
2. Shut down solenoid failed.
3. Speed sensor failed.
4. KCM controller has a malfunction.
5. Circuit failure or the mechanical failure of the shut down solenoid
排故方法：1、通电时和熄火时停车电磁阀工作正常，可排除停车电磁阀故障；
2、出现故障时，发动机转速无法升降，且持续往下掉，直至熄火；
3、出现故障时，从显示屏上检查（目测）发现发动机转速在H模式11档
时在600转-1800转之间变化不稳定，然后自动熄火；
- 185 -
4、检查测量发现发动机转速传感器正常，确定为转速信号放大器故障，
5、更换转速信号放大器后，故障消除，机器工作正常。
Troubleshooting:
1. Checked and found the shut down solenoid works normally during the machine power on and shut off
operation.
2. When the failure occurs, engine speed can not be accelerated and decelerated through the dial switch.
Engine speed drops continually till the engine is shut off.
3. When the failure occurs, engine speed at 11 th of H mode displayed on the monitor drops f rom
1800rpm to 600rpm, and continued to shut off.
4. Checked and found engine speed sensor is normal. Engine speed amplifier is suspected.
5. Replace the engine speed amplifier, tested and proved machine works normally. Problem solved.
排故体会：转速信号放大器故障会导致机器动作慢或熄火。
Experience: Speed amplifier malfunction will cause machine shut off or operated slowly.
- 186 -
08、发动机憋车 Engine stalled
故障现象：SY215C8M工作时出现严重憋车。
Symptom: SY215C8M has the failure of engine stall during the work.
故障分析：区分发动机故障、液压故障来分析：
1、电比例阀故障；
2、线路故障（如：前泵比例阀 702#线、后泵比例阀 703#线）

；
3、 KCM 控制器故障；
4、发动机转速异常（或转速传感器坏）。
Failure analysis: Failure may be caused by engine or by the hydraulic system.
1. Proportional solenoid valve failed.
2. Circuit fairue. For example, wire 702# of front pump PRV or wire 703# of rear pump PRV failed.
3. KCM controller has a malfunction.
4. Engine speed is abnormal or engine speed sensor is failed.
排故方法：1、到达现场检查发现，憋车时发动机转速掉速达到 400~500 转；
2、将机器更改为液控后，憋车现象消除，由此可见，该机器出现憋
车现象为电器系统故障；
3、测量前后泵比例阀线圈电阻为 17.5 欧姆~18 欧姆，比例阀正常；
4、前后泵电比例阀电压 702#线 13V、703#线电压 13V,电压正常；
5、检查发动机转速 H 模式 11 档为 2260 转，因此憋车故障为发动机
转速标定过高，发动机失速保护功能生效(川崎控制器有此功能),
导致发动机掉速严重,
6、重新将油门拉线进行调整,油门位置电压 3.7V 时相对应发动机转速
为 2220 转,重新将发动机转速进行标定.重新试机后, 憋压时发动机
掉速在标准范围 200 转之内,该机器工作正常。

- 187 -
Troubleshooting:
1. Checked and found engine speed drops 400 ~ 500rpm when failure occurs.
2. Checked and found engine speed is normal when the machine is set under hydraulic control mode. It
is clear that electrical system has a malfunction.
3. Measured resistance of the pump proportional solenoid valve is 17.5 ~ 18 ohm which is normal.
4. Measured voltage of wire 702# of the front pump proportional solenoid valve and the voltage of wire
703# of the rear pump proportional solenoid valve is 13V. The measured voltage is normal.
5. Checked engine speed at 11th position under H mode is 2260rpm which is higher than specification.
KCM controller has the function of overspeed protection. If the engine speed is set higher than
specification, KCM will cause engine speed drop severely to protect the engine.
6. Adjust the cable of the governor actuator, calibrate the engine speed correctly, tested and proved the
maximum engine speed drop is smaller than 200rpm which is within specification.
注：SY215C8M 挖机的转速标定标准：各模式下，最高转速为：H 模式=2200+20；
S=2150+20；L=1950+20；A/I=1350+20
Note: Engine speed calibration: H mode = 2200+20；S=2150+20；L=1950+20；A/I=1350+20rpm.
排故体会：正流量机器转转速标定方法1定要掌握,按公司标准标定。
Experience: Speed calibration method of PFC machine must be grasped. Calibrate as per specification.

- 188 -
09、显示屏数据偶尔显示为零 Data displayed in the monitor is zero occasionally
故障现象：1台SY200C挖掘机在工作过程中出现间段性数据为零现象。
Symptom: Parameters displayed on SY200C monitor is zero occasionally.
故障分析：此故障在机器震动比较大时才发生，很大可能为线路搭铁或接插件接触
不良有关，其次可能为控制器5V电源输出不稳定或触摸屏故障。
Failure analysis: Since this failure occurs when machine has a strong vibration, it is suspected that the
ground wire of the circuit opens intermittently, 5V circuit of controller unstable, or monitor failure.
故障原因：1、线路故障；2、控制器故障；3、触摸屏故障。
5V circuits
1. Circuit failure.
2. Controller has a malfunction.
3. Monitor fails.
排故方法：1、检查控制器到触摸屏传输线路完好，接插
件无松动；
2、根据显示器数据显示机油压力，水温，燃
油油位等数据全为零，可判定为与控制器输出的5伏电源有关，检测
5V电源线有接地现象；
3、进一步检查发现右操纵盒下发动机油门控制盘的5V电源线由于长期和
右操纵手柄安装支架磨擦，导致电线绝缘层磨损，5V电源线在机器震
动时，偶尔有搭铁现象。
4、修复破损的5V电源线，设备的各项参数显示正常，故障排除。
Troubleshooting:
1. Checked and found wires between the controller and the monitor are connected properly. No wire
connector is loosed.
2. Displayed parameters such as oil pressure, coolant temperature, and fuel level are all zero. It is sure
- 189 -
that failure has something to do w ith the 5V wire output from the controller. One of the 5V wire is
shorted to the ground.
3. Further inspection found the 5V wire of dial switch has its insulation layer damaged due to scratching
with t he c onsole e ach ot her. T he exposed 5V w ire s hort t o ground oc casionally w hen t he m achine
vibrates.
4. Repair the failed 5V wire, tested and proved all the parameters displayed normally. Problem solved.
排故体会：该故障属于隐性故障，故障发生时间有不确定性，解决问题更须谨慎，
更仔细。
Experience: This failure occurs intermittently. It is not sure when will this kind of failure occurs and has
the failure phenomena. Service engineer should be carefully and cautious to this kind of failure.
——提供者：蒋崇培 Service engineer: Jiang Cong Pei
- 190 -
10、无通讯，无升速 No communication, engine speed can not be accelerated
故障现象：SY420RC无升速，无通讯（注：此机型为EC-7配自制三一屏电气系统）。
Symptom: SY420RC has no communication. Engine speed can not be accelerated.
故障分析：主要原因为EPEC2038故障或直流转换器故障。
Failure analysis: Major reason is EPEC2038 or transfer module failed.
故障原因：1、EPEC2038通讯模块故障； 2、直流转换器故障；
3、EPEC2023故障； 4、线路问题。
Probable cause of failure: EPEC2023 controller, EPEC2038 communication module, transfer module,
or circuit failure.
排故方法：Troubleshooting: Repair the failed
connector
Yes
Related circuit of CAN Conector or wire
has a failure failure

Repair the failed
No wire of CAN
Flush sofeware to Sofeware uninstalled or

Yes
EPEC2023 and EPEC2038 wrong
No
Connector link to PC by
Replace EPEC2038（Note: EPEC2038
USB-CAN，to read data
is for communication between EC -7
of the controller
& monitor. Communication is normal?
No
Use USB-CAN wire connect

Controller
EC-7, related data is normal?
data displayed
No by CANmoon
Replace EPEC2023 controller
排故体会：通过EC-7数据线与EPEC2023的连接，可快速判断是否是EPEC控制器故障。
Experience: Connect with EPEC2023 by EC-7 data link can determine if EPEC controller failed or not
quickly.
- 191 -
11、高速时转速不稳 Engine speed is unstable at high speed
故障现象：一台SY360C-8在交机过程中发现11档工作时转速不稳定。
Symptom: SY360C-8 engine speed is found unstable at 11th throttle gear during new machine delivery.
故障分析：此现象大致可判断为油门马达或控制器故障；
Failure analysis: Approximately, governor actuator or controller should be suspected.
故障原因：1、检查5V电源电压是否正常；
2、检查506号线电压变化范围是否正常；
3、检查油门马达、控制器是否正常。
1. 5V circuit is normal or not.
2. Voltage range of wire 506 is normal or not.
Make sure the cable not
3. Governor actuator and controller is normal or not. interfered with its
bracket when the cable

排故方法： Y is installed.
Calibrate speed on monitor Incorrect software
Troubleshooting:
N
Governor actuator coil and N Replace

position sensor are normal failed parts
Y
Cable of governor actuator N
Adjust cable
installed properly
Y
5V power at 11th postion is N
normal
Y
Fuel circuit is restricted 5V c ircuit o f c ontrollerfailed Replace TRU
Replace fuel f ilter an d ch eck Check again t o find outthe fuel circuit
N
engine s peed c an be 2200± failure, m ake s ure en gine s peed can
20rpm or not. achieve rated speed.
Y
Recalibrate engine speed, OK
- 192 -
排故体会：此故障为典型的油路引起的电气故障，由于油路堵塞导致发动机转速达
不到额定转速，而控制器11档需标定的转速是2200±20rpm,所以控制器在
11档转速标定时，一直处在一个循环标定的状态当中，所以控制器保存的是
一个不稳定的转速，由于排故期间没有全盘考虑，导致排故思路混乱，所
以要在以后的故障排除过程中首先要仔细分析原因，再解决故障，以提高
工作效率。
Experience: This fault is typically caused by fuel circuit problem which leads to electrical faults, engine
speed can not reach the rated speed due to fuel blockage Engine speed at 11th throttle position need to be
calibrated to 2200 ± 20rpm, so that controller is in a state of cycle calibration which keeps in an unstable
engine speed. Because there is no overall consideration, troubleshooting is lead to confusion. In the future
we ne ed t o a nalyze t he r easons c arefully dur ing t roubleshooting pr ocess a nd t hen s olve t he pr oblem i n
order to improve efficiency.
- 193 -
12、整车无电 Machine has no electric power
故障现象：除喇叭，驾驶室内饰灯外，所有电气件都无电。
Symptom: All the electric components except horn and cab light have no electric power.
故障分析：1、电瓶接触器问题；
2、点火开关故障；
22# harness
3、源线路问题。
Failure analysis: 13# harness
1. Battery relay failed.
2. Start switch failed.
3. Power supply circuit failed. Start circuit
故障原因：1、启动回路保险是否正常；
2、电瓶继电器是否工作；
3、点火开关性能是否正常。
1. Fuse of starting circuit is normal or not.
2. Battery relay is normal or not.
3. Start switch is normal or not.
排故方法：1、首先检查启动回路保险正常；
2、检查电瓶接触器线圈有24V电压；
3、拆下右操作箱,测量点火开关上13#线无24V电压；
4、检测点火开火上22#线也无24V电压；
5、检查右操作箱内接插件发现为22#号线束的插针退出导致断路。
6、修复断路的电路，全车供电得以恢复，故障排除。
Troubleshooting:
1. Checked and found the fuse of starting circuit is normal.
- 194 -
2. Checked and found battery relay voltage is 24V.
3. Checked and found 13# wire of start switch has no 24V voltage.
4. It is found 22# wire of start switch has no 24V voltage too.
5. Further research found the wire 22# is opened.
6. Repair the failed circuit, tested and proved power is supplied normally. Problem solved.
排故体会：排除电器故障必须按部就班，根据原理图来判断每一个电器件的好坏，从
而提高解决故障的工作效率。
Experience: Electrical fault troubleshooting mu st be done step by step, according t o t he schematic t o
determine each electrical part failed or not. This will enhance the efficiency of troubleshooting.
- 195 -
13、发动机无法熄火 Engine can not be shut down
故障现象：机器无法熄火，油门失控（EC-7控制的SY220C5机型）。
Symptom: Engine can not be shut off. Dial switch fails to control engine speed.
故障分析：控制油门马达的相关电器件,线路损坏，或发动机燃油油路故障。
Failure analysis: Governor actuator related electric component and wire failed, or fuel circuit failure.
故障原因: Probable cause of the failure:
1、高压燃油油泵故障；Fuel injection pump has a malfunction.
2、油门电机故障； Governor actuator failed.
3、阀门控制器故障； Dial switch failed.
4、控制器硬件故障； Controller damaged.
5、控制器程序混乱。 Controller software confused.
排故方法：
Troubleshooting: No
Shut off manually Fuel pump or fuel circuit failure
Yes
No Dial switch
Pull cable manually No pulse signal Replace dial switch
failed
Yes Check pulse signal circuit
Replace governor Yes Position sensor and throttle Has p roblem: c ircuit f ailed
actuator motor has failure or not No problem: EPEC failed
No
Yes
Reflush software Software improper
No
Yes
Replace EPEC2023 EPEC failed
No
Replace Governor
Actuator
- 196 -
排故体会：在排除故障过程中，通过各个电气零部件所反应的1些外部特性来
判断零部件性能的好坏，可大大缩短解决故障的时间。
Experience: Whether an electrical component is failed or not can be estimated by its performance. This
will greatly reduce the troubleshooting time.
- 197 -
14、420RC显示屏有时无数据显示 420RC has no data displayed occasionally
故障现象：自主控制器电气控制系统的旋挖钻机，工作时出现显示屏偶尔无数据显
示，并伴有发动机无法升速的现象，几分钟后又能自动恢复正常。
Symptom: Rotary d rill configures with the Sany controller. It has a failure of no data displayed
occationally during the work. At the same time engine speed can not be accelerated. Failure will
recovered automatically several minutes later.
故障分析：当显示屏无数据显示，可能是由于显示屏与控制器通讯，或控制器与ECU
通讯中断引起，发动机无法调速是由油门旋扭故障，控制器与ECU通讯中
断故障，线路接插件接触不良，或HCU.TRU通讯模块故障引起。
Failure an alysis: Failaure of no data displayed may be caused by t he communication between the
controller and monitor interrupted, or the communication between controller and ECU interrupted.
Engine speed f ails t o b e accelerated may be caused by the dial switch failure, communication between
controller and ECU interrupted, wire circuit opened intermittently, or failure of HCU and TRU.
故障原因：1、线路接插件故障；
CAN resistance: 120 ohm
2、HCU.TRU硬件故障；
1. Wire connector has a malfunction.
2. HCU and TRU failed.
排故方法：1、检查油门旋扭阻值正常，线路无摩损，短路等
现象；
2、检查CAN通讯线无短路，断路，接插件无接触不良现象，CAN终端通讯
电阻正常；
3、更换新控制器后故障现象还未排除；
4、打电话请智能工程开发所相关人员提供技术支持，得知此现象为控制
器通讯模块抗干扰能力差引起，更换升级产品后正常。
- 198 -
Troubleshooting:
1. Checked and found the resistance of the dial switch is normal. Wires of the dial switch are not worn
and no circuit short phenomena can be found.
2. Checked and found the circuit of CAN data link has no short or open phenomena existed. Measured
resistance at the CAN terminal is normal.
3. Replace with a new controller, tested and found the failure still existed.
4. Make a call to related engineer of the R&D center to ask a help, and found this failure phenomena is
caused by the poor anti-jamming ability of the controller communication module. Replace with the
updated module, tested and proved problem solved.
排故体会：检查电器故障应该由简单到复杂逐步判断，了解各个电器元件
工作原理，电气性能及作用。
Experience: Troubleshooting of electrical failure should be carried out from simpe to comflex step by
step, and understand well the system operation and function of each component.
- 199 -
15、马达能带动发动机运转但不能着车 Engine can be cranked but can not be started
故障现象：机器在交机过程中不能启机，但启动继电器每 3S 就有一次输出（注：SYFCS
控制器，SY420RC 机型）。
Symptom: Engine can not be started during the new machine delivery. Start relay has output for every
three seconds. Machine model is SY420RC and the controller is SYFCS.
故障分析：控制器故障，ECU 保险烧坏。
Failure analysis: Controller has a malfunction. The fuse of ECU is failed.
故障原因：可能由于外部原因引起的程序混乱。
Failure cause: may be due to external reasons and cause the software confused.
排故方法：1、用万用表测得启动（每 3S 左右一次），先导，跟熄火延时同时有 24V
电压输出，并检测 ECU 保险 OK；
2、刷新程序，更换新控制器后故障现象依旧存在；
3、用万用表测得 ECM 端电源电压 24V
证明线路无问题；
4、查看故障指示灯，无任何故障信息；
5、电话咨询智能工程开发所人员得知
原因可能是 CAN 通讯短路或发动机
ECU 电源故障.
6、经检查发现为 ECU 接插件上防尘圈脱
落导致接插无法插牢固而引起的接触
不良。
ECM controlled start
7、修复松脱的接插，故障排除。
switch
- 200 -
Red one is the waterproof
Installed improperly a nd casue t he
and dustproof seal.
wire circuit opened intermittently
Troubleshooting:
1. Measured 24V voltage at start relay, pilot relay, and shutoff relay once every three seconds. It is sure
that the fuse of ECU is normal.
2. Flush software, replace the controller, tested and proved problem still existed.
3. Measured suppy power at the ECM is 24V, it means the power supply circuit is normal.
4. Check the faulty indicator, and found no related faulty information.
5. Make a call to the related R&D engineer to ask for help. The R&D engineer said the root cause of the
failure may be CAN data link shorted or engine ECU power supply circuit has failure occurred.
6. Further research found the dustproof seal of the wire plug of engine ECU drops down and make the
connection opened intermittently.
7. Repair the loosed wire connector, tested and proved engine can be started normally. Problem solved.
排故体会：此故障为典型的隐性故障，解决此类故障应该寻找多方面的技术支持，
争取第一时间解决故障。
Experience: This i s a n intermittent f ailure. T roubleshooting f or t his ki nd of failure, t echnical support
from other departments may be required to solve the problem timely.
——提供者:蒋崇培 Service engineer: Jiang Cong Pei
- 201 -
16、SY215 无法加速，仪表各参数为零 Can not be accelerated, parameters value is zero
故障现象： SY215挖机工作一段停机后,再启动发动机无法加速,仪表盘显示的各个参
数全部为零。
Symptom: SY215 e xcavator w orks f or a pe riod. Shut dow n t he e ngine. Restarts a nd f ound t he engine
speed can not be accelerated. Displayed value of all the parameters is zero.
故障分析：1、显示屏与控制器间的通讯故障；
3、显示屏故障。
Failure analysis:
1. Communication between the monitor and the controller has a failure occurred.
3. Monitor has a malfunction.
故障原因：显示屏与控制器间的通讯线压断造成通讯中断。
Root cause of the failure: Communication between the monitor and controller is interrupted.
排故过程：检查显示器与KCM控制器的通讯，打开后盖板，用万用表测量通讯线CAN+、
CAN-，发现通讯线CAN+不通，打开线束检查通讯线CAN+被盖板压断，造
成通讯中断，重新接线后故障排除。
Troubleshooting: Open t he c ontroller c over t o check t he da ta l ink be tween the KCM controller and
monitor. Measured w ire C AN+ and C AN- by using m ultimeter, and found t he C AN+ w ire i s opened.
Repair the failed wire, tested and proved problem solved.
- 202 -
排故体会：1、检查机器故障时,需要多方面的观察,详细询问出现的各种故障现象,
从而提高故障判断的准确性, 了解SY215机器的显示屏控制电路。
2、建议在车身上增加线束的固定点,将线束固定好。
Experience:
1. Enquiry the operator all kinds of failure related phenomena detailly, and then inspect the machine
from multiple degrees to do the troubleshooting. Understanding the control circuit of the SY215
monitor well to enhance the troubleshooting accuracy.
2. Suggest increasing supporting points of the harness in order to fasten the harness better.
——提供者：合肥湘元 Dealer: He Fei Xiang Yuang
- 203 -
17、旋挖钻全车无动作 Rotary drill has no actions
故障现象：一台SR220旋挖钻，在工地出现只有桅杆有动作，其它动作均无。
Symptom: SR220 rotary drill has no actions except the backstay.
故障分析：1、因为桅杆有动作，而且是由单独的辅泵供油的，由此可判断为发动机
与联轴器之间的动力输入是正常的，可排除联轴器损坏方面的问题；
2、液压方面：因为此种故障涉及多个动作都没有，首先要想到液压方面
的先导油路是否正常，因为先导油路的通断是由电磁阀来控制实现
的，可测量电磁阀线圈阻值，正常时为25欧±1欧；
3、电气方面：此种故障首先要考虑到先导锁定开关，因为它得电工作后
才会控制先导锁定电磁阀的动作。
Failure analysis:
1. Backstay can be operated which oil is supplied by a single auxiliary pump. It is sure that engine power
is normally transferred through the coupling. Coupling should not be suspected.
2. Hydraulic a spect: S ince a ll o ther o perations a re f ailed, it is s uspected th at p ilot c ircuit is a bnormal.
The pilot circuit is controlled by the hydraulic activation solenoid valve, so this solenoid valve should
be suspected. Its resistance should be 25±1 ohm.
3. Electric aspect: All ot her operations are f ailed, t he h ydraulic a ctivation s witch s hould be s uspected.
Only when this switch is closed, the hydraulic activation solenoid can get electric power and let pilot
oil pass through and supply to the pilot system.
故障原因：先导电磁阀线圈损坏。 Pilot solenoid valve

Root cause of the failure: The coil of hydraulic activation solenoid is failed.
排故方法：1、打开电源，通过显示器检查先导锁显示信
号正常；
2、拔下先导电磁阀线圈，用万能表测量线圈
的电阻值，测量阻值过于偏大为2.6千欧.
- 204 -
3、更换电磁阀后，故障排除。
Troubleshooting:
1. Turn t he s tart s witch on. Checked i n t he m onitor a nd f ound t he di splayed i nformation of h ydraulic
activation solenoid valve is normal.
2. Remove t he coil of t he hydraulic activation s olenoid valve, m easured i ts resistance with multimeter
and found it is 2.6kΩ which is far from the specification.
3. Replace the failed solenoid valve, tested and proved machine works normally. Problem solved.
排故体会：1、当全车所有动作包括桅杆动作如果都没有，很有可能为发动机与液压
泵之间的联轴器损坏打滑造成的；
2、如只有桅杆动作，可直接检查，先导电磁阀是否损坏，测量其线圈阻
值。
Experience:
1. If a ll th e a ctions o f th e machine are f ailed, it is possible th at th e coupling b etween th e e ngine a nd
hydraulic pump is damaged.
2. If only the backstay can be operated, check the resistance of the hydraulic activation solenoid valve to
determine whether it is failed or not.
——提供者：计双杰 Service engineer: Ji Shuang Jie
- 205 -
18、发动机不能启动 Engine can not be started
故障现象：一台 215C8 钥匙开关打到“ON”显示屏不显示，发动机不能启动。

Symptom: Monitor of SY215C8 has no power when start switch is on. Engine can not be started.
故障分析：造成全车无电的原因有以下几种情况：
1、主保险丝熔断；
2、电瓶继电器不吸合；
3、启动钥匙开关内部触点接处不良；
4、线路自身断路，短路。
Failure analysis: Probable cause of machine has no power supply listed below:
1. Power supply fuse is damaged.
2. Battery relay fails to engage.
4. Wire circuit failed, shorted or opened.
故障原因：13-2#线路有一处与钢板短路，导致主继电器无法吸合，全车无电。
Root c ause of t he failure: Wire 1 3-2# has i ts i nsulation w orn out b y t he s teel pl ate a nd s horted t o the
ground, which cause the main relay can not be engaged and machine has no power supply.
排故方法：1、先检查主保险丝，发现保险丝是好的且接触良好；
2、再准备一根导线把电瓶的正极同电瓶继电器的正极（13-2#线端）直接
短接，继电器吸合，全车得电。说明电瓶继电器和钥匙开关都是好
的。
3、用万能表测电瓶到钥匙开关的 13-2#线是通路，从钥匙开关到电瓶继
电器的线是通路，后测得，电瓶到钥匙开关的线电压是 24V，而回到
电瓶继电器的电压是 0V；
4、进一步检查发现 13-2#线路有一处与钢板短路，导致主继电器无法吸
- 206 -
合，全车无电。
5、把 13-2#线故障部位接回，用绝缘胶带包好，试车正常。
Troubleshooting:
1. Checked and found the power supply fuse is normal.
2. Using a wire to connect from battery positive pole to the battery relay positive pole of wire 13-2#, the
main relay engaged and the machine has power supplied. It is sure the battery relay and start switch
are normal.
3. Checked with the multimeter, and found the wire 13-2# from battery to start switch is not broken. The
voltage from battery to the start switch is 24V but the voltage from the start switch to the battery relay
is 0 V.
4. Further research found wire 13-2# has its insulation worn out and shorted to the frame, which cause
the main relay fails to engage and machine has no power supplied.
5. Repair the worn wire and fastened properly, tested and proved problem solved.
排故体会：排除任何故障一定要熟悉各车型的电路图，做到心中有数。
Experience: Be f amiliar w ith th e e lectric circuit w hen doi ng t he t roubleshooting. Know f airly w ell a t
each step.
——提供者：郑州湘元 Service engineer: Zhen Zhou Xiang Yuan
- 207 -
19、发动机不能着车 Engine can not be started
故障现象：发动机起动冒黑烟，不能着车。
Symptom: Engine can be cranked but can not be started. Has black smoke during the crank.
故障分析：1、控制器故障；
2、主泵故障；
3、主阀阀芯发卡；
4、发动机本身故障。
Failure analysis:
2. Main pump failure.
3. Main valve spool seized.
4. Engine failures.
故障原因：1、首先检查显示屏参数，看各传感器工作是否正常；
2、检查主泵的工作压力是否正常；
3、检查主阀是否有阀芯发卡现象；
4、检查发动机低压油路是不是正常。
1. Check parameters in the monitor, all sensors are normal or not.
2. Main pump output pressure is normal or not.
Proportional
3. Main valve spool has seizure or not.
solenoid valve
4. Engine fuel circuit is normal or not.
排故方法：1、拆除主溢流阀，发动机能正常启动，排
除发动机故障；
2、改液控后能正常启动，排除泵的故障；
3、检查主阀阀芯，没有发现故障，排除阀
- 208 -
的故障；
4、检查显示屏数据，发现电比利阀电流较低，为 350 毫安，正常情况应
该为 400 毫安左右；
5、更换转换板后，整机启动正常。
Troubleshooting:
1. Remove the main relief valve, engine can be started normally. Engine should not be suspected.
2. Set the pump under hydraulic control mode, engine can be started normally. Pump is normal.
3. Check the main valve spools, no seizure could be found. Main control valve is normal.
4. Check the parameters in the monitor and found the current to proportional solenoid valve is 350mA,
which is lower than the specification. Normally, it should be about 400mA.
5. Replace the transfer module, tested and proved engine can be started normally. Problem solved.
排故体会：熟悉各主要部件的性能参数，有利于判断部件是否出故障。
Experience: Be familiar with the specification of the major components will be helpful to determine
whether it performs normally or not.
——提供者：王超 Service engineer: Wang Chao
- 209 -
20、自主控制器程序故障 Program failure of the controller
故障现象：机器工作两小时掉速熄火，全车断电后能重新起动，但受负载就熄火，
提升动臂缓慢，其他动作正常。
Symptom: Engine s peed drops and shut off automatically after working two hours. Engine can be
restarted but machine can not take the load. Boom up operation is slow while other actions are normal.
故障分析：1、油路问题所导致熄火；2、动臂液压回路故障；3、电控程序故障。
Failure analysis:
1. Fuel circuit has a failure which cause the engine shut down automatically.
2. Boom hydraulic circuit has a failure.
3. Software of the controller has a malfunction.
故障原因：控制器程序故障。
Root cause of the failure: Software of the controller has a malfunction.
排故过程：1、油路检查，正常；
2、通过显示屏查看发现提升动臂的压力只能到 180，而电比例的电流偏
高，判断控制对提升动臂的输出信号有问题。
3、刷新程序，但排除不了故障；
4、刷新老程序，而所有数据及各动作正常。
Troubleshooting:
1. Checked and found fuel circuit is normal.
2. Checked a nd f ound t he boom up pr essure i s j ust onl y 180M pa, a nd t he c urrent t o the proportional
solenoid valve is very high. It is suspected that controller output signal for boom up is abnormal.
3. Flush with the new software, tested and proved problem still existed.
4. Flush with the original software, all the parameters and operations are normal. Problem solved.
排故体会：在刷新程序时，要刷对程序。
Experience: Service engineer should find out correct software and flush it into the controller properly.
——广州巨和：李桥兵 Service engineer: Li Qiao Bing
- 210 -
21、SY205挖机回转动作慢 SY205 swing operation has a long cycle time
故障现象:一台SY205正流量挖机回转动作慢，其它动作正常。
Symptom: SY205 swing operation is slow while other operations are normal.
故障分析：一般分为电控系统故障和液压方面故障，回转手柄操作时，控制器通过先
导压力传感器检测回转二次先导压力控制，通过控制器计算向主泵前泵电
比例阀输送比例电流，调节主泵输出流量，二次先导压力控制主阀给回转
马达供油，供油量越大，回转速度越快。
Failure analysis: Usually, this kind of failure is caused b y hydraulic or electronic problems. When the
swing pi lot va lve i s ope rated, c ontroller r eceives s wing pi lot pr essure s ignal t hrough t he pi lot pr essure
sensor. And t hen s end p roper c urrent t o the front pum p proportional s olenoid valve t o adjust the pump
output flow. Pilot pressure controls the main oil supplys to the swing motor. The more the oil supplied,
the faster the swing motor rotates.
故障原因： 1、回转马达损坏故障；
2、主阀回转阀芯卡滞；
3、手操作阀故障，主阀上回转先导二次压力不够，阀杆不能全部打开；
4、回转先导压力传感器或线路故障，控制器检测不到先导压力信号。
1. Swing motor has a failure existed.
2. Swing main valve spool seized.
3. Swing pilot valve failed. Insufficient pilot oil causes the main valve spool not open completely.
4. Swing pilot pressure sensor or its circuit failed. Controller can not detect the swing pilot signal.
排故过程：1、从显示屏上检查回转时先导压力为0，前主泵主压力为10MPa,前泵电
比例阀电流0mA，判定无回转二次先导压力信号到控制器，主泵按最小
流量输出液压油，故而引起动作慢；
2、安装压力表检测送至主阀回转阀芯上先导压力为3.9 MPa，正常，排除
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手操作阀及先导油路故障；
3、检查控制器输出至回转先导压力传感器50#线上为5V，测00号线电压为
0，中线输入不变，电压正常，控制器等线路正常，问题可能出在回转
先导压力传感器损坏；
4、将回转先导压力传感器与左行先导压力传感器对调，回转动作恢复正
常，左行走动作慢；
5、更换回转先导压力传感器，故障消失。
Troubleshooting:
1. Checked in the monitor and found the swing pilot pressure is 0, front pump pressure is 10Mpa, and
the current to the front pump proportional solenoid valve is 0mA. It is sure that there is no swing pilot
pressure signal sends to the controller. Front pump output is the minimum and swings slowly.
2. Install a pressure gauge, and measured the swing pilot pressure to the swing main valve spool i s
3.9Mpa which is normal. It means pilot circuit and swing pilot valve are normal.
3. Measured voltage of wire 50 # from controller to the swing pilot sensor i s 5V and wire 00 # is 0V .
Electric circuit is normal. Swing pilot pressure sensor is suspected.
4. Replace swing pilot pressure sensor, tested and proved swing operation is normal. Problem solved.
排故体会: 当先导压力传感器损坏或送至控制器线路故障，控制器检测不到先导压
力信号，则控制器按最小流量向主泵输送比例电流，引起主泵排量为最小
量，动作缓慢。
Experience: If the pilot pressure sensor or its circuit is failed, controller can not receive the pilot pressure
signal. Controller will send a proper current to the pump proportional solenoid valve to make the pump
output flow is the minimum, and cause the machine has a slow operation.
——提供者：李茂明 Service engineer: Li Mao Ming
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22、挖掘机不能起动 Engine can not be started
故障现象：一台08年的挖掘机SY230无法启动。
Symptom: SY230 excavator, made in 2008, engine can not be started.
故障分析：1、启动继电器故障；
Failure analysis:
1. Start relay failed.
3. Controller failure.
故障原因：控制器故障。
Root cause of the failure: Controller failed.
排故方法：1、用万用表检测启动继电器，是好的，没问题；
2、检查启动马达从电池来的电源线，有24V电源；检查控制马达启动的
电源线没电源，说明是控制器问题；
3、检查发现控制器的50号线没有5V电源输出，证明控制器的问题，更换
新的后，故障排除。
Troubleshooting:
1. Checked with multimeter and found the start relay is normal.
2. Measured at the motor and found there is 24V from battery but no control voltage from controller.
3. Checked & found the wire 50# of controller has no 5V output. Replace the controller. Proble solved.
排故体会：排除故障时，应该有简单到复杂，由外到内，从原理上分析解决问题。
Experience: Troubleshooting should be done from simple to comflex, and from external to internal.
Using the system operation to guide your analyzing and solving problem.
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23、偶尔右边行走无力 Right side travel motor has a poor performance occasionally
故障现象：SY215 挖机，3100 小时，右边行走无力并伴有憋车，此故障时有时无。

Symptom: 3100 hours SY215, right side traveling has a poor performance occasionally.
故障分析：1、右行走先导压力传感器故障；
2、P2 泵电磁比例阀插接口接触不良。
Failure analysis:
1. Right travel pilot pressure sensor failed.
2. Rear pump proportional solenoid valve wire connector is opened intermittently.
故障原因：1、右行走先导压力传感器是否异常；
2、P2 泵电磁比例阀是否故障，检测电压、电阻是否在范围值内。
1. Right travel pilot pressure sensor is normal or not.
2. Rear pump PSV is normal or not. Voltage and resistance of the PSV is within specification of not.
排故过程：1、检测发现右行走先导压力传感器插孔已断裂，传感器损坏不明显；
2、检测 P2 泵电磁比例阀的电压、电阻均正常；
3、更换行走先导压力传感器后试车正常。
Troubleshooting:
1. Checked and found the wire connector of the right travel pilot pressure sensor is cracked.
2. Measured voltage and resistance of the rear pump PSV is withing specification.
3. Replace the fail right travel pilot pressure sensor, tested and proved problem solved.
排故体会：主阀前部先导压力传感器护板扣比较容易断裂，在挖掘机工作中高频率
的震动下容易损坏护板下面的先导压力传感器。
Experience: The plate of the transition block may be broken due to machine vibration, which will cause
the pilot sensors under it damaged.
——提供者：尚建波 Service engineer: Shang Jian Bo
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24、雨刮器不工作 Wiper fails to work
故障现象：雨刮器不工作。
Symptom: Wiper fails to work.
故障分析：保险丝是否损坏；雨刮器线路是否正常，雨刮器接地线断路；雨刮器电
机是否损坏；雨刮器连接部位是否有脱落。
Failure analysis: Fuse is damaged or not. Wiper circuit is normal or not. Wiper ground wire is opened or
not. Wiper motor is failed or not. The wiper elbow is failed or not.
故障原因：检查保险丝损坏，换保险丝打开点火开关、保险丝又损坏；检查雨刮器
连接部位正常。换雨刮器电机后工作正常。
Failure cause: Checked and found the fuse is damaged. Fuse failed again after replacement and pushing
the wiper switch. The wiper elbow is normal. Replace the wiper motor, problem solved.
排故方法:
雨刮器不工作
分析：
雨刮器不工作
是检修25#线
F5保险是否烧断是检查25#线是否短路
否更换F5保险
否
雨刮器开关是否损坏是更换雨刮器开关
35#、36#线是否短路是检修35#、36#线
雨刮器故障检修或更换雨刮器
线路图
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Troubleshooting:
排故体会: 要想快速准确地排除故障,必须心中有图纸。
Experience: If you want to figure out the root cause of the failure quickly and accurately, you must be
familiar with the electrical drawing very well and remember it in your heart.
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25、OPUS 显示屏参数为零 Paramaters value displayed on the Opus monistor is zero
故障现象：SY215显示屏断电后出现所有参数为零,同时整机无动作,无法升降速,将
KCM插头拔下重新安装,机器工作又正常,断电后再通电所有参数又都为
零。(机器配置为:KCM控制器、OPUS德国显示屏、AC2000油门马达)。
Symptom: Parameters displayed on the monitor is zero after the machine is power off. At the same time
engine speed can not be changed, and the machine has no action. Reconnect the KCM connector, machine
restored. This failure repeats againe once the machine is power off.
故障分析：Troubleshooting:
Fuse of wire 42# damaged? Y Wire 42# shorted? Y Repair the short circuit
Voltage of wire 42# is 24VDC? N Repair the open circuit
KCM controller failed, replace and

Voltage of wire 50# is 5VDC? N
calibrate engine speed.
KCM controller failed, replace and

Wire 506# has voltage? N
calibrate engine speed.
Communication between KCM controller and OPUS monitor is failed, or other failures.
Communication module Monitor or

of KCMcontroller failed CAN data link
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故障原因： 1、KCM控制器与OPUS德国屏通讯中断；
2、KCM控制器故障；
KCM controller
3、线路故障（主要指控制器24V电源及5V电源线路）。
1. Communication between controller and monitor is interrupted.
2. KCM controller is malfunctioned.
3. Circuit failure of the controller.
排故方法：1、检查控制器电源42#线电压正常（DC24V）
2、出现故障时测量控制器50#线电压为0。（DC5V）
3、将KCM插头重新拔下在机器通电时再插上去，机器所有参数均又正常，
测量50#线电压此时为5V，由此可以判断KCM控制器故障；
4、更换KCM控制器后，机器工作正常。
Troubleshooting:
1. Measured voltage of controller power wire 42# is 24VDC which is normal.
2. Measured voltage of controller wire 50# is 0 when the failure occurs.
3. Disconnect the KCM connector. Power the machine and reconnect the KCM connector. All the
parameters are normal, and the measured voltage of wire 50# is 5VDC. It means controller failed.
4. Replace the KCM controller, tested and proved machine works normally. Problem solved.
排故体会：该故障通常情况下是 OPUS 德国屏与 KCM 控制器出现故障,将 KCM 插头
重新拔下后在通电情况下再插上,机器工作正常,相当于将 CAN 总线重启，
断电后又异常。
Experience: This ki nd of failure is us ually caused b y Germany O PUS m onitor or K CM c ontroller.
Disconnect the KCM connector and reconnect it when the machine is power on, which will reset the CAN
data link and make the machine restore to normal status. Failure occurs again once the machine is power
off.
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26、机器无动作，油门加不上 Machine has no action, engine can not be accelerated
故障现象：一台SY75型机器，出现喇叭保险丝频繁熔断，机器无法启动，强行启动后，
机器无动作，油门加不上。
Symptom: Fuse of hor n i s burnt frequently on SY75. Engine can not be started. Once the engine i s
started informality, machine has no action and engine speed can not be accelerated.
故障分析：根据故障现象，出现上述故障初步分析系电路问题：
1、线束问题；
2、主控制器故障；
3、GPS故障。
Failure analysis: As per the failure phenomena described, it should be a electrical circuit failure.
1. Harness failure.
2. Main controller is malfunctioned.
3. GPS failure.
故障原因：线束短路搭铁。
Root cause of the failure: Harness is shorted to ground.
排故方法：1、检查各线束接头，未发现拆卸、松动迹象，用万用表检查线束，发现
与喇叭、室内灯及备用灯电源相关的23#线短路，进一步检查发现短路
部位系室内灯线束与驾驶室地板连接处绝缘损坏。更换新件后试机，
喇叭工作正常，但机器仍无法启动。
2、将钥匙开关转到“START”位时，K3不吸合，检查主控器输出端62#线
至K3端62#线为通路，但控制器端62#线无电；更换新的主控制器，故
障现象无改变。故可排除主控制器问题。
3、检查发现GPS信号灯闪烁不正常（绿灯亮一下，红灯闪烁六次，正常应
为绿灯，红灯交替闪烁）；拆开驾驶室下部底板，发现有一束线扭在一
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起，将线束重新固定后，特别是将座椅后部各线束用扎带重新固定后，
GPS信号恢复正常，机器启动恢复正常，油门控制与动作也恢复正常。
Troubleshooting:
1. Checked and found no harness connectors are loosed or opened. Using the multimeter to check the
harness, and found the wire 23 # which has relation with horn, cab lamp, and service lamp is shorted.
Further research found insulation of this wire is damage at the cab floor. Repair the failed wire, horn
works normally but engine still can not be started.
2. K3 relay not engaged w hen engine i s cranked. Wire 6 2# from controller to K 3 relay is normal, but
wire 62# has no voltage at the controller end. Replace the controller, problem still existed.
3. Checked and found the GPS indicator flashes abnormally. Green indicator flashes one time follows
by red indicator six times. Normally, the green and red indicator flashes alternately. Further research
found the some wires are complected under the cab each other. Re-arrange the wires and fasten them
properly. GPS signal restored, engine can be started normally, and machine works normally. Problem
solved.
排故体会：小型挖掘机由于结构紧凑，造成许多部件堆放在1起，尤其线束，若固
定不牢，在机器工作过程中产生的振动，导致线束扭结，进而松动，最
终导致接触不良，机器无法正常工作。
Experience: Space a mong t he c omponents of the small s ize ex cavator i s co mpacted. If t he w ire o r
harness is not fastened properly, it would complet due to machine normal vibration. Wires may be loosed
or opened intermittently and cause the machine fails to work normally.
——提供者：孙明辉 Service engineer: Sun Ming Hui
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27、无法熄火，油门失控 Can not be shut down, throttle is out of control
故障现象：一台05年出厂的LSY220型机器在工作时出现无法熄火，油门失控。
Symptom: LSY220, made in2005, can not be shut down and throttle is out of control.
故障分析：发动机可以正常起动，但油门无法控制；
1、柴油泵故障；
2、油门电机故障；
3、油门控制器故障；
4、油门旋钮故障；
5、线束短路搭铁；
6、主控制器问题。
Failure analysis: Engine can be started normally, but the throttle is out of control.
1. Fuel injection pump failed.
2. Motor of governor actuator failed.
3. Governor actuator failed.
4. Dial switch failed.
5. Harness short to ground.
6. Controller is malfunctioned.
故障原因：EPS控制器损坏。
Root cause of the failure: EPS controller failed.
排故方法：
1、先导线路各接头无松动迹象，线束表皮也无破损痕迹；用万用表检测，
未发现短路、断路问题，故可排除线束故障；
2、松动油门拉线，启动机器后手动调节油门，发动机转速正常，由此可
排除柴油泵故障；
3、用万用表测油门电机侧传感器端1#与3#端子电阻在标准范内，且1#
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与2#、2#与3#端子间电阻基本相同，由此可排除电机故障；
4、起动机器，手动调节油门旋钮，变阻器阻值同步变动，由此可排除油
门旋钮问题；
5、将原油门控制器更换为新件，试机；故障现象无改变，由此可排除油
门控制器问题；
6、将主控器换为新件，将原线路恢复后，试机，机器工作正常。
Troubleshooting:
1. Checked and found wire circuit is normal. No wire loosed, opened, or shorted.
2. Disconnect the throttle cable and start the engine. Engine speed can be accelerated manually. Fuel
pump should not be suspected.
3. Measured resistance of the motor between pin 1 # and pin 3# is within specification. Also that th e
resistance between pin 1# and pin 2# or between pin 2# and pin 3# is almost the same. Motor should not
be suspected.
4. Start the engine, rotate the dial switch. The measured resistance changes in synchronization. It is sure
that the dial switch is normal.
5. Replace the governor actuator, tested and found the problem still existed.
6. Replace the controller, tested and proved machine works normally. Problem solved.
排故体会：机器在工作过程中，有些部件会随着时间的推移，性能也发生变化，尤
其是电气部件。因此，在使用机器时要加强对相关部件的维护，特别是
电气元件，如控制器、电机等，防止受潮进水。
Experience: As the machine working hours accumulated, the performance of some components may be
deteriorated especially the electrical components. Operator should pay more attention to the maintenance
to the related components, such as the controller, motor, and so on.
——提供者：孙明辉 Service engineer: Sun Ming Hui
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28、SY230C6B 挖机无法启动 SY230C6B can not be started
故障现象: SY230C6B 挖机无法启动。

Symptom: SY230C6 can not be started.
故障分析：1、启动挖掘机启动马达不工作,应先查电气方面,再查马达有无故障；
2、启动挖掘机启动马达工作,但无法启动，应先检查柴油路及液压系统。
Failure analysis:
1. If the starting motor not work, check the circuit first and then motor has failure or not.
2. If the starting motor cranks but engine can’t be started, check fuel system and hydraulic system.
故障原因:1、启动挖掘机启动马达不工作,先检查电气方面；
2、电瓶亏电；
4、电瓶继电器故障；
6、启动继电器故障；
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7、安全继电器故障。
8、启动马达故障;
1. Starting motor fails to crank engine. Inspect the electrical system for root cause first.
2. Battery lacks power.
4. Battery relay failed.
6. Start relay is failed.
7. Safety relay problem.
排故方法： 1、启动时测量电瓶对地电压是否正常(正常时 DC24V)；
2、测量电瓶继电器常开触点闭合时是否接触良好；
3、检测点火开关启动位置时11号线是否有DC24V电压；
4、启动时控制器602号线是否有DC24V输出；
5、启动机器时启动继电器是否吸合；
6、安全继电器K11是否工作正常；
7、线路故障； Safety
relay
8、先导线路故障；
Troubleshooting method：
1. Battery to ground voltage is 24VDC or not when engine is cranking.
2. Battery relay works normally or not.
3. Voltage of wire 11# of the start switch is 24V4C or not.
4. Voltage of controller wire 602# is 24VDC or not when engine is cranking.
5. Start relay engaged or not when engine is cranking.
6. Safety relay K11 works normally or not.
7. Circuit failure.
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8. Control circuit failure.
排故过程：该机器启动时发现K3启动继电器工作正常，安全继电器的S端对地电压
为DC24V，可以说明该机器电瓶、点火开关、控制器、启动继电器正常，
检查时发现安全继电器不工作，常开触点B点与C点不闭合，更换安全继
电器后启动机器,一切正常。
Troubleshooting: Checked a nd f ound s tart r elay K3 w orks nor mally during t he cranking. Measured
voltage of the contact S of the safety relay is 24VDC, which means battery, start switch, controller, and
the start relay works normally. Further research found the normal opened contact B and C of the safety
relay can not be closed. Replace the failed safety relay, tested and proved engine can be started normally.
Problem solved.
排故体会：1、该机五十铃发动机安全继电器原理：启动时给安全继电器的S端提供
24V电源，经内部R1给Q23级管一个基级电压，Q23级集电极与发射极导通,
电经安全继电器线圈,通过Q2的C端与E端接对,B端与C端闭合。2、启动
后,R端由发电机输出27V的电压,经齐纳二极管（稳压2级管）到Q13级管
基极，Q13极管集电极与发射极导通，S端电压经Q1集电极，到发射极对
地，Q23极管无极基极电压，保护启动回路。
Experience: This machine is powered by ISSUZU engine. System operation of the safety relay is:
1. When starting, the battery provides the S terminal of safety relay a 24V power supply. The terminal S
then transfer through R1 inside a basic voltage to the triode Q2. The collecting pole Q2 of the triode
conducts to the emitting pol e. And the power passing through the circuit of the safety relay,
connecting the terminal C and the terminal E on the triode Q2, makes the terminal B and the terminal
C closed and start the starting motor.
2. After t he en gine i s s tarted, t he t erminal R o f t he generator out puts a 27V power, t hrough t he Zener
diode, to the base of the three tubes Q1. The collecting pole of the Q1 conducts to the emitting pole.
And the power at the terminal S through the collecting pole of the Q1 to the ground of the emitting
pole. The base voltage on the non-polar transistor Q2 protects the starting circuit.
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29、控制器显示故障代码 20 Trouble code 20 is displayed
故障现象：一台 SY235 型挖机，工作约 160 小时，设备在做 50 小时保养时发现报
故障代码 20，但挖机工作正常。
Symptom: Working hours of SY235 excavator is 160H . Faulty code 20 activates when 50 hour
maintenance is performed but machine works normally.
故障分析：1、故障代码 20 表示主泵压力不正常；
2、主泵压力传感器损坏；
3、压力传感器到控制器的线路故障；
Failure analysis:
1. Faulty code 20 means the main pump pressure is abnormal.
2. Main pump pressure sensor failed.
3. Circuit of main pump pressure sensor has failure.
4. Controller failed.
故障原因：主泵压力传感器电路与左右回转先导压力传感器电路接反。
Root cause of the failure: Wire of pump pressure sensor and swing pilot pressure sensor interchanged.
排故方法： 1、检测主泵压力传感器，正常；
2、检测压力传感器到控制器间电路，正常；
3、检查各线号与相应压力传感器是否一一对应，发现主泵压力传感器电
路与左右回转先导压力传感器电路接反，纠正后故障消除。
Harness of main Main pump

pump pressure sensor pressure sensor
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Swing pilot Swing pilot
pressure sensor pressure sensor
Troubleshooting:
1. Checked and found main pump pressure sensor is normal.
2. Checked and found the electrical circuit between the pressure sensor and controller is normal.
3. Double check the pressure sensor harness, and found the harness of main pump pressure sensor and
swing pilot pressure sensor is interchanged. Correct the harness mistake, tested and proved problem
solved.
排故体会：发现故障后，要从现象到本质，逐步推进，从简到难，从外到内。要仔
细分析，认真观察。
Experience: When failure occurs, service engineer should grasp actual failure through the phenomenon.
Troubleshoot from simple to complex step by step. Analysis carefully and observe exquisitely.
——提供者：朱善超 Service engineer: Zhu Shan Chao
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30、SY135 无法正常熄火、断电 SY135 can not be shut down and power of normally
故障现象： SY135 机器无法正常熄火、断电。

Symptom: SY135 excavator can not be shut down and power of normally.
故障分析：通常机器出现无法熄火与无法断电问题是共同存在的，所以我们只分析
机器无法正常熄火原因，由于该种机型是单独的熄火装置，可以从以下
几点分析：
1、点火开关故障，会导致无法正常熄火；
2、64#线、65#线故障；
3、停车电磁阀故障；
4、停车继电器故障；
5、停车拉线卡滞。
Failure an alysis: Machine c an not b e s hut do wn i s usually happened t ogether with m achine c an not
power of. So we just needs to analyze the reasons of machine can not be shut down. This model has a sole
shut down component. Probable cause of failure listed below:
1. Start switch failed and causes machine can not be shut down.
2. Wire 64# and 65# failed.
3. Shut down solenoid failed.
4. Shut down cable interfered with other parts.
故障原因：发现在驾驶室外部的 65#线在平台处线被压扁断裂，重新连后故障解决，
机器正常。
Root cause o f t he failure: Wire 65# is staved and
broken out o f t he c ab. Repair t he f ailed w ire, p roblem
solved. Shut down solenoid
排故方法：1、检查熄火电机通断正常，且拉
线无卡滞现象，因此排除熄火
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电机故障； Wire 65#
2、检查电源打开，继电器吸合正常，排除继电器故障；
3、当把电源关闭时，熄火电机到继电器 63#线 24V 电压正常；
4、把鈅匙打开通电时，熄火电机到继电器 65#线电压不稳在 14-22V 之
间变化，因此判断是 65#线故障，检查 65#线发现在驾驶室外部的平
台处线被压扁断裂，重新连接后正常。
Troubleshooting:
1. Checked and found shut down motor is normal. Its cable is not interfered.
2. Checked and found the shut down relay engaged normally. It should not be suspected.
3. Votalge from shut down motor to the relay wire 63# is 24VDC which is normal when switch off.
4. Turn s tart s witch on. Voltage from s hut down m otor t o t he relay wire 65 # is uns table 14 – 22VDC.
Further research found this wire is staved out of cab. Repair the failed wire. Problem solved.
排故体会：无论故障的大小，都要细心每一步的检查，在处理以后的故障中将对 31
挖机更深一层的了解！
Experience: Whether a failure is difficult to solve or not, troubleshoot carefully for each step. It will be
helpful to understand Sany excavator and troubleshooting in the future.
——提供者：龙振国 Service engineer: Long Zhen Guo
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31、SY215 喇叭不响 SY215 horn fails to work
故障现象： SY215 机器出现喇叭不响故障。

Symptom: Horn of SY215 machine fails to work.
故障分析： 1、5A 保险丝熔断；5A fuse is broken.
Failure analysis: 2、喇叭继电器故障；Horn relay failed.
3、线路故障；Circuit failed.
4、喇叭按钮开关故障；Horn switch failed.
5、喇叭故障。Horn failed.
故障原因: 手柄处导线磨损断开。
Root cause of the failure: Horn wire is worn with the pilot lever and broken.
Horn switch
Electrical schematic
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排故方法：根据上图（电器原理图）可以从以下方面分析：
1、检查喇叭保险丝通断正常；
2、检查喇叭处插头连接完好；
3、按下喇叭按钮检查手柄处 31#线处无 DC24 电压，测量喇叭按钮通断
正常；
4、拆开右手柄护套，剪开护套后发现导线断开（见图），连接后正常。
Wire near pilot lever Wire is broken Repair the wire
Troubleshooting:
1. Checked and found the horn fuse is normal.
2. Checked and found the wire connector of the horn is connected normally.
3. Wire 31# has no 24VDC when the horn switch is turned on. Measured horn switch is normal.
4. Remove the rubber grommet of the right pilot lever, cut open the intertexture layer and found the horn
wire is broken. Repair the failed wire. Tested and proved horn works normally. Problem solved.
排故体会： 1、由简单到复杂仔细检查，可迅速排除故障；
2、喇叭开关处导线很硬，非常容易折断。
Experience:
1. Inspect carefully from simple to comflex, problem will be solved quickly.
2. Horn wire near its switch is very hard which is easily to be broken.
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32、收音机收听时有时无 Radio failed intermittently
故障现象： SY215 机器收音机有时可以收听有时不能。

Symptom: Radio of SY215 fails intermittently. Radio power and volume switch
故障分析： 1、收音机接收信号不良；
2、扬声器故障或扬声器喇叭线接触不良；
3、收音机内部故障；
4、收音机电源 20b 号线接触不良；
5、收音机电源及音量调节旋扭故障。
Failure analysis:
1. Radiao signal is faint.
2. Radio horn or its circuit is opened intermittently.
3. Radiao failed. Power circuit of the radio
4. Power wire 20b of the radio is opened intermittently.

5. Radio power and volume switch is failed.
故障原因：收音机电源及音量调节旋扭故障。
Root cause: Radio power and volume switch failed.
排故方法： 1、通电开通收音机电源开关，调节音量
检查收音机是否能正常启动；
2、如果收到机无法正常启动则通电测量 20b 号线对地电压有无 24V；
3、如果无法正常启动，但 20b 对地电压有 24V，则判断收音机开关电源
故障或收音机内部故障；
4、收音机能正常启动但无法接收频道，或频道接收信号不良，则换一
个地方测试，如不行更换收音机；
5、该机器无法启动电源，检查发现 20b 号线对地电压为 24V 但收音机
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有时无法启动，检查发现收音机电源及音量调节旋扭内部接触不良，
更换旋扭后正常。
Troubleshooting:
1. Power on the radio and adjust the volume. Checked whether the radio can be operated or not.
2. If the radio can not be operated normally, measure the voltage of wire 20b is 24VDC or not.
3. If t he radio can not be operated normally and the wire 20b has 24V DC voltage, the radio power
switch or internal failure should be suspected.
4. If the radio can be operated normally but no radio signal received, move the machine to another place
or replace with a new radio to do the troubleshooting.
5. Checked and found this radio can not be operated. Wire 20b has 24V DC voltage but radio fails to
work. Further research found the power on and volume adjust switch of t he radio has an internal
failure of opening intermittently. Replace the failed switch, tested and proved problem solved.
排故体会：先易后难，采用排除法，将故障范围慢慢缩小再排故。
Experience: Using the exclusive method to do the troubleshooting, easy first and difficult later.
Narrowing the failure range slowly and figure out the root cause finally.
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33、所有参数为零无法升降速 All the parameters are zero, speed can not be changed
故障现象： SY230C6B 挖机出现所有参数为零无法升降速故障,更换综合转换板
后,工作正常,但工作 1 个小时左右转换板又损坏。
Symptom: SY230C6B has a failure of all parameters are zero and engine speed can not be changed. After
replacing the transfer module, machine works normally for about one hour and fails again.
故障分析： 1、线路故障，41#线对地短路；
2、50#线对地短路；
3、传感器（各压力开关、转速传感器、水温传感器、主泵压力传感器、
燃油油位传感器、机油压力传感器等）短路故障导致；
4、电瓶电压不稳定，或焊接时未拆电瓶线；
5、发电机故障，发电机调节器故障，发电电压过高。
Failure analysis:
1. Wire 41# is shorted to the ground.
2. Wire 50# is shorted to the ground.
3. Sensor is shorted and causes the failure. Such as pressure switches, speed sensor, coolant temperature
sensor, pump pressure sensor, fuel level sensor, engine oil pressure sensor, and so on.
4. Battery voltage is unstable, or the battery cable is not disconnected when welding on the machine.
5. Alternator or its regulator failed and cause the output voltage is excessively high.
故障原因：发电机损坏，发电电压过高导致综合转换板 5V 模块损坏。

Root cause of the failure: Alternator failed. Its output voltage is high enough to cause the 5V circuit of
the transfer module damaged. Alternator
排故方法：
1、当时检查为转换板损坏，更换一个新的，一切正常；
2、检查线路 50#、41#线并没有搭铁及短路现象；
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3、机器工作约 1 小时发动机突然不能升速，很快的就自动熄火，这时检查综合转换
板 50#线无 5V 输出，而 41#线有 24V 电压输入，将 Transfer module
机器改为液控启动机器，测量发现电源正常，并没
有搭铁现象。让挖掘机操作手操作机器，发现发电
机 B 端子及 L 端电压一下子升到 35 伏，马上又变为
正常。发电机发电电压正常为 28 伏左右，判定发电机输出电压异常，最后经过
多次测试，确定为发电机故障；
4、更换发电机，更换一个新的综合转换板后，机器工作正常。
Troubleshooting:
1. Machine works normally after replacing the transfer module.
2. Checked and found wire 50# and 41# are not shorted or shorted to ground.
3. Works for about 1 hour , engine speed can not be accelerated suddenly, and the engine shut down
automatically and rapidly. Checked and found wire 50 # of the transfer module has no 5V DC output
while the wire 41# has 24VDC input. Set the machine under h ydraulic control mode, engine can be
restarted. Measured and found t he s upply pow er circuit is normal, no short circuit existed. Measure
the voltage at B and L pole of the alternator when the machine is operating, the measured voltage is
35VDC a nd t hen returns back to the normal value 28VDC. Measured several times and the same
results reveils that the alternator is failed.
4. Replace the failed alternator and replace a new transfer module, machine works normally.
排故体会：发电机输出电压过高，会导致综合转换板 5V 模板损坏，以后再碰到这种
故障应吸取一定的经验。
Experience: If the alternator output voltage is excessively high, 5V circuit of the transfer module will be
damaged. This failure case will be helpful for the troubleshooting of the similar failure in the future.
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34、燃油油位显示异常 Displayed fuel level is abnormal
故障现象： SY230 机器燃油油位有时显示异常。

Symptom: Displayed fuel level of SY230 is abnormal.
故障分析： 1、传感器油浮损坏进油等；
2、信号线 509 号线断路；
3、浮动机构卡滞；
4、滑动电阻中有断点；
5、控制器故障。 Resistance is broken
Failure analysis:
1. Float of the fuel level sensor damaged.
2. Wire 509# is broken and opened.
3. The floating section of the fuel level sensor seized.
4. The resistance of the fuel level sensor is broken.
故障原因：燃油油位传感器滑动电阻中有断点。
Root cause: Resistance of the fuel level sensor is broken.
Lever of sensor
排故方法： 1、检查油位传感器油浮完好；
2、测量 509 号线无短路断路故障；
3、油动浮动机构无卡滞现象； Float Wire 509#
4、慢慢滑动浮动机构，测量 509 号线对地电阻，发现中间出现断点；
5、因滑动电阻中间出现断点，导致反馈给控制器信号错误，因此会出
现油位显示不准现象，更换油位传感器，该故障消除。
Troubleshooting:
1. Checked and found the float of the fuel level sensor is normal.
2. Measured wire 509# is not opened or shorted. It is normal.
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3. The floating section of the fuel level sensor can move smoothly. It is not seized.
4. Measure t he r esistance o f the wire 5 09# to t he gr ound when the float is r otated. It i s found t hat t he
resistance of the fuel level sensor is broken.
5. Since the resistance has a broken point inside, the displayed fuel level is incorrect. Replace the failed
fuel level sensor, tested and proved problem solved.
排故体会：了解油位传感器的工作原理，能更快更准找到故障点。
Experience: Understanding the working principle well, will help to find out the root cause quickly and
accurately.
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35、翘板开关故障案例 Failure case of the turnup switch
故障现象： SY210C1挖机整机大灯不亮。
Symptom: Work lamp of SY210C1 fails to work.
故障分析：
Failure analysis:
F4 fuse is failed Y Replace 15A fuse
Wire 24# has 24VDC voltage? N Wire 24# opened or shortedd Repair the failed wire
Close switch S2
Wire 33# voltage is 24VDC N Switch S2 failed Replace switch S2
K6 relay is normal N Replace K6 relay
Wire 34# voltage is 24VDC N Wire 34# is shorted or opened Repair the failed wire
Bulb of the work lamp failed
Replace bulb
- 238 -
故障原因：1、F4保险丝丝是否烧断；
2、灯光开关S2是否故障；
3、继电器K6是否故障；
4、线路是否故障；
5、工作灯灯泡故障。
1. F4 fuse is damaged.
2. Lamp switch S2 failed.
3. Relay K6 is failed.
4. Circuit failure.
5. Lamp bulb failed.
排故方法：1、检查工作灯F4保险丝正常；
2、检查24#线对地电压正常(DC24V)；
3、检查33#对地电压为0V，说明S2翘板开关故障。
Troubleshooting:
Switch S2
1. Checked and found F4 fuse is normal.
2. Measured voltage of wire 24# to ground is 24VDC which is normal.
3. Measured voltage of wire 33# to ground is 0V. Switch S2 failed.
排故体会：思路要清晰，排故要仔细。
Experience: Troubleshoot logically and carefully.
- 239 -
36、210C5B 无法升速及无显示 210C5B can not be accelerated and no display
故障现象：210C5B 工作 3000 小时，启动后发动机无法升速，显示屏无数据显示。

Symptom: SY210C5B, 3000 hours. Engine speed can not be accelerated and monitor has no display.
故障分析： 1、油门马达或油门马达线路断路或短路；
2、控制器的故障；
3、主压传感器开路，或线路短路、断路； Negative pressure sensor
4、副压传感器开路，或线路短路、断路。
Failure analysis:
1. Governor actuator or its electrical circuit failed.
3. Pump output pressure sensor or its circuit failed.
4. Pump negative pressure sensor failed.
故障原因：主泵负压力传感器 50 号线偶尔接地短路，造成控制器 EC-7 损坏。

Root c ause of t he failure: Wire 50# of the pump negative pressure sensor is shorted to the ground
intermittently, which causes the EC-7 controller failed.
排故方法：1、检查 5 伏电源无输出，能启动即控制器 24 伏电源输入正常。
2、把机器上面所有涉及 5 伏的传感器接头拔下，测量 50 号线对地电阻，
检测电阻无穷大，说明线路正常。
3、考虑该机使用 3000 小时保养状况一般，短时间连续更换控制器，重点
检查 5 伏电源线路情况，在检查主泵时，主泵上面线束粘附油垢，清
理油垢后发现负压力传感器线束用一根细铁丝绑在先导管路接头上
面，由于之间有间隙在挖掘机工作时震动造成 50 号磨破，搭铁，从而
造成烧毁控制器。
Troubleshooting:
1. Checked and found controller has no 5V DC output. Engine can be started. It means 24VDC input of
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the controller is normal.
2. Disconnect the connector of all the sensors which has 5VDC voltage. Measured resistance of the wire
50# to ground is infinite. It means the sensor circuit is normal.
3. Think about this machine is now used for 3000 hours, and the maintenance job is jus so so. The repair
history shows that the controller of this machine is failed frequently in a short time. Double check the
5VDC c ircuit. It i s f ound t hat t he ha rness of t he m ain pum p i s oi ly. Cleaning the oily di rty of t he
harness, and found the sensor harness is hanged to the pilot hose by a thin iron wire. Insulation of wire
50# is worn out by t he iron wire due to vibration when t he machine is working. Wire 50# is then
shorted to the ground and caue the controller failed.
排故体会：在出现发动机油门无法升速的时候，一定要细心，首先要检查线路，否则
会烧毁控制器，因为控制器价格较高。
Experience: Please be careful anytime when the user complained about engine speed can not be
accelerated. Electrical circuit must be checked first, otherwise the controller may be damaged. The
controller is expensive.
——提供者：龙振国 Service engineer: Long Zhen Guo
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37、210C5B 油门旋钮失效 210C5B dial switch failed
故障现象: 发动机工作时，转速波动过大。
Symptom: Engine speed waved excessively when the machine is working.
故障分析：发动机转速基本正常，但是有较大的波动，根据这一现象，基本可排除
发动机本身的故障，通常从以下几方面分析：
2、油门旋钮或者控制器故障；
3、控制器本身程序的问题。
Failure analysis: Engine speed is normal but waved excessively. Engine should not be suspected.
2. Dial switch or controller failed.
3. Software of the controller is malfunctioned.
故障原因：油门旋钮的滑片磨损，造成档位跳档。
Root cause of the failure: The plate of dial switch is worn, throttle position can not be fixed.
Resistance of
the dial switch
Dial switch
排故方法：1、到达现场后启动机器，打开显示屏工作界面操作机器观察转速变化，
发现转速波动 100 多转，同时档位显示在 7~9 档之间跳动；
2、拿万用表测量旋钮在 7~9 档之间电阻有空挡，由此可以判定为油门旋

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钮原因.
3、拆开旋钮发现内部接触有断点，更换后正常。
Troubleshooting:
1. Checked the engine speed displayed in the monitor on the jobsite, it is found that engine speed waved
about 100rpm and the displayed throttle changed from 7 to 9 automatically.
2. Measured with the multimeter, there is no resistance sometime when the dial switch is change from 7th
to 9th position. It is sure that the dial switch is failed.
3. Diamantle t he dial switch, and found the plate of the dial switch is worn. Replace t he failed dial
switch, tested and proved engine speed is normal. Problem solved.
排故体会：排除故障从简单处着手，往往可缩短排除故障的时间。
Experience: Perform t he t roubleshooting f rom t he s imple phe nomena, will s horten t he troubleshooting
time usually.
——提供人：龙振国 Service engineer: Long Zhen Guo
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38、SY205 全车无电 SY205 machine has no electric power
故障现象：SY205C8M 挖机拧动点火开关后，显示屏不亮，也无法起动，全车无电。
Symptom: When the start switch of SY205C8M is turned on, machine and monitor has no power. Engine
can not be started.
故障分析：1、KB1 开路；
2、启动开关 13#端子接线未插好；
3、电源继电器故障；
4、点火开关故障。
Failure analysis:
1. KB1 is opened.
2. Wire 13# is opened at terminal of the start switch.
3. Battery relay is failed. Control wire of
battery relay
故障原因：电源继电器控制线圈的输入端已锈蚀接触不良。除掉锈蚀部位，重新连
接控制线后正常。
Root c ause of t he failure: Terminal of battery relay control wire is eroded and opened intermittently.
Clean the erosion of the terminal and reconnect the wire. Problem solved.
排故方法：1、仔细检查 F1 保险是否烧毁，一般目测可判断其好坏，如有必要可用万
用表测量其通断，发现正常。
2、检查电瓶接线柱是否松动或者接触不良，检查发现无松动。
3、检查启动开关 13#端子是否松动，在钥匙开关拧到 ON 的位置，测量
13#是否有 24V 电压，经测量有 24V。
4、在拧动点火开关 OFF-ON 的时候仔细听电池继电器处未发出“哒”的
声音，仔细检查发现其控制线圈的输入端已锈蚀接触不良。除掉锈蚀
部位，重新连接控制线后正常。
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Troubleshooting:
1. Check the fuse F1 is normal or not by visual inspection or multimeter. Ok, it is normal.
2. Checked and found the battery cable is fastened properly on the battery.
3. Check the wire 13# at the the start switch terminal is loosed or not. Measured voltage at this terminal
is 24VDC when the start switch is turned on.
4. Check t he ba ttery r elay when t he s tart s witch i s shifted be tween off a nd on. It i s f ound t he ba ttery
relay not engaged. Double checked and found the terminal of the battery relay control wire is eroded.
Clean the erosion of the terminal, tested and proved problem solved.
排故体会：整车无电，是电气故障类内较为常见的故障，要判断引起该故障的原
因，还得寻根溯源，顺藤摸瓜，由简入繁，从看得见的导常进行优先处
理，以最少的时间为客户解决实际问题。
Experience: The failure of machine has no power is a frequent failure of electrical system. To figure out
root cause of the failure, service engineer should troubleshoot from simpe to complex step by step along
the road sign of the failure phenomena. Started from the visual abnormal phenomena, solve the problem
quickly to reduce the user’s downtime.
——提供者：袁阳 Service engineer: Yuan Yang
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39、360 正流量挖机行走跑偏 360 PFC excavator has a travel offset
故障现象: 机器使用 3000 小时，行走跑偏，改液控正常。

Symptom: Machine has an excessive travel offset after using 3000 hours. Machine travels normally if it
is under the hydraulic control mode.
故障分析：1、行走马达故障；
2、履带松紧程度不一致；
3、改液控正常，排除主泵及调节器故障。
4、行走动作信号压力传感器异常或电压异常；
5、KCM 控制器输出异常。
Failure analysis:
1. Travel motor has a failure occurred.
2. Track tension of the two tracks is not the same.
3. Travels normally under hydraulic control mode, it means main pump and adjuster work normally.
4. Travel pilot pressure sensor is abnormal or the voltage of the sensor is normal.
5. Output signal of the KCM controller is abnormal.
故障原因：左行走先导压力传感器损坏，没有传输给控制器信号，控制器给比例电
磁阀的电流不够，从而左泵的排量过小。
Root c ause of t he f ailure: Left t ravel pi lot pr essure s ensor i s f ailed. No le ft tr avel s ignal s ends to the
controller. Output oil flow of the left pump is smaller than the right pump.
排故方法：1、到达现场后发现该机向左跑偏，先检查履带松紧度--正常；
2、在行走时，后泵压力大于前泵。其他工况下主压力一致都在 340kg；
3、检查行走时比例阀输出电流后泵为 470mA，前泵为 530mA，由此判
断为输入左右行走信号异常或者 KCM 输出异常；
4、再检查左右先导压力发现左行走先导压力始终只能达到 14kg，调换左
右行走压力传感器后显示右行走压力也只能达到 14kg，由此确定为先
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导压力传感器故障；
5、更换损坏的传感器, 试车正常，故障排除。
Troubleshooting:
1. Checked and found machine has a left turn when it travels. Track tension of two tracks is normal.
2. Oil pressure of the rear pump is higher than the front pump when machine travels. Oil pressure of the
front pump and rear pump is normal when other operation is performed. It is 340kgf.
3. Measured current to rear pump is 470mA which is lower than the front pump 530mA when machine
travels. It is the proof that the controller input or output signal is abnormal.
4. Checked in the monitor and found that the left travel pilot oil pressure is 14kgf. Interchange the left
travel pi lot oi l pr essure sensor w ith the right t ravel pilot pr essure s ensor, i t i s f ound t hat t he r ight
travel pilot oil pressure is 14kgf while the left travel pilot oil pressure is normal.
5. Replace the failed travel pilot oil pressure sensor, tested and proved problem solved.
Left travel
pilot oil
pressure
Left travel
pilot oil
pressure
排故体会：在现场维修时，以解决故障为主，在不影响机器使用的情况下，可以利
用机器上的不是很重要的配件替换故障配件，是很重要的办法。
Experience: When doing the troubleshooting on the jobsite, interchange method is usually used. It is
useful and important.
——提供者：龙振国 Service engineer: Long Zheng Guo
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40、SY230 控制器烧坏 SY230 controller failed
故障现象：07SY23280671 使用 EC-7 控制器的挖掘机车，突然显示屏信号不准，屏上
各按键功能失效。之前有服务人员曾更换过控制器但当时一换就又烧坏
了。此车没有装控制器至今。采用了落后的简单改控，现客户要求加装
控制器恢复电控。
Symptom: SY230, s erial num ber i s 07S Y23280671, equipped with E C-7 c ontroller. Displayed
information in the monitor is inaccurate suddenly. All the function keys of the monitor are failed. A new
controller i s f ailed onc e it i s i nstalled. M achine i s s et unde r t he h ydraulic c ontrol m ode a nd w orks f or
some time. Now end user requires the controller and set machine under electronic control mode.
故障分析：1、显示屏信号只是不准，故显示屏仍有电，控制器出问题可能性最大；
2、考虑到控制器烧坏的原因有：控制器电源电压异常；控制器输出电压
短路；控制器输出电压被高压电接入。
Failure analysis:
1. Displayed information is inaccurate, monitor still works. It is the most possible that controller failed.
2. Possible root cause of controller failed includes: power voltage of the controller is abnormal, output
voltage of the controller is shorted, and high voltage invades the output circuit of the controller.
故障原因：控制器电源电压异常；控制器输出电压短路；控制器输出电压被高压电
接入。
Probable cause of the failure: Power voltage of the controller is abnormal. Output voltage of t he
controller is shorted. High voltage invades the output circuit of the controller.
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排故方法：1、由于 42 号线控制器电源保险 F11 没坏，控制器电源是正常的。
2、电压表检查控制器线束 OO#线和 50#线的电压，发现电压竟然为 24V，
判定该线路上有与电池正极线有短接现象。经过一翻仔细的导线短接排
查。发现通住电磁阀的线束和通往主阀传感器组的线束破皮短接现象。
Troubleshooting:
1. Fuse F11 of the controller power circuit is normal. It means controller power supply is normal.
2. Measured voltage of the controller wire 00 # and 50# is 24VDC, it means this circuit is shorted to the
battery vol tage. Double checked and found the insulation of the wire of solenoid valve and pilot
sensors is broken which cause the circuit shorted.
排故体会：熟悉电气原理图，先简单后复杂的排故思维不能忘。坚信自己学习的理
论，不怕繁琐脏累，细心并多疑其可能发生的地方，终能快捷地找到问
题的出处。
Experience: Service engineer should be familiar with electrical schematic, remember to troubleshoot the
simple first and then the complex. Working hard and observe the road sign carefully, be confidence that
you can solve the problem quickly.
——提供者：韩晓锋 Service engineer: Han Xiao Feng

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41、显示屏无显示全车无动作 Monitor has no display, machine has no action
故障现象：SY210C 负流量机器。显示屏无显示，无法升降速，烧保险，全车无动作。
Symptom: SY210C N FC excavator has no display on monitor. Engine speed can't be changed. Fuse
failed and machine has no action.
故障分析：1、全车无动作：可能 EC-7 损坏，先导锁电磁阀损坏；
2、无法升降速：可能油门旋钮损坏；步驱损坏；步进电机损坏；转速传
感器损坏；EC-7 损坏；
3、显示屏无显示且烧保险:可能显示屏损坏或有搭铁现象。
Failure analysis:
1. Machine has no action. It may be caused by failed EC-7 or the hydraulic activation solenoid valve.
2. Engine speed can not be changed. It may be caused by failed dial switch, stepping motor, speed sensor,
or EC-7 controller.
3. Monitor is failed to display information and fuse burnt. Monitor may be failed or shorted to ground.
排故方法：1、电源线 29#保险通电就烧，检查显示屏电源线 29#无搭铁，步驱电源
线 29#有搭铁现象。断开步驱连接，显示屏有显示，但所有参数均为 0；
拆检步驱，二极管击穿；
2、更换步驱；检查油门旋钮，步进马达参数，转速传感器参数正常；
3、无 5V 电源，综合转换板 5V 电源损坏；更换综合转换板，重新校准转
- 250 -
速后正常。
Troubleshooting:
1. Fuse of the power wire 29# is burnt once the machine is powered on. Checked and found the power
wire 29# of the monitor i s not shorted to ground, but the power wire 29 # of the stepping m otor i s
shorted to ground. Disconnect the stepping motor, monitor can display information but all the
parameter is zero. Dismantle the stepping motor, and found its diode is failed.
2. Replace the stepping motor. Checked and found the dial switch, the parameters of stepping motor, and
the speed sensor is normal.
3. 5VDC vol tage can not be measured. Checked and found the transfer module of 5V DC vol tage i s
damaged. Replace the transfer module, calibrate engine speed, tested and proved problem solved.
排故体会：故障现象表现较多，比较复杂，排查应本着先易后难的原则，切忌头脑
发热，盲目下手。
Experience: There is much more failure phenomena and they are complex. Troubleshoot the simple one
first and then the complex one. Keep your mind clear and troubleshoot step by step.
——提供者：王宏斌 Service engineer: Wang Hong Bing
- 251 -
42、SY135C 转速异常 SY135C engine speed is abnormal
故障现象：当油门提升到 4 档时发动机转速到最高 2000 转。

Symptom: The maximum engine speed is 2000rpm when the dial switch is at 4th.
故障分析：1、油门旋钮故障；
2、EC-7 控制器故障；
3、AC1500 马达故障；
4、压力开关故障；
5、二次增压按钮或电磁阀故障；
6、线路故障。
Failure analysis:
2. EC-7 controller failed.
3. AC1500 governor actuator failed.
4. Pressure switch failed.
5. Pressure boost button or solenoid failed.
6. Circuit failure existed.
故障原因：二次增压按钮不复位，只要当发动机转速到 1400 以上，就会二次补充
系统最大压力,反馈给控制器,发动机转速就会到最大。
Root c ause of t he failure: Pressure boos t bot ton i s f ailed t o r eturn ba ck t o ne utral pos ition. Once t he
engine speed is higher above 1400rpm, the hydraulic system pressure will be boosted always. This signal
is feedback to the controller and causes the engine running at the highest speed.
- 252 -
排故方法：1、检查油门旋钮电压在每个档位是否正常；
2、检查 EC-7 控制器输出 5 伏电压是否稳定正常；
3、控制器内部元件异常或程序异常；
4、检查二次增压按钮；
5、检查二次增压电磁阀发卡或损坏。
Troubleshooting:
1. Check the dial switch is normal or not at each dial position.
2. Check the output 5VDC voltage of the controller is stable and normal or not.
3. Controller or its software is normal or not.
4. Pressure boost botton is normal or not.
5. Check the solenoid of the pressure boost is seized / damaged or not.
排故体会：按照 SY135C 电气原理图逐步分析，排除每一个环节点是否正常。

Experience: Analysis step by step according to the electrical schematic of SY135.
——提供者：伍锡斌 Service engineer: Wu Xi Bing
- 253 -
43、SY235C8E 发动机无法启动 SY235C8E engine can not be started
故障现象：发动机无法正常启动，充电指示灯不亮灯。
Symptom: Engine can not be started. Charging indicator fails to work.
故障分析：1、蓄电池电源不足；
2、钥匙开关触点故障；
4、安全继电器或启动继电器故障；
6、线路断点或短路故障。
Failure analysis:
1. Battery is undercharged.
2. Start switch fails.
4. Safety relay or start relay is failed.
6. Circuit is opened or shorted.
故障原因：1、线路短路故障；
2、发电机到充电指示灯 14#线短路，导致安全继电器工作。误使发动已
经启动。

1. Circuit is shorted.
2. Wire 14# between the alternator and the charging indicator is shorted, which cause the safety relay cut
- 254 -
off the starting circuit and engine can not be started.
排故方法：1、检查电源是否在 24-27 伏间；
2、检查钥匙开关触点接触良好；
3、检查控制输出 620#线电压是是否 24 伏；
4、检查继电器线圈 620#线电压是否 24 伏，触点是否良好；
5、检查启动马达线圈 12#线是否 24 伏电压;触点是否良好；
6、重新更换发电机到充电指示灯的 14#号线。
Troubleshooting:
1. Check the battery voltage is between 24V and 27V or not.
2. Check the contacts of the starting switch is normal or not.
3. Check the output voltage of the wire 620# is 24V or not.
4. Check the voltage of wire 620# at relay contact, it is 24V or not. Relay contacts are normal or not.
5. Check the voltage of wire 12# at starting motor solenoid, it is 24V or not. Contacts are normal or not.
6. Replace the wire 14# between the alternator and the charging indicator.
排故体会：按照 SY235C8 原理图逐步分析，排除每一个环节点是否正常。

Experience: Analysis step by step according to the electrical schematic of SY238C8.
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44、SY55C 发动机频繁地自动熄火 Engine shut down automatically frequently
故障现象：工作时发动机熄火频繁。
Symptom: Engine auto shut down frequently during the work.
故障分析：1、燃油、发动机油泵、发动机内损等故障；
3、AC1500 马达故障；
4、熄火继电器、熄火装置故障；
5、钥匙开关故障；
6、线路故障。
Failure analysis:
1. Engine problems such as fuel, injection pump, engine’s wear, and so on.
3. Failure of AC1500 governor actuator.
4. Failure of shut down relay or shut down motor.
5. Start switch fails.
6. Circuit failure.
故障原因：设备电源为 12 伏直流，而安装的电源继电器为 24 伏，导致继电器无法
正常闭合。
Root cause of the failure: Voltage of this machine power is 12VDC, but 24V battery relay is installed.
Battery relay fails to work normally.
- 256 -
排故方法：1、检查燃油、发动机油泵、发动机内损是否正常；
2、检查控制器输出 5 伏电压是否稳定正常；
3、控制器内部元件异常或程序异常；
4、检查钥匙开关触点接触是否良好；
5、检查熄火继电器、熄火装置是否正常。
Troubleshooting:
1. Check the engine works normal or not. Such as fuel system, the injection pump, and so on.
2. Check the output 5VDC voltage from the controller is stable and normal or not.
3. Controller or its software is abnormal or not.
4. Check the contacts of the starting switch is normal or not.
5. Check the shut down relay or shut down motor is normal or not.
排故体会：按照 SY55C 电气原理图逐步分析，排除每一个环节点是否正常。

Experience: Analysis step by step according to the electrical schematic of SY55C.
- 257 -
45、德国显示屏无法正常计时 Germany monitor can’t count the work hours normally
故障现象：该机在工作过程中，德国屏工作时间不能正常计时。
Symptom: Work hour can not be counted by the Germany monitor normally during the work.
故障分析：1、OPUS 德国显示屏计时模块故障，更换显示屏；
2、控制器故障，导致数据无法传输，显示屏无法检测数据；
3、发动机转速传感器故障，导致控制器无法检测到发动机转速并及时传
输到控制器；
4、德国显示屏常通 ACC 电源断路或线路，导致计时模块无法正常工作。

Troubleshooting:
1. Monitor is malfunctioned. Replace the failed monitor.
2. Controller is malfunctioned. Parameter can not be transferred. Monitor has not data updated.
3. Engine speed sensor is failed. Controller can not get the speed signal.
4. ACC power circuit of Germany monitor is opened or shorted.
故障原因: 德国显示屏 22 号 ACC 电源线断路，导致显示
屏计时模块无法正常工作。
Root cause of the failure: ACC power wire 22# of Germany monitor
is opened. Monitor fails to work normally.
排故方法：1、启动机器，通过检查显示屏数据发现，发动机转速正常并能正常
升降速，由此可判断，发动机转速传感器
正常，转速信号线无断路短路现象，控制
器数据传输正常； Time is incorrect
2、测量 22 号线处电压为 24V，电源正常；
3、检查 22 号线与德国屏接线端处，发现 22
号线松动，接触不良，因此可判定问题点在该插头处；
- 258 -
4、将 22 号线重新压接完好、试机，显示屏计时正常。
Troubleshooting:
1. Checked and found the displayed engine speed is normal. Engine speed can be changed normally. It is
sure that the speed sensor is normal. The speed sensor circuit is normal. Data transfer from the
controller to the monitor is normal.
2. Measured voltage of wire 22# is 24VDC. It means the power supply is normal.
3. Checked and found wire 22# is loosed at the connector of the monitor, which cause the circuit opened
intermittently.
4. Repair the wire 22#, tested and proved the displayed work hour is normal. Problem solved.
排故体会：1、思路要清晰；2、排故要仔细。
Experience: Always make your mind clearly and do the troubleshooting carefully.
- 259 -
46、OPUS 德国显示屏白屏 Germany monitor Opus has a white screen displayed
故障现象：该机通电后，德国显示屏白屏。
Symptom: Germany monitor has a white screen displayed after the machine is powered on.
故障分析：1、OPUS 德国显示屏内部故障或内部排线松动；
2、线路故障，导致德国屏工作电压不足或不稳定；
3、电瓶电压不足导致。
Failure analysis:
1. Internal defection of the Germany monitor.
2. Circuit failure causes the monitor voltage unstable or lower than specification.
3. Battery voltage is too low and causes the failure.
故障原因： 21 号线接触不良，导致电压不稳或不足。
Root cause of the failure: Wire 21# is opened intermittently, which cause the lower voltage or unstable.
排故方法：1、通电后，发现显示屏白屏；
2、将控制器电源断开，显示屏正常显示；
3、检查电瓶电压为 24V，正常；
4、检查线路，发现 21 号线接触不良，导致电源电压供电不足.
5、将 21 号线重新接线后显示屏显示正常。
Wire 21# supply power t o c ontroller and m onitor. If it is opened in termittently, it w ill cause v oltage
unstable or insufficient.
- 260 -
Troubleshooting:
1. Monitor has a white screen displayed after machine is powered on.
2. Cut off the controller power, and found the monitor displayed normally.
3. Measured battery voltage is 24VDC, which is normal.
4. Checked and found wire 21# is opened intermittently, which causes the power supply is insufficient.
5. Reconnect the wire 21#, tested and proved monitor displayed normally. Problem solved.
排故体会：显示屏白屏故障点大都出现在屏上，但如果电源电压供电不足或不稳的
话，会出现白屏或花屏现象。
Experience: Monitor failure is usually caused by t he monitor defection. But if the voltage of power
supply is unstable or insufficient, the displayed screen may be white or grey.
- 261 -
47、SY215 偶尔无法启动 SY215 can not be started occasionally
故障现象：机器出现偶尔无法启动故障现象。
Sypmtom: Machine can not be started occasionally.
故障分析：
Failure analysis:
Y Y
Starting motor works normally Battery undercharged Charge the battery
Y
Voltage of wire 12# is 24VDC Starting motor failed Replace starting motor
N Replace start switch

Voltage of wire 11# is 24VDC Start switch failed
Y
Voltage of wire 105# is 24VDC Starting relay K3 failed Replace start relay K3
Y
Wire 105# opened or shorted Repair wire 105#
N
Voltage of wire 42# is 24VDC Wire 42# shorted or opened Repair wire 42#
Voltage of wire 50# is 5VDC Replace Kawasaqi controller
K3 relay loosed
故障原因： K3 继电器松动。
Root cause of the failure: Relay K3 is loosed
排故方法：1、经检查电瓶电压充足（DC24V）；
2、测量42#线对地电压为DC24V，控制器电源正常；
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3、测量50#线对地电压为DC5V，说明转换板5V模块正常；
4、检查液压先导105号#线无断路现象；启动状态下测量K3继电器线圈
105#号线电压正常；
5、启动状态下用万用表测量启动马达12#线无电压，测量K3继电器11#
线有24V，而当K3继电器闭合后，12#号线无电压输出。
6、检查发现K3继电器触点接触不良，重新安装后，机器启动正常。
Troubleshooting:
1. Checked and found the battery is normaly. (24VDC)
2. Measured voltage of wire 42# is 24VDC. It means power supply to the controller is normal.
3. Measured voltage of wire 50# is 5VDC. It means the 5V transfer module is normal.
4. Checked and found wire 105# of hydraulic activation solenoid is normal. Voltage of wire 105# at K3
relay is normal when the engine is cranked.
5. Measured and found wire 12# of the starting motor has no voltage when the engine is cranked. Wire
11# of relay K3 has 24V voltage. It means wire 12# has no voltage when the relay K3 is engaged.
6. Double check and found the contacts of K3 relay is opened intermittently. Repair the contracts, tested
and proved machine can be started normally. Problem solved.
排故体会：思路清晰，先简后难。
Experience: Troubleshoot logically and step by step, easy first and then difficult.
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48、SY75 自动怠速功能异常 Auto idle speed function of SY75 is abnormal
故障现象：该机在工作过程中，先导手柄处于中位，无法正常到自动怠速。
Symptom: Auto idle speed function of this machine is failed when pilot valves are in neutral position.
故障分析：机器无法自动怠速，可以从以下几方面检查入手：
1、压力继电器故障；
；
2、控制器故障，
3、AC 马达故障或卡滞；
4、显示器故障；
5、自动怠速按扭开关故障。
Failure analysis: When the auto idle speed function is failed, probable cause of failure listed below:
1. Pressure relay is failed.
2. Controller malfunctioned.
3. AC motor failed or its cabel seized.
4. Monitor is failed.
5. Auto idle speed switch is failed.
故障原因：单色控制器故障。
Root cause of the failure: Controller is malfunctioned.
排故方法：1、启动机器，通过检查显示屏数据发现，发动机转速正常并能正常
升降速，由此可判断，发动机转速传感器正常、转速信号线无断
路短路现象，控制器数据传输正常；
2、通过显示屏观感各个先导动作信号，显示正常；
3、检查显示屏上自动怠速已开启，但发动机转速无法怠速至 1400 转左
右；
4、更换单色控制器，能正常自动怠速。
Troubleshooting:
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1. Start the machine, checked the data displayed in the monitor. It is found that engine speed is normal
and the engine speed can be accelerated or decelerated. It means the speed sensor, the speed s eneor
circuit, and the data link between controller and monitor is normal.
2. Checked the pilot signal in the monitor by operation the pilot valve lever one by one. It is normal.
3. Checked in the monitor and found the auto idle speed switch is turned on. Engine speed can not be
dropped to 1400rpm when all the pilot levers are in neutral position.
4. Replace the controller, tested and proved the auto idle speed function is restored. Problem solved.
排故体会：该单色控制器与显示器集成为一起，通过以上分析，故障点应该为制器
无法检测到自动怠速信号，默认为取消自动怠速状态，因此出现无法自
动怠速故障。
Experience: Controller and monitor are intergrated in this model. Through the above troubleshooting, it
is s ure t hat t he controller can not detect the auto idle speed signal. So the auto idle speed function is
cancelled as a default, auto idle speed function is unavailable.
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49、整车无怠速 Machine has no idle speed
故障现象：一台 09DX03110259 号控制系统为自主控制器的旋挖钻机在调试过程中出
现机器无怠速,整机工作时间 15H。
Symptom: 09DX03110259 rotary drill, controller designed b y Sany itself, has no idle speed during the
factory test. Machine working hour is 15 hours.
故障分析：1、压力开关是否异常用；
2、程序版本错误；
3、停车熄火装置电压是否有问题；
4、鼎新油门马达更换为川崎直流电机整改时线路有误；
5、自主控制器内部故障。
Failure analysis:
1. Pressure switch is abnormal or not.
2. Software version is wrong.
3. Voltage of the shut down motor is wrong or not.
4. Circuit problem when the Kawasaki governor actuator is used to replace DX governor actuator during
the Problem Improve Projection.
5. Sany designed controller has an internal defection.
故障原因：1、控制器与 OPUS 德国屏熄火输入通讯异常；
1. Data link between the controller and Germany OPUS monitor is abnormal.
2. Controller has a defection.
排故方法：1、检查控制器电源 42#线电压正常（DC24V）
；
2、测量控制器 50#线电压正常（DC5V）油门档位也正常其它模拟数据也
未出现异常；
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3、检查熄火装置电压、信号线，各接插件也没有松动现象；
4、测量 SYHCU 的 13#线在无电情况下电阻值为无穷大，而标准数值应为
19.9K 左右；
、重新刷程序、标定发动机转速故障排
5、更换新的自主控制器（SYHCU）
除。
Troubleshooting:
1. Measured voltage of the controller power wire 42# is 24VDC, which is normal.
2. Measured voltage of the controller wire 50# is 5VDC, which is normal. Checked and found the throttle
position and other analog data are normal.
3. Checked and found the volage, signal, and connector of the shut down motor are normal.
4. Measured resistance of SYHCU wire 13# is infinite when it is power off. Normally, it should be about
19.9KΩ.
5. Replace the controller SYHCU, re-flush the software, and calibrate engine speed. Tested and proved
problem solved.
排故体会：排故时应全面思考、抽丝剥茧、一步一步进行排查、多方位多角度去考虑
问题。
Experience: When doing the troubleshooting, service engineer should think about all the failure
phenomena, kick off the exterior phenomenon step by step along the failure road sign, and find o ut the
root cause of the failure finally.
——提供者：胡文飞 Service engineer: Hu Wen Fei
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50、SY215C8 行走跑偏 SY215C8 has a travel offset
故障现象：SY215C8 型机器，做单独行走动作时行走向左跑偏，行走加上大臂提升、
小臂、回转、铲斗动作操作时行走不跑偏，其它工作装置工作正常。
Symptom: SY215C8 failure phenomena: machine turns to left when travel only, t ravel offset is n ormal
when machin travel operation combined with boom up, stick, swing, or bucket. Others are normal.
故障分析：根据故障现象造成行走跑偏的原因： Pressure sensor failed
1、左边履带过松；
2、低压传感器到控制器线束短路或
搭铁；
3、行走低压传感器损坏；
4、左行走马达内泄；
5、左行走阀芯卡滞；
6、控制器损坏。
Failure analysis:
1. Track tension of the left track is insufficient.
2. Harness between the pilot pressure sensor and controller is shorted each other or shorted to ground.
3. Travel pilot pressure sensor is failed.
4. Left travel motor has an excessive internal leakage.
5. Left travel main valve spool is seized.
6. Controller failed.
故障原因：左行走低压传感器损坏，造成行走操作时传感器无电信号反馈回控制器。
Root cause of the failure: Left travel pilot pressure sensor failed. No signal feedback to controller.
排故过程：1、其他动作和行走一起做，行走后泵供油，前泵给其他动作供油，控
制器通过右行左压力传感器控制后泵的排量，所以行走正常。
2、进入显示屏菜单观察在操作左行走时左行走压力显示为零，前泵主
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压力显示为 10MPa，前泵比例阀电流显示为 350mA，控制器无法检测
到先导压力信号，故而前泵按小流量输出，所以左行走慢。
Travel pilot pressure sensor
3、将左右行走压力传
感器调换，左行走
正常，右行走慢。
所以可以判定是左行走
压力传感器损坏。
4、更换左行走先导压力传感器，故障消除。
Troubleshooting:
1. When travel and other operation is performed at the same t ime, front pump supplies oil to other
operation and rear pump supplies oil to the travel motor. Controller adjusts the rear pump output oil
flow through the right travel pilot pressure sensor. So the travel operation is normal.
2. Checked in the monitor when the left travel is performed only, it is found the left travel pilot pressure
is zero, front pump pressure is 10Mpa, and the current to the front pump solenoid is 350Ma. It is sure
that controller can not detect the left travel pilot signal. Front pump oil flow is minimum
3. Interchange the left travel pilot pressure sensor with the right travel pilot pressure sensor, tested and
proved left travel is normal while the right travel is slower than the left side.
4. Replace the failed travel pilot pressure sensor, tested and proved machine travels normally.
排故体会：先导压力传感器或控制器线路故障，控制器检测不到先导信号，则按最
小流量向主泵输送比例电流，引起主泵排量为最小量，动作缓慢。
Experience: Pilot pressure sensor or its circuit to controller is failed will c ause the controller fails to
detect the pilot signal. So the controller outputs a proper current to the pump PSV to make the pump oil
flow is the minimum. Related action will be slower than specification.

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51、全车无电 Machine has no electric power
故障现象：除喇叭，驾驶室内饰灯外，所有电气件都无电。
Symptom: All the electrical components except horn and cab lamp have no electrical power.
故障分析：因为喇叭，内饰灯还有电，但别的电器设备均无电，可排除电源继电器
的故障，可以从以下几方面分析：
1、F1保险损坏；
3、源线路问题。
Failure analysis: Horn and cab lamp has electrical power. It means the battery relay is normal. Service
engineer should do the troubleshooting focus on following aspects.
1. F1 fuse is damaged.
2. Start switch failed. Wire 22#
Wire 13#
3. Power circuit has a failure.
故障原因：1、启动回路保险是否正常；
2、电瓶继电器是否工作；
3、点火开关性能是否正常。
1. Fuse of the starting circuit is normal or not.
2. Battery relay works normal or not.
3. Start switch work normal or not. Starting circuit schematic
排故方法：1、首先检查启动回路保险正常；
2、检查电瓶接触器线圈无24V电压；
3、拆下右操作箱,测量点火开关上13#线无24V电；
4、检测点火开火上22#线也无24V电压；
5、检查右操作箱内接插件发现为22#号线束的插针退出导致断路。
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6、修复线路，试车正常。
Troubleshooting:
1. Checked and found the fuse of starting circuit is normal.
2. Measured and found the coil of battery relay has no 24V voltage.
3. Measured the voltage of start switch at wire 13#, it is found no 24V voltage.
4. Measured the voltage of start switch at wire 22#, it is found no 24V voltage.
5. Checked the wire connector inside the ride console, it is found that wire 22# is exited and cause the
circuit opened.
6. Repair the opened circuit, tested and proved problem solved.
排故体会：排除电气故障必须按部就班，根据原理图来判断每一个电气部件的好坏，
从而提高解决故障的工作效率。
Experience: Do the troubleshooting for the electrical system, service engineer should be step by step and
determine whether an electrical component is normal or not according to the electrical schematic to
enhance the troubleshooting efficiency.
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52、215C8M 无自动怠速 Auto idle speed function of 215C8 failed
故障现象：215C8M 挖掘机无自动怠速。
Symptom: Auto idle speed function of SY215C8M is failed.
故障分析：1、检查油门旋钮是否正常；
2、油门拉线是否发卡；
3、步驱是否正常；
4、压力传感器是否正常。
Failure analysis:
1. Dial switch is normal or not.
2. Cable of the governor actuator is seized or not.
3. Governor actuator is normal or not.
4. Pilot pressure sensor is normal or not.
故障原因：小臂压力传感器损坏。
Root cause of the failure: Arm pilot pressure sensor failed.
排故方法：通过显示屏，查看机器运行信息，翻至先导压力信号时发现斗杆挖掘先
导压力显示为 36kg。正常情况下，全车不工作时，各先导压力信号应该
为 0。此时斗杆挖掘显示为 36 kg。控制器接到此信号，就认为机器仍在
工作，所以就不能将发动机转速降到自动怠速档位。更换先导压力传感器，
故障消除。
Arm pilot pressure sensor
Displayed data when

all pilot levers are in
neutral position
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Troubleshooting: Checked the machine operation information through the monitor. It is found that stick
in pilot pressure is 36kg. Normally, this pressure should be zero when all the pilot levers are in neutral
position. Since the controller received the abnormal stick in pilot pressure signal, controller conciders the
machine i s w orking. Engine s peed w ill not dr op t o a uto i dle s peed 14 00rpm. Replace the failed pi lot
pressure sensor, tested and proved auto idle speed function restored. Problem solved.
排故体会：发动机无自动怠速，一般来说是电路问题。在检查时首先就要检查各个先
导压力传感器是否正常，然后再检查控制器是否正常。要把各个故障点挨
个摸清，逐个排查。
Experience: It i s us ually the e lectric pr oblem w hen e ngine’s auto i dle s peed f unction i s f ailed. Firstly,
service en gineer should check w hether t he pi lot pressure s ensor i s nor mal or not . And t hen c heck t he
controller work normally or not. Do the troubleshooting step by step along the road sign.
——提供者：吉林三君 Service engineer: Ji Lin San Jun
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53、发动机无法加油门 Engine speed can not be accelerated
故障现象：上午工作正常，中午停机，下午开机时油门加不上。该机1000多小时。
Symptom: Machine works normally in the morning and shut down in the midnoon. Engine speed can not
be accelerated in the afternoon after the engine is started. Working hours is more than 1000H.
故障分析：该机1000多小时，正常停机再开机后出现故障,可从以下几点考虑:
1、首先询问公司确认挖机没有被锁；
2、通电通过显示屏确认油门旋钮；
3、检查直流油门马达；
4、检查线路通断；
5、检查控制主板。
Failure analysis: Since the working hour is more than 1000H, troubleshoot following aspects:
1. Firstly, inquire the factory whether it is locked or not.
2. Power on the machine, to check the dial switch is normal or not through the monitor.
3. Governor actuator works normally or not.
4. Is there any circuit failure?
5. Controller is malfunctioned or not.
故障原因：K12（GPS）继电器至油门旋钮50号线接触不良。
Rootcause of the failure: Wire 50# from GPS relay K12 to dial switch is opened intermittently.
排故方法：1、检查油门马达拉线没有松动。显示屏上油门档位只能旋动到2档；
2、检查油门旋钮阻值在0-5千欧正常；
3、旋动油门旋钮506号线和0号阻值0.5-4.5千欧变化正常；
4、检查油门旋钮50号线对地5伏，506对地2.5伏,旋动油门电压值不变；
5、检查控制油门旋钮50号线的K12继电器吸合正常；
6、由K12（GPS）继电器直接引线到油门旋钮50号线故障解除。
Troubleshooting:
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1. Checked the governor actuator cable is not loosed. Displayed throttle position can only up to 2th.
2. Checked and found the resisitance of the dial switch is 0 – 5KΩ, which is normal.
3. Measured resistance between wire 0# and 506# of the dial switch is 0.5 – 4.5KΩ, which is normal.
4. Measured voltage of the wire 50# is 5VDC and wire 506# is 2.5VDC. The measured voltage not
changes when the dial switch is operated.
5. Checked and found the relay K12, which connects with wire 50# of dial switch, works normally.
6. Re-connect a wire from the GPS relay K12 to the dial switch, tested and proved problem solved.
排故体会：该故障由于和GPS有关，同时由于线路接触不良有虚电压，排故时会判断
错误。所以解决问题时要由简到难，对有疑问的元件要判断清楚。
Experience: This failure case is related to GPS. The wire which is opened intermittently has the virtual
voltage, which may make the confusion when doing the troubleshooting. Troubleshoot step by step from
easys to difficult. Make clear each suspected component is normal or not.
——提供者:合肥湘元 Service engineer: He Fei Xiang Yuan
Wire 50# connects to

dial switch
GPS photo
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54、发动机无法熄火 Engine can not be shut down
故障现象：SY135C8 施工结束后，鈅匙关闭机器无法熄火。
Symptom: SY135C8 can’t be shut down by turning start switch to off position after the job is finished.
故障分析：发动机正常工作后，如果无法熄火，分别可以从以下几方面检查，分析：
1、熄火马达相关的线路问题；
2、二极管故障；
3、熄火马达本身故障；
4、熄火继电器故障；
5、燃油泵卡死在断油位置；
6、控制器本身或程序故障。
Failure analysis: If the machine can’t be shut down after the job, analysis from following aspects:
1. Circuit of the shut down motor has failure occurred.
2. Diode failed.
3. Shut down motor failed.
4. Shut down relay failed.
5. Fuel injection pump is seized in fuel off position.
6. Controller or its software is malfunctioned.
故障原因：65#线发现在驾驶室外部的平台处线被压扁，多股铜线断裂。
Root cause of the failure: Wire 65# is staved out of the cab and some copper wires are broken.
排故方法： 1、检查熄火电机通断正常，电机正常； Wire 65# is staved
2、电源打开，检查继电器吸合正常；
Wire 65# is staved
3、当把电源关闭时，熄火电机到继电器 63#线
24V 电压、正常；把鈅匙打开通电时，熄火
电机到继电器 65#线电压不稳，在 14 - 22V
之间变化，于是判断是 65#线路故障；
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4、进一步检查 65 线，发现在驾驶室外部的平台处线被压扁，多股铜线
被压断，重新连接后，机器故障解决。
Troubleshooting:
1. Checked and found the shut down motor operates normally. It should not be suspected.
2. Power on the machine, checked and found the relay works normally.
3. Power the machine, voltage of wire 63 # to the shut down motor is 24VDC which is normal. Power on
the machine and the measured voltage of wire 65 # from shut down motor to the relay is 14 – 22VDC
which is unstable. Wire 65# is suspected.
4. Double c heck a nd f ound w ire 65# is staved out of t he cab and some of the copper wire i s broken.
Repair the failed wires, tested and proved problem solved.
Shut down relay
Shut down motor
排故体会：无论故障的大小，都要细心一步一步的检查，从电路到机械，由线路到
电器元件的过程！
Experience: Whether t he f ailure i s easy or difficult to solve, troubleshoot carefully and step by step.
Troubleshoot the electrical first and then the mechanical problem, circuit first and then the electrical
component.
—— 提供者：合肥湘元 Service engineer: He Fei Xiang Yuan
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55、显示屏显示数据偶尔显示为零 Displayed data on the monitor is zero occasionally
故障现象：SY200C负流量挖掘机在震动比较大时偶尔出现显示屏显示数据为零现
象，停机后又自行恢复正常显示。
Symptom: SY200C i s a N FC excavator. Displayed p arameters on the monitor a re z ero i f the machine
vibration is excessive. Failure phenomena disappeared automatically after the machine is shut down.
故障分析：此故障在机器震动比较大时偶尔发生:
1、线路短路、搭铁故障；
3、显示屏故障；
4、接插件接触不良。
Failure analysis: This failure only occurred occasionally when the machine vibration is excessive.
1. Circuit is shorted each other or shorted to the ground.
2. Controller malfunction.
3. Monitor failed.
4. Wire connector is opened intermittently.
故障原因： 50号线与车架搭铁。
#
Wire 50 is 5V power source
Root cause of the failure: Wire 50# is shorted to the ground.
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#
Wire 50 is 5V power source
排故过程：
1、设备施工时震动较大，控制器到触摸屏传输线路良好，接插件无松动；
2、根据电器原理图可知机油压力，水温，燃油油位等数据全为零，和控制器
发出的5伏电源有关，测量5伏电源线有搭铁现象；
3、进一步检查右操纵盒下发动机控制盘 5 伏电源线由于长期和右操纵手柄安
装架干涉，护套磨损，导致 5 伏电源偶有搭铁现象，由于电压低（只 5 伏）
又不至于和安装架焊接在一起，故障在机器震动时偶有发生。
Troubleshooting:
1. Machine vibrates excessively. Data link between controller and monitor is ok, connector not loosed.
2. As per the electric schematic, if the oil pressure, coolant temperature, fuel level are displayed 0, root
cause must be related to 5V power source from controller. Measured 5V wire is shorted to ground.
3. Double c heck a nd f ound t he 5V w ire w orn w ith t he f rame a nd c ause i ts i nsulation da maged. This
power source wire is shorted to the frame intermittently when the machine vibrates excessively.
排故体会：该故障属于隐性故障即故障发生没有规律，最好在现场等故障发生时处
理，这样有针对性，也便于检查故障。
Experience: This is an intermittently occurred failure. It is better to do the troubleshooting on the job site
when the failure phenomena appeared.
——提供者：李宏伟 Service engineer: Li Hong Wei

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56、135C 不能停机熄火 135C can not be shut down
故障现象：下午开机工作，再停机时不能停机熄火。工作时间1000h。
Symptom: Machine can not be shut down in the afternoon. Working hour is 1000H.
故障分析：因机器工作正常，故障是突然发生，主要故障在停机马达和线路上：
1、首先检查停机马达；
2、停机继电器；
3、检查停机线路；
4、检查钥匙开关。
Failure analysis: Machine works normally before failure occurred. This failure occurs suddenly. Root
cause of the failure should be focused on the shut down motor and its circuit.
1. Shut down motor should be checked first.
2. Shut down relay should be checked.
3. Shut down circuit should be checked.
4. Check the start switch.
故障原因： 65号线在大臂根部断开。
Root cause of the failure: Wire 65# is opened at the boom root.
排故方法：1、不通电状态时22号线和63号线有24伏电压，64号线和65号线没有电压；
2、钥匙开关通电，检查22号线有24伏电压，63号线和64号线没有电压，
65号线10伏电压；
3、钥匙开关断电，22号线有24伏电压，63号线没有电压，64号线没有电
压，65号线没有电压；
Shut down cable

4、断开停机继电器
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63号、64号、65号线，钥匙开关通电继电器上62号有24伏电压，检查
继电器正常；
5、检查64号65号63号线通断，65号线断（停机马达线圈阻值3欧，检查
另外两个停机马达线圈5欧，17欧）；
6、检查65号线在大臂根部断开，根部线有被压的现象。
Troubleshooting:
1. When the machine is power off, measured wire 22# and 63 # have 24V voltage while wire 64# and 65#
has no voltage.
2. Turn the start switch on: wire 22# has 24V voltage, wire 63 # and 64 # have no vol tage, wire 65 # has
10V voltage.
3. Turn the start switch off: wire 22# has 24V voltage while wire 63#, 64# and 65# have no voltage.
4. Disconnect wire 63#, 64 #, and 65 # from the shut down relay. Turn the start switch on, m easured 62#
contact of the relay has 24V voltage. Checked and found the shut down relay is normal.
5. Check the circuit failure of wire 63#, 64# and 65# and found wire 65 # is opened ( resistance of the coil
is 3Ω, resistance of another two coils is 5Ω and 17Ω.)
6. Checked and found wire 65# is staved and broken at the root of boom. Repair wire, problem solved.
排故体会：检查停机马达63号64号65号接在转轴上，通电使停机马达转带动转轴让
22号线对65号和63号通，通过停机继电器使63号和65号线对64号线通，使
停机马达工作，64号线联接停机马达线圈。
Experience: Wire 63#, 64# and 65# are connected to the rotary shaft. When the start switch is turn on, the
shut down motor will rotate its shaft and make wire 22# connect with wire 63# and 65#. And then wire 63#
and 65 # are connected to wire 64# through the shut down relay. Wire 64# is connected to the coil of the
shut down motor.
——提供者：史贵强 Service engineer: Shi Gui Qiang
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57、发动机无法升速 Engine speed can not be accelerated
故障现象：一台 30 吨挖机，自主控制器，步进电机油门马达。该挖机电器维修后，
启动正常，但拧动油门旋钮时，发动机无法升速。
Symptom: A 30 ton’s excavator equips with Sany designed controller and stepping motor. Machine can
be started normally but can not be accelerated after electric sytem repaired.
故障分析：此现象涉及挖机油门升速的工作原理：拧动油门旋钮，将电压信号传送
给控制器，控制器收到升或降速信号后判断需要加、减速的量，再反馈出
步进脉冲和步进方向给步进电机驱动器，步进电机驱动器根据控制器发出
的步进脉冲和步进方向信号驱动步进电机，使步进电机转动带动油门位置
传感器转动，油门位置传感器将步进电机转动的位置电压信号传送给控制
器，控制器根据采集的位置信号判断步进电机是否已经转动到位。通过故
障原理可判断故障范围：步进电机、步进电机驱动器、油门旋钮、控制器。
Failure analysis: The symptom has something to do with the throttle accelerate principle:
Rotate dial switch, voltage signal is transferred to controller, which will send stepper
impulse and stepper direction to stepper driver according to the signal of speed-up or
speed-down. Stepper driver will make stepper motor drive the sensor of the throttle
positon. Throttle position sensor will transfer the voltage signal of the stepper motor rotate
positon to controller. Controller will judge if the stepper motor is in good position or not
according to the position signal. The failure area as per the principle: stepper motor,
stepper driver, dial switch, and controller.
故障原因：步进电机驱动器 A+、A-接反。
Root cause of the failure: Wire A+ and A- of the stepping motor is installed reversely.
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排故方法：1、通过显示器检查油门旋钮档位和电压变化均匀，判断油门旋钮工作正
常；
+ - A+A-
AA
2、检查步进电机线圈 A+、A-和 B+、B-两组线圈电阻 2Ω 左右正常；转
动步进电机检查位置传感器电阻变化均匀且无断电，完好；
3、启动挖机，拧动油门旋钮加速，观察步进电机向小油门方向转动，将
A+、A-交换位置后故障消除。
Troubleshooting:
1. Checked in the monitor and found the voltage changes evenly while the throttle position is changed. It
is sure that the dial switch works normally.
2. Measured resistance of the stepping motor coil between A+ and A- is about 2Ω. Also the resistance
between B+ and B- is about 2Ω. These are normal. Measured resistance of the position sensor when
the stepping motor is rotated is evenly and no brokage. Position sensor is normal.
3. Start the machine. Rotate the dial switch clockwise step by step, and found the stepping motor rotates
towards the deceleration direction. Interchange wire A+ and A-, tested and proved problem solved.
排故体会：在处理一个故障前了解其工作原理，可提高故障判断的准确率。
Experience: Understanding the system operation and t he component working principle will help to
improve the troubleshooting accuracy.
——提供者: 卞干彪 Service engineer: Bian Gan Biao
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58、显示屏显示时间错误 Displayed working hour is incorrect
故障现象：一台 SY420 样机，显示屏显示 18488 小时，其它工况正常。

Symptom: A new machine SY420 displayed working hour is 18488 hours. Others are normal.
故障分析：1、该机为内蒙君泰样机，配德国屏，自主控制器。到货检查时发现显示
屏显示使用小时数为 18488 小时，其他正常；
2、德国屏显示故障，进入屏的显示信息查看正常；
3、自主控制器程序故障，进入自主控制器 420，9106
程序 TRU 检查系统设置时间功能，修改时间。
Failure analysis:
1. This is a new machine stored in dealer Jun Tai of Inner Mongolia, which equips with Germany
monitor a nd Sany designed controller. It is found the working hou r i s 18488H when t his machine
arrives at the dealer. Others are normal.
2. Monitor may be malfunctioned. Checked and found other parameters displayed are normal.
3. Controller software is incorrect, modify working hour by entering the TRU program of controller.
故障原因：420 自主控制器程序故障。
Root cause of the failure: Software of the SY420 excavator is malfunctioned.
排故方法：1、检查德国屏使用小时修改设置，不能对小时数进行修改；
2、由于没有 420 自主控制器程序，检查卫星定位信号正常，联系华新公
司 0512-57831116，进行远程定位修改，修改成功。
Troubleshooting:
1. Entering into the related menu of the monitor to modify the working hour, but it is unavailable.
2. Because do not h ave t he S Y420 s oftware on the jobsite, contact with H ua X in c ompany by
0512-57831116 to let them remote flush software through the GPS. Problem solved.
排故体会：当设备出现问题时，要从可能发生问题的各个方面考虑，由易到难，调
出相关数据，从数据上分析，寻求多方支援。在远程下载时，当下载成功后不要急
- 284 -
于关掉电源，需等候 1 分钟左右（目的是为了远程加载数据成功保存），关掉电源重
新通电检查。
Experience: Considering the failure cause from all sides when the
failure ha ppened, solve the failure from easy to difficult,
analysis according to the data. When download remotely, please
power off a t le ast 1 m inute later to save the remote dow nload
data completely. Power on again to check the working hour.
——提供者：葛爱 Service engineer: Ge Ai
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59、左行走异常 Left travel is abnormal
故障现象：SY215C8M 挖机左行走动作慢，其他动作正常，做直线行走动作时正常。
Symptom: SY215C8M, left travel has a long cycle time. Other operation and straight travel are normal.
故障分析：1、左行走马达内泄；
2、左行走阀芯卡滞；
3、脚踏阀故障；
4、左边履带过松；
5、左行走先导压力传感器损坏或泄漏故障使控制器检测不到先导信号。
Failure analysis:
1. Left travel motor has severe internal leakage.
2. Left travel valve spool is seized.
3. Left travel pilot valve is malfunctioned.
4. Left track tension is improper.
5. Left travel pilot sensor failed or pilot oil leaked causing controller can not detect pilot signal.
故障原因：左行走压力传感器损坏。
Root cause of the failure: Left travel pilot pressure sensor is failed.
Left travel pilot

pressure sensor
Hydraulic system schematic

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排故方法：1、其它动作和行走一起做，行走以及其他动作都正常。此时，直线行走
阀起作用，左右行走后泵供油，前泵给其他动作供油，控制器通过右
行走压力传感器的压力信号控制后泵的排量，所以行走正常，故可以
排除主泵的故障；
2、进入菜单操作行走发现左行走压力为零，前泵主压力为 10MPa，前泵
比例阀电流为 30mA,控制器无法检测到先导压力信号，故而前泵按小
流量输出，所以左行走慢；
3、将左右行走压力传感器调换，左行走正常，右行走慢。可判定是左行
走压力传感器损坏；
4、更换左行走先导压力传感器，故障消除。
Troubleshooting:
1. Perform t he co mbined ope ration w ith t ravelling, t ravel a nd ot her actions a re n ormal. A t th is tim e,
straight travel valve works, left and right travel are supplied by the rear pump and front pump supplies
oil to other operation. Travel operation is normal since the controller controls the output of the rear
pump via the right travel pilot pressure sensor. Main pump should not be suspected.
2. Left t ravel pi lot pr essure i s 0, f ront pum p m ain pressure i s 10M Pa, a nd front pum p P SV c urrent i s
30mA when operating left travel after entry the menu. Front pump output is the smallest because the
controller can’t detect the pilot pressure signal, which leads to left travel slowly.
3. Exchange the left and right pressure sensor, the right travel is slow while the left travel is normal. It
means the left travel pilot pressure sensor is failed.
4. Replace the failed travel pilot pressure sensor, tested and proved problem solved.
排故体会：先导压力传感器损坏线路故障，会导致控制器检测不到先导压力信号，
引起主泵排量为最小量，动作缓慢。
Experience: Pilot pressure sensor or its circuit failure will lead to controller can’t detect the pilot pressure
signal, causing main pump displace minimum flow and machine action is slowly.
——提供者：谢曹荣 Service engineer: Xie Cao Rong
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60、发动机能启动但整车无动作 Engine can be started but machine has no action
故障现象：SY135C6M 起动发动机后，合上先导开关扳动先导手柄全车无任何动作。
Symptom: After the SY135C6M is started, machine has no action with hydraulic lever unlocked.
故障分析： 1、液压油量是否够，主泵吸空；
2、吸油滤芯是否堵塞、先导油路是否堵塞；
3、液压泵是否损坏，有异常响声；
4、先导开关故障；
5、液压先导电磁阀故障；
6、先导压力是否正常；
7、主泵没有工作或者先导泵没有工作；
8、主安全阀压力是否过低或卡死；
Failure analysis:
1. Hydraulic oil is sufficient or not. Main pump has no oil?
2. Suction screen is plugged or not. Pilot oil circuit is plugged or not.
3. Main hydraulic pump damaged or not. Abnormal noise or not.
4. Hydraulic activation switch is failed or not.
5. Hydraulic activation solenoid valve is failed or not.
7. Main pump or pilot pump fails to work.
8. Main relief valve setting is too low ir seized.
故障原因：电磁阀电源输入线焊接处脱焊，电磁阀不得电,不工作。
Root cause of the failure: Welding wire of solenoid drops down. Solenoid has no power, no work.
排故方法：1、首先检查油量、油路是否足够畅通。
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2、检查主泵是否工作，用手感觉主泵和先导泵及先导泵，出油管是否有
压力（由于该型号挖机没有主压力传感器，无法在显示屏上读取信息，
无法判断其是否工作），发现正常。
3、合上先导开关，看是否能启动发动机，如发现无法启动则说明先导开
关是正常的。
4、用万用表量先导电磁阀是否有电输入，取下电磁阀插头，量取无电压，
仔细发现电磁阀电源输入线焊接处脱焊，重新焊接上挖机故障排除，
如果有 24V 输入则为正常。

Troubleshooting:
1. Check the oil level and oil circuit first to be sure oil circuit is not plugged.
2. Check the main pump by touching your hand on the main pump, pilot pump, and output hoses. It is
found the pump works normally. Note: this model has no main oil pressure sensor on the pump, so we
can not determine whether the pump works normally or not via the information on the monitor.
3. Unlock t he h ydraulic activation control l ever t o check whether engine c an be s tarted nor not . If t he
engine can not be started, it means the hydraulic activation switch is normal.
4. Measure the solenoid valve to check whether it has voltage or not . Disconnect the solenoid wire
connector and found no voltage. Double check and found the power wire of the solenoid drops down
from the welding. Re-weld the wire, tested and proved problem solved.
排故体会：要先检查液压油量是否足够，主泵是否工作，先导是否正常，油路是否
正常，电磁阀是否能打开，一个一个的排除，进而才能确定是问题出在什
么地方。
Experience: Check the hydraulic oil level is sufficient or not first. Main pump works no rmally or not .
Pilot o il s ystem is n ormal o r n ot. Oil c ircuit is normal o r n ot. Solenoid va lve w orks nor mally or not .
Check them one by one to find out the root cause of the failure.
——提供者：袁阳 Service engineer: Yuan Yang
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61、SY215F1 保险更换 2 次仍烧坏 SY215 has the fuse F1 burnt frequently
故障现象：SY215F1 保险（主电源保险）更换二次过程中仍烧坏，造成全车无电。

Symptom: Fuse F1 of SY215 power supply failed frequently. Machine no power.
故障分析：1、从原理图中找造成 F1 保险短路烧坏的原因。如下图
2、看上图能造成 22 号线的电流过大的原因有：16 号线所接的
预热系统短路；11 号线启动系统短路；13 号线 KB 继电器短路；22
号线熄火系统短路。
3、16 号线所接的预热系统本车没装，不必考虑。11 号线的启动系统线
路复杂，根据先简单后复杂的原则暂先不考虑；13 号线所接电源继电
器，如果发生短路，前提是必须将钥匙开关打到 ON 位置才会发生，
可是目前情况是钥匙开关在 OFF 位置就会烧保险 F1 所以可排除。
4、最后 22 号线熄火装置短路很有可能，相对不复杂先检查。
Failure analysis:
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1. Analysis the reason from the schematic why caused F1 fuse burn frequently.
2. From the schematic we can find the reason which caused wire 22# current excessive high, as
following: preheating system of wire 16# is shorted; start system wire 11# is shorted; KB relay of wire
13# is shorted；Shut off system wire 22# is shorted.

3. This e xcavator didn’t install preheating system of wire 16#, not this reason; start system wire 11#
complex, a ccording t he principle of first s imple then c omplex, t hink a bout l ater；if the w ire 13# is
shorted, the ke y switch must be turned on, but now the key switch is of f and the fuse burned so
excluded this reason.
4. Finally wire 22# shut down system may have problem, and it isn’t complex, so check first.
故障原因：熄火马达本身损坏,造成短路,从而总爆 F1。

Root cause of the failure: Shut down motor damaged which cause the circuit shorted and F1 failed.
排故方法：1、用万用表检查熄火装置上 22 号线对地电阻为零。说明有短路。
2、经过对该进入熄火装置的线束多点对地
检测，未发现有短接处，终断定是熄火
装置内部有短接现象。 Shut down cable
3、根据索赔和维修条例不易拆解该装置，
选择更换新件。
4、更换新的熄火装置后，F1 保险不再烧坏。故障消除。
Troubleshooting:
1. Using multimeter check the resistance of wire 22# of shut down circuit, which is zero. That means this
wire is shorted.
2. Checked and found wires of the shut down motor are not shorted. The shut down motor is suspected.
3. As per the warranty rules, shut down motor can not be dismantled. Replace a new shut down motor.
4. After replacing new shut down motor, F1 fuse didn’t burn again. Problem solved.
排故体会：心装原理图，先简单后复杂的去思考问题。
Experience: Must understand schematic, troubleshoot simple first and then complex to solve problem.
- 291 -
62、SY75 整机无动作 SY75 has no action
故障现象：SY75，1300 小时，全车无动作,更换显示屏后,有动作,但油门又加不上。
Symptom: Working hour of SY75 is 1300H. Machine has no action. Replace the monitor, machine can
be operated but can not be accelerated.
故障分析：1、先导电磁阀阀芯卡滞；
2、主泵联轴器损坏；
3、先导减压阀故障（因小挖没有先导泵）；
4、控制器故障，不能输出电压给先导电磁阀；
5、线路故障。
Failure analysis:
1. Pilot solenoid valve spool seized.
2. Main pump coupling damaged.
3. Pilot reducing valve failed. Note: small size excavator has no pilot pump.
4. Controller fails to output voltage to the hydraulic activation solenoid valve.
5. Circuit failure.
故障原因:单色监控器的输出电压不正常导致先导电磁阀不能工作，从而机器没有工
作；更换显示器后整机有动作但是由于监控器（WDKSY60-40 型）与
（WDKSY-60 型）对油门马达的控制方式不一样，导致最后无法升速，增加
一路 5V 电源后，油门工作正常。
Root cause of the failure: The output voltage of single color monitor is abnormal, caused pilot valve not
work, and machine has no a ction. A fter changing monitor m achine ha s action but b ecause m onitor
WDKSY60-40 and WDKSY-60 have different way to control the governor actuator, engine speed can not
be accelerated. Added a 5V power supply, machine can be accelerated properly.
排故方法: 1、由于 SY75 挖掘机是由单色监控器作为控制器，用万用表测量监控器
（WDKSY60-40 型）的 606 号线输出值为 16.70V，符合要求。但此时为
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空载，即在未插线圈插头时测量的值。将电磁阀线圈插上后测量 606
号线电压，发现其电压降至 3V。达不到电磁阀闭合要求。故判断单色
监控器故障；
2、更换后试车，全车有动作。所有动作均正常。但是出现油门不能升速
现象。且显示屏显示“油门旋钮线路断路”。检查油门旋钮线路，发现
旋钮线束只有两根线（0 号线和 506 号线）。油门旋钮插头上还空一根插
针没有接线。咨询工厂研究院后得知单色监控器 WDSY60-60 型的为了解
决之前型号监控器存在转速不稳跳档现象而将油门旋钮上设计三根线，
即 50 号、506 号、0 号。而现在这台 SY75 使用的是 WDSY60-40 型监控
器，油门旋钮只有两根线。故此，在车身线束上引出一根 50 号线接入
油门旋钮后试车。故障排除。整车工作完全正常。
Troubleshooting:
1. SY75 e xcavator us ed s ingle color m onitor a s c ontroller, u sing mu ltimeter to measure m onitor
WDKSY60-40 wire 606 # voltage 16.70V, as demanded. But have no load, that is mean the value is
measured before plug Solenoid valve on. After plug Solenoid valve on and measure wire 606# voltage
falls to 3V, cannot reach Solenoid valve close demand. Single color monitor is suspected.
2. After replacing the monitor, tested and found machine has action but can not be accelerated. And
displayed information indicates “dial switch circuit is opened”. Check the dial switch circuit and find
only two wires（wire 0# and 506#）. Dial switch has one pin empty. After consulting R&D center and
know that single color monitor W DSY60-60 is designed to solve the problem of engine speed
unstable for former m achines, they designed three wire fo r dial switch, 50#, 506#, and 0#. But this
SY75 used WDSY60-40 monitor, dial switch has only two wires. So connect one wire for 50 # to the
dial switch. Tested and proved problem solved. Machine works properly.
排故体会: 工厂研究院在更新原有硬件的同时，发生的变化由于不能及时告知服务
人员，导致在排除故障的时候存在原有故障消失，而产生一个新的故障。
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通过及时沟通就能将问题解决。
Experience: After R &D de partment renewed the old hardware, did not inform the change to s ervice
engineer, caused old problem solved but make a new problem. If communicate on time can solve
problem.
---- 提供者：闫海港 Service engineer: Yan Hai Gang
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63、挖掘机出现一级锁机状态且无法解锁 Machine is locked and can not be unlocked
故障现象：SY235 工作 18 小时，处一级锁机状态无法解锁，无法远程定位、解锁。

Symptom: SY235 works 18 hours, top class locked and cannot be located and unlocked remotely.
Displayed information: top class locked GPRS photo
故障分析：
1、GPRS 的线路有故障会造成锁机现象；
2、远程控制系统可控制锁机，因为是新机基本可以排除因欠费导致的锁机；
3、施工地点的通讯信号不好，会造成锁机现象；
4、SIM 卡损坏会造成锁机；
5、控制器程序及自身有问题，也会造成锁机现象；
6、GPRS 本身故障也会造成锁机。
Failure analysis:
1. GPRS circuit fault can cause lock phenomenon.
2. Remote control system can lock machine. It is a new machine, no payment problem to lock machine.
3. Worksite communication signal not good, can make machine locked.
4. If SIM card damaged, can caused lock machine.
5. Controller program have problem, can make machine locked.
6. GPRS itself fault can make machine locked.
故障原因： GPRS 内部短路。更换 GPRS 后挖机工作正常。

Root cause of the failure: GPRS inside shorted. After replacing GPRS, excavator works normally.
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排故方法：
1、检查 GPRS 的电源线，有 24V 电源，正常；
2、将 SIM 卡拆下放在手机上测试，信号正常，且不存在欠费的现象，正常；
3、打电话咨询华兴公司，确定公司未锁机，且出现远程无法定位的现象；
4、打开驾驶后侧检查盖板，查看 GPRS 电源指示灯是否指示。这时 GPRS 电源
指示灯无指示，使用万用表测量线路，线路正常，后测量 GRRS,测量结果
GPRS 内部短路；
5、更换 GPRS 后挖机工作正常。故障排除。

Troubleshooting:
1. Check power supply wire of GPRS，it is 24V which is normal.
2. Remove the SIM card, tested in the mobile phone. Signal is normal and cost paid. It is normal.
3. Ask Huaxin company by phone, confirmed it is not locked by Huaxin and fails to locate remotely.
4. Open cabin back side cover to check GPRS power indicator, and found the indicator is off. Measure
circuit using multimeter, circuit is ok. Measure GPRS and found GPRS is inside shorted.
5. Replace the GPRS, tested and proved problem solved.
现象的所有因素全部考虑进去，并由简单到复杂逐一排除。
Experience: According to t he failure phenomenon, m ust think pr oblem overall, a fter f ind f ault, s hould
consider every factor who maybe caused this problem, from simple to complex check one by one.
——提供者：王永庆 Service engineer: Wang Yong Qin
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64、SY210 机型全车动作慢 All actions have a long cycle time
故障现象：SY210 挖机突然全车动作变慢，油门有点混乱。
Symptom: SY210 excavator suddenly acts slowly. Throttle position is disordered.
故障分析： 1、机器全车动作慢说明液压泵的排量过低，控制液压泵流量主要有液
压控制和电路控制；
2、先导油路压力过低可产生全车变慢；
3、液压泵电磁比例阀有故障；
4、电脑板或是转换板有故障；
5、主泵的主压，负压传感器有故障；
6、调节器阀柱卡住。
Failure analysis:
1. All actions have a long cycle time means hydraulic pump flow too low. For controlling the hydraulic
pump flow, normally have hydraulic control and circuit control.
2. Pilot oil pressure too low may cause excavator work slow.
3. Hydraulic pump proportion solenoid valve failed.
4. Controller or transfer module failed.
5. Main pressure and negative pressure sensor of the main pump failed.
6. Adjustor valve spool seized.
故障原因：控制器到传感器之间的 5 伏电源线的接头松动。
Root cause of the failure: 5V power supply wire connector between controller and sensor is loosed.
排除方法： 1、通过显示屏观察，先导油路的压力显示为正常值，观察主泵的传感
器的数值均为 0，则可判断故障出在电路上；
2、更换主压与负压传感器，显示数值还是为 0，排除传感器故障；
3、用万用表测量传感器的 5 伏电压值为 0，说明传感器没有反馈电压导
致主电脑板检测不到电压，无法控制比例阀，导致液压泵排量一直处
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在最低位置，使全车动作变慢；
4、更换主电脑板和转换板，故障依然存在，说明故障出在主电脑板和
传感器之间的线路上；
5、检查控制器到传感器之间的 5 伏电源线的接头松动，紧固接头，重
新启动，故障排除。
Troubleshooting:
1. Pilot oil pressure is normal, main pump sensor value is 0. It is means fault is on the circuit.
2. Replace main pressure sensor and negative pressure sensor. Display value is still 0, sensor no fault.
3. Using multimeter measure sensor 5V wire is 0V. It means sensor has no feedback voltage to
controller, which caused the c ontroller can not control PSV. H ydraulic pum p works at the lowest
displacement, and the machine works slowly.
4. Replace the controller and the transfer module, fault still there. It means fault is on the wire between
main board and transfer board.
5. Check 5V power supply wire connector, it is loosed. Tighten connector, restart, fault solved.
排除体会：根据故障现象来推导与此故障有关联的因素，在通过别的一些故障现象
来确定具体的故障原因。
Experience: According fault phenomenon to judge the possible factor, and through other fault
phenomenon confirm the exact fault reason.
——提供者：张先锋 Service engineer: Zhang Xian Feng
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65、显示器显示水温高 Monitor displayed coolant temperature is very high
故障现象：显示器显示水温高。
Symptom: Monitor shows the coolant temperature is very high.
故障分析：水温高通常有以下原因造成：
1、水温传感器内部是否损坏；
2、水箱油冷器是否被异物灰尘堵塞；
3、水箱与油冷器之间密封海绵有无损坏；
4、风扇皮带有无老化、拉长或调整不当；
5、风扇叶片有无装反或受损变形，导致进风不足；
6、水箱内冷却水是否不足；
7、发动机脚垫橡胶有无老化损坏，使发动机下沉，风扇偏离；
8、水泵有无损坏，使水压不足，流动不畅；
9、发动机节温器有无损坏，打不开或打开角度太小；
10、发动机的负载过大。
Failure analysis: probable cause of high coolant temperature listed below.
1. Coolant temperature sensor is failed or not.
2. Radiator and oil cooler is block by foreign material or not.
3. Sealing sponge between radiator and oil cooler is damaged or not.
4. Fan belt is aging, extended, or tension is adjusted properly or not.
5. Fan blade reverse or deformed, which causes the insufficient wind pass through radiator.
6. Coolant level is proper or not.
7. Engine support rubber is aged or, which causes engine sank and fan not on position.
8. Water pump failed, causes water pressure not enough and water flow not smooth.
9. Regulator damaged, can not open or open distance is insufficient.
10. Engine is overloaded.
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故障原因：节温器故障，打开角度较小，使冷却水不能充分实现大循环，致使仪表
盘显示 5-6 格的高温。

Root cause of the failure: Regulator is failed. Its opening distance is smaller than specification. Part of
coolant can not flow to radiator for cooling. Analog gauge displayed 5-6 case high temperature.
排故方法：更换节温器后，运转检查 1 切正常。
Troubleshooting: Replace the regulator, tested and proved problem solved.
排故体会：发动机水温高故障发生率较高，通常可从以下两方面着手：
1、发动机本身原因；
2、液压系统的负载过大。
Experience: Engine high coolant temperature can be suffered frequently. Normally, we can do the
troubleshooting from following two aspects:
1. Engineer problem.
2. Hydraulic load is excessive.
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66、SY215 工作无力 SY215 has not enough power
故障现象：SY215工作时候复合动作缓慢，冒黑烟，尤其是大臂提升慢，油耗每小时
高达到19升。
Symptom: SY215 has long cycle time during the combined operation and emits black smoke, especially
the boom up operation is slowly. Fuel consumption is 19 liters per hour.
故障分析：
1、保养不及时，油路不畅，发动机高速运转时候不能正常工作；
2、主压力或者先导压力低引起；
3、转速标定不正确，或者位置传感器电压不正常，控制器不能让液压泵正常输
出值功率。
Failure analysis:
1. Maintenance job not done timely. Fuel is restricted. Can not work normally at high speed.
2. Main oil pressure or pilot oil pressure is lower than specification.
3. Engine s peed c alibration is in correct, o r the position s ensor vol tage is abnormal. Controller fails to
make hydraulic pump output normal value.
故障原因：
1、咨询客户保养是否按照要求在规定时间定时保养；
2、是否有人进行过压力调节；
3、转速是否调节过，油门拉线是否松动达不到额定转速.检查转速和压力是否
在正常值；
4、位置传感器电压是否在要求范围3.7V；
5、主阀上各先导传感器是否完好。
1. Should enquiry the operator or the end user, whether the maintenance job is done timely.
2. Oil pressure is adjusted by somebody or not.
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3. Engine speed is adjusted or not. The cable of governor actuator is too loose to achive the rated engine
speed. Check the engine speed and oil pressure are normal or not.
4. The voltage of position sensor is within specification 3.7V or not.
5. All the pilot oil pressure sensors are normal or not.
排故方法：
1、咨询过保养都是按照要求完成；
2、起机检查主压力在345KG左右,先导压力32KG,调节先导压力到38KG；
3、转速在S模式下能达到2100转；
4、位置传感器电压3.58V,重新标定转速,位置传感器电压标定到3.7V，试车检
查,机器工作正常,没有发现黑烟,动作达到了出厂时的速度。
Troubleshooting:
1. Customer done maintenance according to the maintenance interval.
2. Measured main oil pressure is 345Kg, pilot pressure is 32Kg. Adjust pilot oil pressure to 38Kg.
3. Engine speed can reach 2100rpm at S mode.
4. Position sensor voltage is 3.58V. Calibrate engine speed and set the position sensor voltage to 3.7V.
Tested and proved excavator has no black smoke and the engine speed reached demand.
排故体会：
1、根据客户反映的情况检查, 认真对待每一个故障, 想到可能发生的一切；
2、按照机型和控制器型号去排除故障；
3、现在20吨挖机在工作到1000小时和1500小时后位置传感器电压和先导压力都
有所改变，需要重新标定和调节；
4、建议各分公司都备有一个转速标定器,及时解决故障,减少客户抱怨,让客户得
到更大利益；
5、自主控制器挖机转速可以在显示器里自动标定,现在很多挖机在工作一段时间
后都有反映动作变慢,去到工地时候一定要检查转速是否在额定转速相差10转
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内,如果没有在要求范围,必须重新标定,转速相差大自主控制器不能正常输
出功率。
Experience:
1. According to the situation of customer saying, treat every problem seriously, think every reason.
2. According to machine model and controller model to solve problem.
3. Now for 20 ton excavator after worked 1000 hour or 1500 hour the position sensor and pilot pressure
changed and need readjust.
4. Advice every branch company should have one running speed measure device, solve problem on time,
let customer gain best profit.
5. Sany designed controller engine speed can be calibrated in monitor automatically. Now so many
excavator act slow after work some time. When go to worksite must check if engine speed is less than
10rpm with the rated speed. If it is out of range, engine speed must be calibrated. If the speed different
is excessive, controller cannot output normal power.
——报告人:童斌纲 Service engineer: Tong Bin Gang
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67、卸载时斗杆有停顿现象 Arm is not smooth during the stick out operation
故障现象:SY215 挖机，工作 1300H，斗杆卸载时动作迟缓，3 秒后恢复正常。

Symptom: SY215 excavator，worked 1300H，stick out action paused and restored 3 seconds later.
故障分析:造成这种故障原因有:
1、斗杆阀杆发卡；
2、油口溢流阀发卡；
3、调节器发卡；
4、主控制器损坏；
5、斗杆卸载传感器损坏及线路故障。
Failure analysis: Probable cause of the failure listed below:
1. Arm valve spool seized.
2. Line relief valve seized.
3. Adjustor valve spool seized.
5. Stick out pilot pressure sensor or its circuit failed.
故障原因：202#号线电压不稳，正常为 0-5V, 而 202#号线电压最大输出为 2-3V，因
此判断 202#线有接触不良的部位，把控制器备用 500#改为 202#线，后故障
排除。
Root cause of the failure: Wire 202# voltage is unstable. Normally it is 0-5V, measured max voltage of
wire 202# is 2-3V. So wire 202# is failed. Modify the controller spare wire 500# to 202#，fault solved。
排故方法:
1、清洗斗杆阀杆Ⅰ，阀杆Ⅱ；
2、清洗油口溢流阀；
3、调节器发卡可以利用电控改为液控来判断是否存在问题，改完试车，卸
载动作迟缓现象排除，可以肯定造成此故障为电气元件，用万用表量压力
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传感器为正常，量出 202#号线电压不稳，正常为 0-5V, 而 202#号线电压
最大输出为 2-3V，因此判断 202#线有故障，把控制器备用 500#改为 202#
线，后故障排除。
Troubleshooting:
1. Wash arm 1 valve and arm 2 valve spools.
2. Wash the line relief valve.
3. We can change electric control to hydraulic control to judge if the pum p adjustor is seized or n ot.
Tested under hydraulic control mode and found machine work properly. So failure should be caused
by electric parts. Measured pressure sensor is ok, but wire 202# voltage is unstable. Normally it should
be 0-5V, but the measured maximum voltage of wire 202# is 2 -3. S o wire 202 # is f ault. Using t he
controller spare wire 500# to replace wire 202#，tested and proved problem solved。
排故体会:运用排除法很好判断故障。
Experience: Use exclusive way to judge fault。
——吕孟政：Service engineer: Lv Men Zheng
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68、215C8M 斗杆回收速度慢，右回转工作无力 Stick in and swing right slowly
故障现象：设备工作时斗杆回收速度慢，右回转工作无力。
Symptom: Stick in operation is slowly, and the right swing operation has insufficient power.
故障分析：因为其它动作正常，基本可以排除泵的问题，主要从与右回转及斗杆回
收有关的阀，及电气部分着手检查。
Failure an alysis: Because the other actions are normal, main pump should not be suspected.
Troubleshooting should focus on valve which can affect right swing, stick in, and electricity.
故障原因：连接斗杆挖掘和右回转的压力传感器顺序插反。
Root cause of the failure: Pilot pressure sensor wire of stick in and right swing is interchanged.
排故方法：
1、检查和测量斗杆挖掘时，泵压输出正常；
2、试机检查无自动降速功能；
3、检查监控面板上显示，发现斗杆挖掘和右回转的压力传感器在动作时显示
“ON”或“OFF”时工作相反；
4、检查过渡块上斗杆挖掘和右回转的压力开关的插头连接顺序错误。后询问
用户得知，该机曾让个人维修点维修过，在维修过程中安装的次序搞错了。
5、更正传感器插头，试车正常，故障排除。
Wire of these two pilot pressure
sensors is interchanged.
Troubleshooting:
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1. Checked and found the pump pressure is normal when stick in operation is performed.
2. Tested and found auto idle speed function is unavailable.
3. Checked on the monitor, and found when stick in and right swing action is performed one by one, the
displayed status of pressure switch “on” and “off” is interchanged.
4. Checked and found the pressure sensor plug for stick in and right swing are installed in wrong order.
Enquiry the customer and know t hat t his m achine ha d been r epaired b y personal co mpany, and t he
sensor plug is installed in wrong turn during the service progress.
5. Correct the sensor wire plug tested and proved machine works normally. Problem solved.
排故体会：充分利用监控面板上能监控到的信息，进行有效的分析、判断处理故障。
向用户严肃申明，维修必须在三一指定的维修服务网点进行，否则会给用户造成不必
要损失，将由客户自行承担。
Experience: Use t he i nformation w e ge t f rom m onitor, a nalysis a nd j udge t he f ault. Tell c ustomer th is
machine must be repaired by our employee, if not, all the responsibility will undertake by customer
themselves.
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69、SY200 挖掘机转速异常 SY200 engine speed is abnormal
故障现象：SY200 发动机加不起油门，不能熄火，其他显示正常。
Symptom: SY200 engine can not be accelerated, can not be shut down, and others are normal.
故障分析：1、EC-7 控制器故障；
3、油门马达控制器故障；
4、转速传感器故障；
5、线路故障。
Failure analysis:
1. EC-7 controller fault；
2. Governor actuator fault；
3. Governor actuator controller fault；
4. Speed sensor fault；
5. Wire circuit fault.
故障原因：发动机转速传感器安装不到位。
Root cause of the failure: Engine speed sensor is not installed properly.
排故方法： 1、启动发动机，从显示屏上观察，除转速显示为零外，其他显示正常；
2、检查油门位置传感器是否正常；
3、检查油门马达的输入输出信号是否正常；
4、检查油门马达本生是否正常（线圈的阻值是否为无穷大，是否为 0
欧，正常的阻值约为 30 欧左右）；
5、检查传感器没有装到位，间隙过大导致 EC-7 控制器检测不到发动机
的转速信号。
Troubleshooting:
1. Start engine and found the engine speed displayed is 0. Others are normal.
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2. Check if the throttle position sensor is normal.
3. Check the governor actuator if the input and output signal is normal.
4. Check if the governor actuator is normal. Normally, its coil resistance is around 30Ω.
5. Check if the speed sensor is installed properly. Excessive clearance will cause EC-7 controller cannot
detect engine speed signal.
排故体会：在排除 1 些故障的时候，很有必要询问最近客户有无动过什么地方，从
新问题着手，往往有事半功倍的效果。
Experience: When solve some failure, it is necessary to ask customer if they have done something
recently, start from new problem, sometime will get twice the result with half the effort
——提供者：李铁山 Service engineer: Li Tian Shan
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70、SR180 旋挖加速不良 SR180 accelerated poorly
故障现象：SR168整改为SR180（4280小时）的旋挖钻。
1、通电有故障代码373，147；
2、不能正常启动，要启动34次；
3、启动着车后，怠速正常，1加油门就熄火，无黑烟，中速正常。
Symptom: SR168 is modified to SR180 rotary drill when the working hour is 4280H.
1. Faulty code 373 and 147 is detected when the machine is powered on.
2. Engine can not be started normally, needs to crank for three to four times and then started.
3. After engine started, engine runs at low idle speed normally. But shut down automatically once it is
accelerated. No black smoke, engine runs normally at middle speed.
故障分析：
1、读取故障码373（断油发动机熄火）147（油门信号漂移），检查线路连接；
2、检查气路和油路；
3、怠速和中速正常，说明发动机本身，电控柴油泵没有问题。
Failure analysis:
1. 373 mean fuel off and engine shutdown. 147 means throttle signal drifted. Check wire circuit.
2. Check the inlet air and fuel circuit.
3. Engine runs normally at low idle speed and middle-speed normal. It means engine is normal, diesel
fuel pump should be normal.
故障原因：
1、检查EPS控制油门的两根线的连接是否良好；
2、检查气路和油路；
3、检查ECM控制器。
Failure cause:
1. Two wires of EPS governor control are normal or not.
2. Inspect the inlet air and fuel circuit.
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3. ECM controller is normal or not.
排故方法：
1、用万用表测量航空插头的61，59号线的导通性，发现接触不良，更换航空
插头，能测量到电压，但故障代码依然存在，则说明EPS有信号传到ECM；
2、拆卸空滤，检查进气道和增压器1切正常。更换柴油滤芯发现无变化，直接
打吊瓶，故障依旧。检查回油单向阀，检查电子油泵清洗滤网发现正常；
3、康明斯来人检测发动机ECM控制器内的参数发现加减油门无显示，其他空气
温度，水温，进气压力，喷油脉冲，转速都正常。一加油门发现脉冲突然没
有。检测EPS油门控制的输入和输出信号发现正常。则说明ECM控制器的输出
油门脉冲信号有问题。更换发动机线束发现问题依然存在。更换ECM，发动
机线束故障灯消失，但依然加不起油门；
4、EPS检查完好无损，只因为ECM的输出油门脉冲有问题，判断ECM的控制程序
有问题，重新下载XJ91613.99程序后，试车OK。
Troubleshooting:
1. Using multimeter to measure wire 61# and 59#, and find circuit opened. Replace the wire plug, can
measure voltage but fault code still existed. It means signal is sent from EPS to ECM.
2. Remove the air filter, it is found air inlet passage and turbocharger work properly. Replace fuel filter
problem still existed. Checked and found fuel return check valve and the suction screen of the
electronic fuel pump are normal.
3. Cummings service engineer checked t he p arameter o f engine E CM, a nd found t hrottle a cceleration
and deceleration signal have no display. Others are normal, such as air temperature, coolant
temperature, air inlet pressure, fuel injection pulse, and engine speed. The fuel injection pulse
disappeared once engine is accelerated. Checked the input and output signal of EPS throttle control is
normal. It m eans ECM out put throttle signal ha s fa ilure. Replace t he engine harness, p roblem s till
existed. Replace the ECM, fault light off but still cannot be accelerated.
4. EPS is normal. Since ECM onput throttle signal has failure, ECM software is suspected. Flush the
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software XJ91613.99. Tested and proved problem solved.
排故体会：
1、原车的ECM损坏是因为航空插头的松动引起与ECM得接触不良，从而导致非法
断电最终致使ECM的损坏。
2、更换过31的ECM（J91614.05），因为程序不对机子也不正常。所以将三一ECM
刷上XJ9163.99后才正常。
3、都是因为程序闹的，希望公司将机子的基本信息做到位，避免下次服务人员
走弯路。
Experience:
1. Initial equipped ECM is damaged due to plug loose and circuit opened intermittently. Finally caused
ECM damage.
2. After replace with Sany ECM (J91614.05), machine can not work normally due to incorrect software.
Flush software XJ9163.99 to Sany ECM, and then machine works normally.
3. All problems caused by software, so suggest the factory finishs this basic job to prevent service
engineer turns a round next time.
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71、SY135C 挖机回转不工作 SY135C can not swing
故障现象：SY135C8 挖掘机回转无动作，其它动作正常。
Symptom: SY135C8 can not swing, other operations are normal.
故障分析：
1、先导手柄回转阀芯故障导致先导油路未能导通；
2、回转马达安全阀阀芯发卡，液压油溢流回油箱；
3、液压主控阀回转阀芯发卡，液压油不能到达回转马达；
4、回转马达内部柱塞或其它零部件损坏，导致回转马达不能正常工作；
5、回转机构内部齿轮或其它零部件损坏，导致回转减速机构不能正常工作；
6、回转机构与回转支承连接副故障，如齿轮磨损等。
Failure analysis:
1. Swing pilot valve spool failed and caused pilot oil blocked.
2. Line relief valve spool of the swing motor seized, and cause pressure oil back to oil tank.
3. Swing valve spool of the main control valve seized, no hydraulic oil goes to swing motor.
4. Plunger or other parts of swing motor damaged, caused swing motor fails to work.
5. Gear or other parts of swing drive damaged, caused swing drive fails to work.
6. Mechanical problem between swing device and swing support, such as gear wear.
故障原因：1、回转减速箱内部一级减速中心齿轮磨损严重；
2、回转减速箱内部二级减速支撑架损坏。
1. Sun gear of the swing drive is worn severely.
2. Planet gear frame of the swing drive is damaged.
排故方法：
1、启动机器并作回转动作，仔细观察作回转动作时回转平台可两边摆动，摆
动时有异常响声，明显感觉机械卡滞现象。则可判断回转减速机构内部故
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障或回转机构与回转支承连接副故障；
2、拆下回转机构与回转平台连接的一圈螺栓，吊起回转机构总成，检查回
转机构与回转支承连接副，发现回转主动齿轮及回转齿圈齿轮均正常；
3、拆检回转减速箱，发现一级减速中心齿磨损严重，二级减速支撑架损坏；
4、更换新的回转机构总成后，故障排除。
Troubleshooting:
1. Starting machine and swing the excavator, found swing platform moved when swing, and have noise,
feel someplace blocked. So we can judge swing drive inside problem or mechanical problem between
swing drive and swing support;
2. Removed the bolts which connect swing drive and swing platform, hang up s wing unit, check swing
drive and swing support connection. It is found swing driving gear and swing ring gear is normal.
3. Dismantle swing drive, it is found the sun gear is worn seriously and planet gear frame is damaged.
4. Replace the failed parts, tested and proved problem solved.
排故体会：先要知道工作原理，并且现场仔细观察才能找到故障。
Experience: Service engineer m ust understand t he work principle, and observe ca refully at w orksite to
find out root cause of the failure.
——提供者：贵州通程 Service engineer: Gui Zhou Tong Cheng
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72、SY215 全车无动作 SY215 has no action
故障现象：一台工作约 4500 小时 SY215 整车无动作。

Symptom: SY215 has no actions when the working hour is 4500H.
故障分析：全车无动作一般可从以下几方面原因造成：
1、先导电磁阀未通电；
2、先导电磁阀卡滞；
3、先导齿轮泵失效；
4、主泵失效；
5、发动机动力未传送至主泵。
Failure analysis: Machine has no action is possibly caused by following reasons:
1. Hydraulic activation solenoid valve has no power；
2. Spool of hydraulic activation solenoid valve is seized.
3. Pilot pump failed.
4. Main pump failed.
5. Engine power didn’t transfer to main pump.
故障原因：联轴器损坏，发动机动力输出被切断，导致整车无动作。
Root cause of the failure: Coupling failed. Engine power can not be transferred to main pump.
排故方法：
1、启动发动机进入显示屏机器运转信息查询界面，发现先导压力，前后泵压
力均为零； Teeth of the coupling are shaved.
2、测量先导电磁阀的输入电源为 24V 正常；
3、着车，用手摸前后泵高压管，无震颤感；
4、松开先导泵至先导滤芯的软管，启动发
动机，发现无液压油喷出；
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5、打开发动机飞轮罩壳上的观察孔，发现大量红色粉末存在，故判定为联轴
器损坏。
6、更换连轴器，检查液压油液位，给液压泵排空气，试车正常。
Troubleshooting:
1. Start engine and check the information of monitor. It is found pilot pressure, front pump and rear
pump oil pressure are all zero.
2. Using multimeter to measured the voltage of hydraulic activation solevoid valve. It is 24V, normal.
3. Start engine and touch the output oil hose of the main pump. No obvious pulse.
4. Loose the hose from pilot pump to pilot filter, start engine and find no hydraulic oil spray out.
5. Remove t he cover of e ngine flywheel, and found plenty of red powder. It i s r oad s ign of coupling
damaged.
6. Replace the failed coupling, check and sure the hydraulic oil level is normal. bleed air from the main
hydraulic pump. Tested and proved problem solved.
排故体会：先利用显示屏的数据做初步判断，然后再检查电路问题，同时利用经验
判断主泵及先导泵是否工作，之后检查机械连接部件。
Experience: First use data of monitor to estimate problem, then check circuit problem, at the same time
use experience to judge if main pump and pilot pump work, then check mechanic connect parts.
——提供者：苏鹏 Service engineer: Su Peng
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第 3 节发动机 Engine
01、SY420 6D24 发动机启动着马上就熄火 6D24 engine shut down soon once it is started
故障现象：发动机在 2000 转正常工作时，转速突然下降到直到熄火，再启动发动机
无法启动。在代理商服务人员校对柴油高压油泵，更换电子调速器后，
发动机能启动，但启动后马上又熄火。
Symptom: Engine runs normally at 2000 rpm，and then drops suddenly till shut down. Engine cannot be
restarted. Dealer rebuilt the fuel injection pump and replaced electronic governor. Engine can be started,
but shut down soon.
故障分析：
1、发动机能启动说明柴油高压油泵电子调速器正常；
2、发动机启动后又熄火说明故障点在电气控制系统；
3、因发动机能启动说明发动机 ECM 控制器工作正常；
4、发动机转速传感器工作是否正常（发动机 ECM 控制器用）；
5、如 EC-7 控制器损坏不能输出 5V 电源（701 号线 5V 电源）导致不能供给
电子调速器一个电压值；
6、K6 继电器工作是否正常，81 号线、93 号线、45 号线、51 号线是否得电；
7、发动机 ECM 控制器至发动机各电气元器件端子间有无断线短路。

Failure analysis:
1. Engine can be started. It means fuel injection pump and electronic governor are normal.
2. Engine shutdown automaticall once it is started. It means failure fosussed on electric control system.
3. Engine can be started, so engine ECM works normally.
4. Engine speed sensor works normally or not, which send signal to engine ECM.
5. If E C-7 c ontroller is damaged, it can not out put 5V power (wire 701, 5V power), and causes
electronic governor has no voltage.
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6. Relay K6 works normally or not. Wire 81#, 93#, 45#, and wire51# have power or not.
7. Wire circuit from engine ECM to engine electric parts has failure or not.
排故原因：
1、首先根据 6D24 发动机自带故障诊断报警灯，显示信息排找故障点；
2、检查各保险丝是否完好，各线路插头连接牢靠；
3、检查全车线路是否有断线短路；
4、检查发动机各电器元件是否完好；
5、检查 EC-7 控制器、发动机 ECM 控制器工作是否正常。

1. First troubleshoot according to the information of 6D24 engine fault alarm light.
2. All the fuses are normal or not, all the wire connectors are connected tightenly or not.
3. Check if machine wire circuit is opened or shorted.
4. All the engine electric parts are normal or not.
5. EC-7 controller and engine ECM works normally or not.
排故方法：
1、查看故障诊断报警灯显示故障代码,故障灯常亮无法判别故障显示。
（如 33 表
示发动机 ECM 控制器故障）；
2、查看 F11、F12、F15、F16 号保险丝是否完好--完好正常；
3、检查 EC-7 控制器 701 号端子有无 5V 电源输出，检查油门控制直流转换器
705 号端子有无 0.95V 电源输出，在旋动油门旋钮时 705 号端子电压是否随
着油门旋钮旋动从 0.95V 至 3.78V 间变化---是，证明 EC-7 控制器、直流
转换器工作正常；
4 、检查 K6 继电器工作是否正常，81 号线、93 号线是否得电，有无间歇性断
电--无,工作正常；
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5、检查发动机转速传感器是否正常--正常，电阻 2.2K；
6、检查柴油高压泵电子调速器线束：127 号线与 74 号线之间无电压反馈（正常
为 0.5V--4.4V，此为油门齿条反馈位置），122 号线无电压（正常为 5V）；
7、从驾驶室内将发动机 ECM 控制器上线束端子拔下，用万用表欧姆档检测每一
根线是否有短路搭铁。检测结果为：122 号、123 号、124 号、125 号、127
号、71 号、72 号、111 号线为 0 欧姆；
8、经对发动机至驾驶室之间线路线束的检查发现在驾驶室底部与平台之间的控
制系统主线路线束破损短路断线。造成发动机无法启动故障，后对破损短路
断线重新连接包扎。发动机能够启动但高速时工作无力，因线路短路时将涡
轮增压传感器烧毁，使传感器无反馈信号回发动机 ECM,;
9、更换涡轮增压传感器，试车运行整车工作正常，故障排除。
Troubleshooting:
1. Check fault code. The alarm indicator is lighted always, so we do not know which ki nd of f ailure
occurred. For example, faulty code 33 means engine ECM malfunctioned.
2. Checked and found fuse F11, F12, F15, and F16 are normal.
3. Checked and found EC-7 controller 701 t erminal has 5V output, throttle control DC transfer module
705 terminal has 0.95V output，and when rotate dial switch 705 terminal voltage varied from 0.95V to
3.78V. It is sure that EC-7 controller and DC transfer module work normally.
4. Check relay K6 is normal. Wire 81# and 93# have voltage always, which is normal.
5. Checked and found engine speed sensor is normal. Its resistance is 2.2K.
6. Check the electronic governor wire：no voltage between wire 127# and 74#（normally is 0.5-4.4V，this
is for fuel rack feedback position），wire 122# has no voltage（normally is 5V）；
7. Check ECM every wire one separately, and found the resistance of wire 122#, 123#, 124#, 125#, 127#,
71#, 72#, and 111# is 0 Ω.
8. Double check and find wire broken which is below lab bottom control system main circuit. This make
the circuit shorted and engine can not be started. After repairing the failed wire circuit, engine can be
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started but machine lack of power when engine runs at high speed due to boost pressure sensor
damaged which caused by the shorted circuit. No boost pressure signal feedback to engine ECM.
9. Replace the failed boost pressure sensor, tested and proved machine works normally, problem solved.
排故体会: 在维修过程中会遇到缺少配件的问题，要积极主动动脑筋想办法,用可替
代件，保证机器的正常工作，从而不影响客户的工期。
Experience: During the service repair, may be there are no new spare parts, service engineer should use
the interchange method to let machine works normally and reduce the user’s downtime.
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02、冷却液温度高达 106°C Coolant temperature arrives at 106°C
故障现象：冷却液温度高达106°C。
Symptom: Coolant temperature arrives at 106°C.
故障分析：冷却液温度过高一般是由于缺水，冷却液循环系统或发动机超载，散热不
良等原因造成的。
Failure an alysis: High c oolant t emperature i s generally caused b y i nsufficient co olant, c ooling system
failure, engine overloaded, insufficient cooling, and so on.
故障原因：冷却液温度高，原因有：
1、冷却液液面过低；
2、水箱散热片损坏或堵塞；
3、水箱软管扁瘪，阻塞或泄漏
4、温度传感器或仪表失灵；
5、节温器不正确，丢失或失灵；
6、水泵或风扇传动皮带松弛，风扇叶是否变形，破损造成散热差。
1. Coolant level is low excessively.
2. Radiator fins damaged or blocked by foreign debris.
3. Radiator hose pinched and cause coolant blocked.
4. Coolant temperature sensor or instrument failed and cause the reading inaccurately.
5. Regulator failed or removed.
6. Fan belt loose or fan blades deformed, which cause heat poor cooling effect.
排故方法：1、检查冷却液液面是否在合适的范围内；
2、检查水箱散热器是否堵塞；
3、检查水箱软管无扁瘪、阻塞或泄漏现象；
4、检查节温器的开启温度和开度是否合格；
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5、检查水泵或风扇传动皮带松弛度，检查发现在压缩机和驱动轮皮带之
间用手指施加 6 公斤的力，凹下量达到 15 毫米左右，调整皮带张紧
度，故障解除。
Troubleshooting:
1. Check the coolant level to be sure it is within the specification.
2. Check the radiator fins and make sure it is not blocked by the foreign material.
3. Check the radiator hose and make sure it is not pinched or blocked.
4. Test the regulator to check the opening temperature and the opened distance is correct or not.
5. Check the water pump or fan belt tension. It is found the sag of the fan belt under 6kgf force is 15mm.
Adjust the fan belt tension properly, tested and proved problem solved.
排故体会：往往排除故障要从简单处着手，也许来的更快。
Experience: Troubleshoot easy phenomena, will find root cause quickly.
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03、工作10-20分钟憋车并熄火 Engine stalled after working 10-20 minutes
故障现象：工作10-20分钟憋车并熄火。
Symptom: Engine stalled after working 10-20 minutes.
故障分析：起动时能够工作,但每次工作10-20分钟就憋车并熄火。
Failure analysis: Machine can work normally after engine started. Engine stalled 10-20 minutes later.
故障原因：此类故障一般由以下几种原因造成：
1、燃油系统有漏气现象；
2、燃油系统有堵塞的现象:如低压管路上的进油滤网(一级滤芯进油口通
常有一个小滤网,手油泵的进油口有一小滤网)；燃油管路有弯曲打折
的现象；燃油箱内有杂物如袜子等；燃油管子内层胶皮脱落等现象；
3、检查空气滤芯有堵塞,进气管有变形,,及中冷器过脏或破损,涡轮增压
器(用手摇、拉涡轮轴)，间隙过大。
1. Fuel system has air leakage.
2. Fuel system is blocked. Such as fuel filter or s mall strainer located on t he pr iming pum p of t he
low-pressure circuit is blocked. Fuel hose bent and cause the fuel restricted. Fuel tank has debris such
as socks. Rubber hose inner surface peels off, and so on.
3. Check the air filter is blocked, the intake hose deformed, the aftercooler is too dirty or damaged, and
turbocharger has excessive clearance.
排故方法：1、检查燃油系统是否有空气,用手油泵泵油,拆掉第2道滤芯上的放气螺
栓或出油口,没有气泡且手泵有力证明燃油系统没有问题；
2、排除燃油系统管路，或漏气问题,通常有一个打吊针(把手油泵的进油管
拆下,另外接一根油管直接到油箱或另一油源)的土办法,且比较实用,方
便,快捷；
3、经检查，该客户使用的油品质量太差，含水量高及比较脏，用 10-20
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分钟后就造成滤芯堵塞从而导致熄火现象；
4、更换燃油及滤芯，清洗燃油油路后启动机器，现场试车两小时未出现
熄火现象，证明故障解决。
Troubleshooting:
1. Check t he f uel s ystem has air or not . Operate th e p riming pump to bl eed a ir from t he s econd f uelt
filter base. No air could be found and priming pump works normally. Fuel system is normal.
2. To check whether there is air in the fuel system or not, we can remove the inlet hose of the priming
pump, and then connect another hose to the fuel tank or fuel sourse. This method is original, practical,
convenient, and effectual.
3. Double checked and found t he diesel fuel used has a poor quality. A large amount of water and
sediment is found. Fuel filter is clogged after machine works about 10-20 minutes. Engine stalled and
shut down automatically.
4. Replace fuel and fuel filter, clean fuel circuit, and then start the engine. Tested for two hours on the
jobsite, and found machine works normally. Problem solved.
排故体会：此类问题出现后应该首先考虑燃油油路系统，滤网是否堵塞，油泵进油
滤网和油水分离器滤网是否堵塞，然后考虑电气故障。
Experience: To do the troubleshooting for t his kind of failure, s ervice engineer should check the fuel
system first. Filter, fuel water separator, and strainer is blocked or not. And then suspect the electric fault.
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04、怠速过高 Idle speed is too high
故障现象：一f台08年SR200旋挖钻机发动机怠速过高为1275r/min ，调节油门拉线可
以使怠速有所下降，但最高转速只有1825 r/mi而且油门的1、2、3、4档
转速没有变化，固定在1346 r/min。
Symptom: SR200 rotary drill was made in 2008. Engine low idle speed is 1275rpm. Adjust the throttle
cable can lower the low idle speed, but t he hi gh i dle speed is only 1825 r pm. Engine s peed a t t hrottle
position 1st, 2nd, 3rd, and 4th is the same. It is 1346 rpm.
故障分析：在发动机速度正常情况下，1般发动机的转速都是有油门控器控制,或油门
马达来执行的。
Failure analysis: If the engine speed is normal, it should be controlled by the dial switch, and carried out
by the governor actuator.
故障原因：1、油门旋钮损坏；
3、EPEC故障。
3. EPEC malfunctioned.
排故方法：1、用万用表测量油门旋钮电阻(0-2K)，正常,可排除油门旋钮故障；
2、更换新的油门马达故障依旧，可排除油门马达故障；
3、标定发动机档位和转速：发动机的转速也接受EPEC的控制，将工
作模式设为H模式短接EPEC上预留的一个接线，扭动油门旋钮使在
每个挡位上停留3s,这时怠速在982 r/min，1挡1203 r/min，2挡1324
r/min ，3挡1451 r/min，4挡1527 r/min，5挡1621 r/min，7挡1735
r/min，8挡1835 r/min，9挡1984 r/min，10挡2012 r/min，但10挡时

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发动机转速不稳;然后把工作模式调为S在按照刚才的部骤调节，发动
机转速正常;故障原因可能是发动机档位和转速没有经过标定。
EPEC
Troubleshooting:
1. Measured resistance of the dial switch is 0-2KΩ, which is normal. Dial switch is normal.
2. Replace governor actuator, problem still existed. Governor actuator not failed.
3. Calibrated throttle position and engine speed: engine speed is also controlled by EPEC. Select the H
mode and shorted the EPEC reserved wire plug. Rotate the dial switch and stay at each throttle
position for 3s. After calibration, checked low idle speed is 982 rpm, 1 st gear is 1203rpm, 2 nd gear is
1324rpm, 3 rd gear is 1451rpm, 4 th gear is 1527rpm, 5 th gear is 1621rpm, 7 th gear is 1735rpm, 8 th gear
is 1835rpm, 9 th gear is 1984rpm, and the 10th gear speed is 2012rpm. But engine speed is unstable at
the 10th gear. Calibrate engine speed again under S mode. Tested and proved engine speed is normal.
Problem solved.
排故体会：维修过程不当(曾维修过空调,在上面接线)就会造成EPEC程序紊乱。在处
理1些故障的时候最好先询问客户或操作手在出现故障之前是不是有别
人维修过什么东西,这样,往往也可以缩短排故的时间。
Experience: Improper service repair (Air conditioner is repaired and a wire is connected to EPEC.) will
result in E PEC malfunctioned. Before doing t he troubleshooting, service engineer should enquiry the
customer or operator about the repair history which may shorten the troubleshooting time.
——提供者：王宏斌 Service engineer: Wang Hong Bing
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05、210C6M机不能升速不能熄火 Engine can not be accelerated and shut down
故障现象：机器不能升速不能熄火，显示屏无显示。
Symptom: Engine can not be accelerated, can not be shut down, and monitor has no display.
故障分析：因该机型为三菱发动机配EC-7控制器，配日本AC2000油门马达，直流电机
有控制器，在机器不能升速不能熄火，同时出现显示屏无显示现象，可能
出现故障现象：
1、42#线或42#保险烧坏或EC-7控制器故障；
2、29#线或29#保险故障或油门直流电机控制器烧坏。
Failure an alysis: This machine a dopts M itsubishi e ngine, EC-7 c ontroller, a nd J apan A C2000 t hrottle
motor. DC motor has controller. Probable cause of the failure listed below:
1. Wire 42#, the fuse of wire 42#, or EC-7 controller failed.
2. Wire 29#, the fuse of wire 29#, or DC motor control failure failed.
故障原因：现场检查发现42#保险和线路无烧坏或短路现象，更换EC-7控制器后故障
仍存在，可排除42#线和EC-7控制器原因，检查发现29#线保险烧坏，更
换保险后通电就烧保险，29#线路无短路或搭铁现象，检查测量直流电机
控制器发现直流电机控制器内部烧坏短路，致使油门电机无法工作，使
机器不能升速和熄火，29#线烧保险显示屏无电源输入无法显示。处理
方法：更换直流电机控制器后故障排除。
Root c ause of t he failure: Checked and found wire 42# and its fuse are normal. Replace t he E C-7
controller, problem still existed. EC-7 controller is not failed. Checked and found the fuse of wire 29# is
burned. Replace the fuse, but it failed again once the machine is powered on. Wire 29# is not shorted to
other wire or t o ground. Checked a nd found D C M otor controller is i nternal s horted, which causes the
throttle motor fails to work. Engine can not be accelerated and shut down. Fuse of wire 29# is burned and
causes the monitor has no power supply, of course no display. Replace the DC motor controller, problem
solved.
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排故方法: 见下图
Troubleshooting: Refer to following chart.
210C6m机不能升速，熄火
分析：
发动机无法升速及熄检查29号线保直流电机控更换直流电机控

否是
火时显示屏是否正常险是否烧断制器故障制器及29#线保险
是
506#线故障检修506号线
拨动油门旋钮506号
否
线电压是否正常转换板故障更换转换板
检查50#线是
否
否电压正常
50#线故障检修50#线
是
是油门旋钮故障更换油门旋钮
检查601、701号
否 EPEC控制器故障更换EPEC控制器
线电压是否正常
直流电机控制器故障更换直流电机控制器
检查A+A-号线
否
电压是否正常
A+、A-号线故障检修A+、A-号线
转速传感器故障更换转速传感器
启动发动机进发动机转速
否
入显示屏系统是否正常
108#线故障检修108#线
是直流电机故障更换直流电机
排故体会：排除电路故障的时候1定要熟悉电路图,做到心中有图,才能更快,更准,更好
地做服务。
Experience: When doing the troubleshooting for electric system, service engineer must be familiar with
the circuit schematic. And then can be faster, more accurate, and better to do service.
----提供者：颜礼平 Service engineer: Yan Li Ping
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06、210C 发动机高温 210C overheating
故障现象：一台 210 老式挖机工作 15 分钟后水温高温，打开水箱盖加大油门，水从
水箱口喷出。
Symptom: An old-fashioned SY210 excavator overheated after working 15 minutes. Remove the radiator
cap and increase the engine speed, coolant spray out from the filler.
故障分析：1、发动机怠速状态时转速较低，水泵泵水量较小，冷却水在水箱内部形
成微弱偱环，未见大量水涌出，短时间内未见水温高现象；
2、发动机高速运转时，水泵流量大，由于水箱上下水有堵塞，水不能形
成良好的循环，便出现大量水涌出，从而出现水温过高的情况。
Failure analysis:
1. When en gine runs at l ow i dle s peed, water pu mp outputs little coolant which c irculates in cooling
system, no more coolant overflowed from the radiator. No overheating phenomena in a short time.
2. When engine runs at high speed, a large amount of coolant circulated in the cooling system. Coolant
circulation is restricted and overflowed due to radiator inner blockage. Engine overheated.
故障原因：1、水箱内时间久未清洗出现水垢、水锈；
2、水箱堵塞产生高温。
1. A large amount of scale built up in the radiator and not cleaned for a long time.
2. Overheated due to radiator is blocked by the scale.
排故方法：1、检查发动机风扇、风扇皮带、水泵和节温器均正常。燃油泵正常；
2、现场更换缸垫后，试机 10 分钟故障再次出现；
3、现场检查水箱，清洗发现大量污垢；
4、将水箱拆下，送到到市场上专门清洗水箱的公司清洗水箱后，再试机
15 分钟，未出现水温高及水从副水箱及水箱口涌出现象。
Troubleshooting:
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1. Checked and found the engine fan, fan belt, water pump, regulator, and fuel pump are normal.
2. Replace the cylinder head gasket in the field, tested and found engine overheated 10 minutes later.
3. Flush the radiator, and found a large amount of scale.
4. Remove the radiator and sent it to the local professional company to clean it. After installation, tested
for 15 minutes. Coolant temperature is normal and no coolant overflowed from the radiator.
排故体会：现场处理故障，我们 1 定仔细分析，从简单到复杂，11 排除的方式，不
能盲目习惯性的处理故障，多学习理论加强实践。
Experience: When doing t he t roubleshooting on the jobsite, service en gineer s hould analyze carefully
from simple to complex and step by step. Do not dismantle blindly, learn more theory to enhance practice
skill.
——提供者：张志辉 Service engineer: Zhang Zhi Hui
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07、工作中发动机掉速达400转 Engine speed drops 400 rpm during the work
故障现象：工作时发动机掉速达400转以上。
Symptom: Engine speed drops more than 400rpm during the work.
故障分析： 1、用手油泵泵油，拆掉第二道滤芯上的放气螺栓或出油口，没有气泡且
手泵有力证明燃油系统没有问题；
2、检查空滤清洁度,进气管是否变形,中冷器,涡轮增压器,各个部件都
正常,可以证明进气系统正常；
3、故障可能是由于液压泵排量过大造成，将液压泵改为液控,挖机工作
正常，液压系统无问题，故障点在电气系统。
Failure analysis:
1. Priming fuel and bleed air at the 2nd filter base. No air found in the fuel. Fuel system is normal.
2. Checked and found air filter is clean, inlet hose is not deformed, aftercooler, turbocharger are nomal.
It is sure the air inlet system is normal.
3. Suspected t he h ydraulic load i s l arger t han en gine p ower. Select t he h ydraulic co ntrol m ode for t he
main pump. Tested and proved machine works normally. Suspection focused on electric system.
故障原因: 1、从显示器上发现挖机工作时前、后泵负压压力有异常，怠速时压力为
13kg左右，开始做动作时变为30kg左右，憋压时为9.2kg；
2、改为液控后,证明液压系统的负载正常,可以排除液压系统由于负载过
大从而造成的瞬时掉速现象。
Cause of failure:
1. Checked and found in the monitor, negative pressure of the front & rear pump is abnormal. It is 13kg
at low idle speed, 30kg when machine operated, and 9.2kg when main relief valve opened.
2. Machine w orks nor mally when m ain pum p i s unde r h ydraulic c ontrol mode. Failure s hould not be
caused by excessive hydraulic load.
排故方法：1、首先将两个负压传感器打交叉,故障现象依旧；
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2、更换两个负压传感器，挖机工作正常。
Troubleshooting:
1. Interchange the wire plug of the two negative pressure sensors. Problem still existed.
2. Replace the two negative pressure sensors, tested and proved machine works normally.
发动机掉速案例
分析：
发动机燃油是否清洁否燃油质量故障更换清洁燃油，清洗油路
是进入显示屏系统
负压力传感器故障更换负压力传感器
检查负压力是否正常否
负压力减压阀故障检修负压力减压阀
主压力传感器故障更换主压力传感器
检查主压力是否正常否主溢流阀故障检修主溢流阀
安全卸荷阀故障检修安全卸荷阀
是
检查601、701#线
否控制器故障更换控制器
电压是否正常
检查油门拉杆是否正常否油门拉杆故障检修或更换油门拉杆
油门马达齿啮
否油门马达齿磨损严重更换油门马达
合是否正常
排故体会:排除这类故障时,首先要区分故障点在发动机,液压或电器中某1块,然后再
排除,能加快排除故障的速度。
Experience: Do troubleshooting for this kind of failure; service engineer should be clear the root cause is
focused on engine, hydraulic system, or electric system. And then carry out troubleshooting.
——提供者：朱跃平 Service engineer: Zhu Yue Ping
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08、发动机启动困难 Engine is hard to start
故障现象：三菱发动机启动困难6D34。
Symptom: Mitsubishi engine 6D34 is hard to start.
故障分析：气缸压缩比不达标；电瓶电量不足；机油粘度过高；启动马达故障；喷
油泵故障；空气进气管堵塞，燃油系统有空气等。
Failure analysis: Cylinder compression ratio is abnormal, battery undercharged, oil viscosity is too high,
starting motor failure; fuel pump failure, air inlet blocked, and air enters into fuel system.
故障原因：因为积炭把活塞环卡滞导致漏气汽缸压力不足造成启动困难。
Root cause of the failure: Piston rings are seized and cause the cylinder pressure too low to start up.
排故方法：1、盘车时测试电瓶的电量,如果电压瞬间电高于18V,证明电瓶是好的；
反之低于18V证明电瓶电压不够；
2、用手油泵泵油,放气。燃油系统没有气泡没有问题；
3、检查空气滤芯,进气管,及中冷器,涡轮增压器(用手摇拉涡轮轴的轴向
及径向间隙),各个部件都正常,可以排除进气系统正常；
4、检查发现发动机喷射泵；喷油器正常，喷油正时也没有问题。经测量
汽缸压力最高18KG最低15KG（正常值26KG）。
5、拆开汽缸盖后发现严重积炭，积炭把活塞环卡滞导致漏气汽缸压力不
足，故而无法启动。
6、清理积碳，更换损坏件，修复发动机，试车正常。
Troubleshooting:
1. Measure t he b attery w hen cr anking engine. If t he voltage i s hi gher t han 18V, ba ttery i s normal. O r
vice versa, battery is undercharged if the voltage is less than 18V.
2. Priming fuel to bleed air. Checked and found no air in the fuel system.
3. Checked and found air filter, inlet hoses, aftercooler, and turbocharger are all normal. It means the air
inlet system works normally.
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4. Checked and found fuel injection pump, injector, and fuel injection timing are normal. Measured
maximum cylinder pressure is 18kg which is lower than the normal value 26kg.
5. Remove the cylinder head and piston. It is found heavy carbon built up and cause the piston ring
seized in the ring groove. Cylinder pressure is too low to start the engine.
6. Clean the carbon, replace the failed parts and rebuilt the engine. Tested and proved problem solved.
附:三菱6D34汽缸压力检查表
Note: Mitsubishi 6D34 cylinder pressure specification
Inspection item Specification Service limite Suggestion
Cylinder pressure 2550 kPa 1960 kPa

Inspection
（200rpm） (26 kgf/cm2) (20 kgf/cm2)
Cylinder pressure
Pressure defference 390 kPa
Inspection
between cylinders (4 kgf/cm2)
排故体会：遇到此类问题，还要考虑机油的粘度。比如 15W-40 机油粘度过高，冬季
不能在东北施工。
Experience: Do troubleshooting for this kind of failure, oil viscosity must be considered. For example,
15W-40 oil has a high viscosity, and can not be used in Northeast of China in winter.
- 334 -
09、发动机水温高报警 High coolant temperature alarm
故障现象：发动机水温高报警。
Symptom: High coolant temperature alarmed.
故障分析：1、皮带张紧度；
2、节温器；
3、散热器；
4、皮带V型槽；
5、水泵；
6、散热器塞。
Failure analysis:
1. Belt tension.
2. Regulator.
3. Radiator.
4. V-belt groove.
5. Water pump.
6. Radiator blocked.
故障原因：经检查水箱侧壁有砂眼使冷却水泄露，导致发动机水温高。
Root cause of the failure: Radiator has a sand hole, coolant leaks out and engine overheated.
排故方法：1、设备工作时间在1000h左右，可排除气门间隙异常等发动机自身故障；
2、由于副水箱有缺水现象，经检查无明显泄露；
3、将高压气筒接到散热器接头上，向水箱加压，发现水箱侧壁有砂眼，
冷却水泄露，导致水高温；
4、拆下水箱送到当地专业厂家补漏后，装回，试车正常。
Troubleshooting:
1. Machine working hour is about 1000h. Failure should not be casued by engine failure problem such as
- 335 -
abnormal valve lash.
2. Checked and found the coolant level in the coolant tank is lower than specification but no ve stige of
coolant leaked obviously.
3. Using the special tool to increase pressure, checked and found the radiator core has a sand hole and
leaks coolant. Coolant leaked, enginer overheated.
4. Remove the radiator and send to professional factory to repair. Tested and proved problem solved.
排故体会：发动机出现过热情况，不能立即停车，让发动机怠速运转直到水温表达
到绿色区域后停止发动机检查故障原因。
Experience: Once engine o verheated, do not shut dow n e ngine immediately. Run engine at l ow idle
speed until the temperature back to the green zone, and then stop engine for troubleshooting.
——提供者：杜燚 Service engineer: Du Yi
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10、发动机转速无法下降 Engine can not be decelerated
故障现象：一台09年SY135，工作38H，发动机工作时候发动机转速无法下降,始终高
速且有蓝烟现象。
Symptom: SY135 made in 2009, working hour is 38H. Engine can not be decelerated. Blue smokes.
故障分析：1、柴油过脏引起高压油泵柱塞卡死；
2、油门控制马达故障，在最大位置卡死不能回位；
3、增压器严重磨损引起机油进入中冷器，然后进入燃烧室引起。
Failure analysis:
1. Plunger of the fuel pump seized due to dirty fuel.
2. Governor actuator failed and seized at maximum position.
3. Turbocharger worn severely and cause oil entered into combustion chamber through aftercooler.
故障原因：1、检查油门马达是否正常；
2、喷油泵是否正常。
Failure cause:
1. Governor actuator works normally or not.
2. Fuel pump works normal or not.
排故方法：1、发动机高压油泵调速拉杆是否卡死在最大供油位置；
2、检查油门马达、喷油泵调速拉杆和油门拉线是否正常；
3、检查涡轮增压器，发现涡轮增压器浮动轴承严重磨损，间隙较大，打
开中冷器发现中冷器里有大量机油；
4、把中冷器机油清除，更换涡轮增压器后试车发动机工作正常。
Troubleshooting:
1. Fuel rack is seized at the largest fuel supply position or not.
2. Governor actuator, governor control lever, and the cable of governor actuator work normally or not.
3. Checked and found turbocharger bearings were worn severely and cause excessive clearance. A large
amount of oil is found in the aftercooler.
- 337 -
4. Clean the aftercooler thoroughly and replace the failed turbocharger. Tested and proved engine speed
is normal, problem solved.
排故体会：本案例故障发生率比较低,但它们是有共性的,任何1个品牌发动机的涡轮
增压器的浮动轴承都有磨损的现象,从而造成大量机油进入进气管路，从
而进入燃烧室，造成飞车。
Experience: This failure case is seldem to occur. But it is common for all brands of engine that turbo has
bearing wear phenomenon. As a result, a large amount of oi l enters into the combustion chamber and
engine overspeeded.
——提供者：罗灿 Service engineer: Luo Can
- 338 -
11、SY215C 停机半小时后难启动 Engine is hard to start after stopping half an hour
故障现象：该机停机后，不能正常启动，必须手油泵排气才能启动。
Symptom: Engine can not be started after is shut down except bleeding air by priming pump.
故障分析：很明显系统进了空气，可以从以下几方面检查入手：
1、燃油管路连接的各油管接头和空心螺栓是否松动；
2、检查油水分离器有无漏气现象；柴油滤芯是否过脏,有堵塞现象；
3、进油滤网是否有堵塞现象；
4、燃油油管内层是否有脱落；
5、手没泵是否漏气现象，进油及出油单向阀是
否有磨损或关闭不严现象；
6、柴油泵回油单向阀，是否磨损。
Failure analysis: It is obvious that air enters into fuel system. Troubleshoot from following aspects.
1. Fuel hose connectors and hollow bolts are loosed or not.
2. Fuel water separator leaked air or not. Fuel filter is blocked by foreign material or not.
3. Fuel suction screen is blocked or not.
4. Fuel hose inner surface is peeled off or not.
5. Priming pump leaks air or not. Check valve of the priming pump is worn severely or not.
6. Fuel return check valve is worn or not.
故障原因：柴油泵回油单向阀磨损,从而造成发动机停机后,有空气进入燃油系统。
Root cause of the failure: Fuel return check valve is worn. Air enters into fuel system after shut dowm.
排故方法：1、检查管路连接无松动现象；
2、油水分离器无漏气现象；
3、更换柴油滤芯后故障依旧存在；
4、直接将输油泵进油管插在一个外接的油桶内，试车，故障现象依旧；
5、将柴油泵的回油单向阀拆下，发现磨损严重，更换后,故障排除。
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Troubleshooting:
1. Checked and found fuel hose connectors are tightened properly.
2. Fuel water separator did not leak air.
3. Replace the fuel filter, tested and proved problem still existed.
4. Direct the transfer pump inlet fuel hose into a fuel barrel, tested and proved problem still existed.
5. Remove the fuel return checked valve, and found it is worn severely. Replace the check valve, tested
and proved engine can be started normally. Problem solved.
排故体会：1、回油单向阀损坏，会造成停机一段时间后空气从单向阀进入燃油系统，
从而造成难启动；
2、回油单向阀的弹簧压力不够，也会造成憋车现象。
Experience:
1. If fuel return check valve damaged, air will enter into f uel system through the check valve and
causes engine hard to start.
2. If the spring force of the check valve is not strong enough, will cause engine speed drops.
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12、发动机机油受污染 Engine oil is contaminated
故障现象：一台09年SY215C挖掘机出现行走有异响状况，其他正常。
Symptom: SY215C, made in 2009, has abnormal noise during travelling. Others are normal.
故障分析：1、机油油泥过多；
2、机油被冷却液和燃油污染；
3、燃油输油泵故障；
4、散装机油被污染。
Failure analysis:
1. Excessive oil sludge;
2. Engine oil is contaminated by coolant and fuel.
3. Fuel transfer pump fails.
4. New engine oil is contaminated.
故障原因：1、机油油泥过多，需要更换机油和滤清器；
2、所用油被污染，更换机油和滤清器；
3、检查输油泵是否正常。检查泵的输出力。如有必要更换燃油输油泵；
4、排空机油并用未被污染的机油更换，更换机油滤清器。
Failure cause:
1. Excessive oil sludge, oil and filter need to be replaced.
2. The used oil is contaminated, replace the engine oil and oil filter.
3. Fuel transfer pump works normally or not. Check the pump's output pressure. If necessary, replace the
fuel transfer pump.
4. Drain out the oil completely. Replace with uncontaminated oil, replace oil filter.
排故方法：1、检查各种油品；
2、检查系机油变稀，黏度不够引起；
3、更换机油。
Troubleshooting:
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1. Check the fuel quality and oil quality.
2. Checked and found engine oil viscosity is low.
3. Replace with appointed high quality engine oil.
（Abnormal）（Normal）（Comparation）
排故体会：1、定期做好挖机保养维护工作，清洗油路；
2、排除故障时谨慎加小心，不能忽视细节方面的故障。
Experience:
1. Do the maintenance timely according to the maintenance interval.
2. Troubleshoot carefully to prevent detail ignored.
——提供者：周书良 Service engineer: Zhou Shu Liang
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13、发动机抖动 Engine vibrated
故障现象：发动机低速工作时抖动明显，高速工作时不抖动。
Symptom: Engine vibrated obviously at low speed, and normal at high speed.
故障分析：发动机抖动的原因有以下几点：
2、发动机运转不正常，有缺缸现象；
3、发动机曲轴弯曲变形；
4、发动机机角固定螺栓松动或底角垫变形损坏。
Failure analysis: Probable cause of the failure listed below:
1. Engine speed is lower than specification.
2. Engine speed is abnormal. Or misfired.
3. Engine crankshaft is bended or deformed.
4. Bolt of engine support is loosed, the rubber cushion is deformed or damaged.
故障原因：发动机机角碗垫损坏。
Root cause of the failure: Rubber cushion of the engine suppot is damaged.
排故过程：
1、检查发动机转速，怠速：1000转，高速空转：2200转，转速在正常范
围内。
2、工作憋压掉速也在200转之内，做断缸实验，无缺缸现象，发动机各
缸工作完好，说明故障点不在发动机本身。
3、检查发现发动机低速运转时发动机有上下窜动现象。用螺丝刀能够撬
动机角垫，紧固机角垫螺丝后，发动机抖动声音发生变化，有铁与
铁的撞击声，经检查发现发动机机角垫的上碗垫直接与发动机的
固定脚接触了；
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4、更换碗垫，故障排除。
Troubleshooting:
1. Checked a nd f ound engine s peed is normal. Low idle speed is 1000rpm, and t he high idle speed is
2200rpm.
2. Engine s peed dr op i s w itin 200rpm w hen t he m ain r elief va lve i s ope ned. Do the cut out t est a nd
found engine is not misfired. Each cylinder works normally. Engine should not be suspected.
3. Checked and found the engine support bolt is loosed. Tighten the bolt properly, tested and found the
vibration voice varied. It seems there is iron to iron direct contacting noise. Further research found the
rubber cushion of the engine suppot is damaged.
4. Replace the rubber cushion, tested and proved problem solved.
排故体会：
1、排除故障首先要了解故障出现的原理，继而先直观，后推理，先
简单后复杂。
2、排故过程要认真观察细节，做到眼观、耳听、手摸。
Experience:
1. Troubleshooting must first understand the principles of failure occurred. Visual inspect first, and then
logic reasoning. Briefly first and then the complex.
2. During the troubleshooting pr ocess, service engineer s hould obs erve t he de tail carefully. Obtain the
failure phenomena by your eyes, ears, and hands.
——提供者：武汉 9 州龙 Service engineer: Wu Han Jiu Zhou Long
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14、发动机无力，有时熄火 Engine has insufficient power & auto shut down occasionally
故障现象：一台 SY210 负流量挖机在做完保养后工作 1 小时左右，出现发动机无
力，排气管有“突突突”的声音，随后自动熄火。
Symptom: A NFC SY210 excavator has insufficient power about one hour later after the maintenance.
Exhaust pipe sounded abnormal noise, and then engine shut down automatically.
故障分析：发动机无力，有时自动熄火的原因有：
1、柴油油路堵塞；
2、油路中进空气；
3、空气滤芯堵塞。
Failure analysis: Probable cause of failure listed below:
1. Fuel circuit blocked.
2. Air enters into fuel system.
3. Air filter blocked.
故障原因：油水分离器放水阀放水螺钉未拧紧，油水分离器的集水杯漏空气。
Root cause of failure: Drain plug of fuel water separator is not tightened properly. Air enters into fuel
system via the loose plug.
排故过程：1、经检查，柴油滤芯、滤网都是干净的，油路没有堵塞。
2、经检查空气滤芯，里面很干净，空气滤芯没有问题。
3、检查用手油泵排空气，发现油路中进了空气，一直都排不完，最后
发现油水分离器的集水杯下面漏气，更换密封圈后正常，要求在放
油水分离器的水时，要拧紧放水阀。
Troubleshooting:
1. Checked and found fuel filter and strainer are clean. Fuel circuit is not blocked.
2. Checked and found air filter is clean. It is normal.
3. Priming fuel and bl eed a ir from t he fuel s ystem. A large amount of air b ubble i s found. Further
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research found the drain plug of fuel water separator is not tightened properly. Air enters into fuel
system via the loose plug.
排故体会：发动机无力的问题大多是油路和进气管路的故障，排故时首先应该从这
两方面考虑。再次就是对操作手的培训是非常重要的。
Experience: Failure of engine has insufficient power is mostly caused by fuel circuit or inlet air problems.
Troubleshooting should be started from these two aspects first. It is also very important to let the operator
has a good training.
——提供者：内蒙君泰 Service engineer: Jun Tai of Inner Mongolia
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15、发动机低速、中速抖动 Engine vibrated at low and middle speed
故障现象：一台 SY135 发动机三菱 4D34 使用 2200h，发动机低速、中速抖动，高速
不明显，发动机排烟正常，转速正常。
Symptom: SY135 equiped with Mitsubishi engine 4D34. Working hour is 2200H. Engine vibrates at low
and middle speed. Vibration is not obvious at high speed. Engine speed and smoke are normal.
故障分析：1、喷油器故障，能导致发动机抖动；
2、喷油泵故障；
3、喷油正时不准。
Failure analysis:
1. Fuel injector failed.
2. Fuel pump failed.
3. Fuel timing incorrect.
故障原因：柴油泵连接法兰螺丝松动，导致喷油正时有极小改变，滞后。
Root cause of the failure: Bolts of fuel pump flange are loosed, which cause fuel timing retard slightly.
排除方法：1、拆下喷油泵和喷油器，放到实验台检查都没有问题；
2、安装后从新对正时，故障解决。工作 1 段时间后又出此故障，经仔细
检查发现，是由于柴油泵连接法兰螺栓，安装后没有放垫片。导致对
正时有极小偏差。
Troubleshooting:
1. Tested fuel injector and pump on the test bench, they are normal.
2. Install th e f uel pump and correct th e fuel timin g. Tested and proved problem solved. Same failure
occured again after a while. Double checked and found the gasket between fuel pump flange and front
housing was uninstalled, cause a slight fuel timing change.
排故体会：不要凭以往的经验错误的判断问题。
Experience: Do not analyze fault based only on previous troubleshooting experience.
——提供者：王小磊 Service engineer: Wang Xiao Lei
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16、SY135 动作慢 SY135 has a long cycle time
故障现象：客户反映工作时所有动作变慢，复合动作和上坡时更加明显，但挖掘力
度还是够力。档工作时有冒黑烟现象。
Symptom: User complains all the actions have a long cycle time, especially uphill or combined operation.
Excavating power is normal. Engine emits black smoke when works at 10th throttle position.
故障分析：可能为发动机功率不足，液压主泵功率不足或流量过小引起。因该机刚
工作 250 小时左右，液压系统出现磨损致使功率或流量不足问题可能性
不大，且憋压时能达到最高压力值。可能为发动机原因引起以上现象。
Failure an alysis: Probably engine power or hydraulic power is insufficient. Working hour of this
machine is about 250H . Hydraulic system pressure is nor mal. Main pump should be normal. Failure
should be caused by engine related problems.
排故方法：检查液压系统压力能达到标准压力值，主泵及调节器工作正常。进入显
示屏检查发现油门到档，发动机最高转速只有 1650 转左右，达不到标准
转速 2100±50 转。检查发现油门拉线固定螺丝松动，调整油门拉线使转
速达到规定的标准转速，挖机恢复正常工作，故障排除。
Troubleshooting: Hydraulic system pressure is normal, main pump and adjuster work normally. Checked
in t he monitor and f ound e ngine s peed i s onl y 1650rpm when th rottle is a t 1 0th which i s l ower t han
specification 2100±50rpm. It is found the cable tightening bolt of governor actuator is loosed. Adjust the
cable, tighten the bolt properly, and calibrate the engine speed. Tested and proved problem solved.
排故体会：从挖机编号上，该机为负流量液压系统。首先应进入显示屏查看转速是
否正确。若进入显示屏系统后，显示转速正常，则应该检查的项目有：
比例电磁阀电流、负压力值、主压力值、憋压后转速下降值、燃油的清
洁度等。
Experience: Serial n umber o f th is ma chine te lls u s N FC s ystem is a dopted. Service en gineer should
check t he engine s peed i s nor mal or not i n t he monitor. If t he engine s peed i s no rmal, t hen w e s hould
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check the items such as current of PSV, negative pressure, main pressure, engine speed droop when main
relief valve is opened, and when the fuel is dirty or not.
——提供者：姜箭 Service engineer: Jiang Jian
SY135动作慢，复合动作和上坡时更加明显，十档工作时有冒黑烟现象
进入显示屏系统
检查转速是否标准否检查原因：油门拉线固定螺丝松动
检查燃油清洁度
将转速调至标准2100±50r/min
差
清洗燃油箱、低压系统，更换滤芯
主压力值过低
调节主压力
更换主溢流阀
负压力值是否异常
负压传感器互
是负压传感器故障
换后是否改变
否更换负压传感器
拆检负压减压
负压力减压阀故障阀或更换负压
减压阀
比例电磁阀电流是否异常
检查比列电磁阀
否比例电磁阀故障
电阻值是否正常
更换比例电磁阀
是控制器故障
更换控制器
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17、SY215 低温启动困难 SY215 engine is hard to start in the cold weather
故障现象：寒冬的天气，一台工作 3800 小时的 SY215 挖机启动困难。

Symptom: SY215 excavator, working hour is 3800H, is hard to start in the cold winter.
故障分析：1、SY215 机型有预热功能，预热系统出现故障时启动困难；
2、电瓶的电量不足；
3、喷油正时有偏差；
4、停车控制系统出现故障使熄火马达停在停车位置；
5、柴油高压油泵柱塞磨损；
6、气温过低，机油粘稠造成发动机部件运动阻力增大，导致发动机起动
负荷加大，引起起动困难。
Failure analysis:
1. SY215 has preheating function. If preheating system is failed, will cause hard start problem.
2. Battery is undercharged.
3. Fuel injection time is incorrect.
4. Shut down motor is seized in fuel off position.
5. Plunger of fuel injection pump worn.
6. Engine oil is thick due to low ambient temperature, which causes engine hard to start.
故障原因：柴油高压油泵磨损，加上冬天起动阻力加大引起起动困难。
Root cause of the failure: Thick oil and worn fuel pump plunger cause engine hard to start.
排故方法：1、检查预热示灯，灯亮。表明 F13 保险丝和预热开关及预热继电器工作

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正常。预热工作正常。排除预热系统故障的可能性。
2、检查电瓶的电量：从电瓶观察口显示的颜色，为绿色，按下喇叭，声
音宏亮，表明电瓶电量正常。
3、启动时检查发现熄火装置拉线拉动的高压油泵断油拐臂位置正常。
4、启动时检查发动机的转速，转速为 350 转/分。发动机且已有烟排出，
可能是起动阻力大，加热油底壳后启动发动机，发动机排烟增多，但
仍启动不了。
5、分析为高压油泵内部柱塞磨损。更换高压油泵总成后启机正常。
Troubleshooting:
1. Checked and found the preheating indicator works normally. It means the fuse F13, preheating switch,
and preheat relay work normally.
2. Checked and found battery is normal. Green color is found via the inspection hole. Horn is powerful.
3. Checked and found the governor fuel off lever is moved to fuel on position when the engine is
cranked. It means the shut down motor works normally.
4. Checked the engine crank speed is 350rpm, and engine has smoke emits out . Suspect t he start
resistance is excessive. Heating the engine oil pan, more smoke emits out when engine is cranked, but
engine still can not be started.
5. Suspected the fuel pump plunger is worn. Replace the fuel injection pump, tested and proved engine
can be started normally. Problem solved.
排故体会：冬天，由于温度低，启动阻力大，这时如果柴油机高压油泵内部三大偶
件磨损量大，增加了起动的难度。
Experience: Temperature in winter is low, engine start resistance increased. If the fuel pump plunger is
worn, engine will be much more difficult to start.
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18、发动机水温过高 Engine coolant temperature is excessively high
故障现象：一台 SY215 挖机三菱发动机，工作 1 小时后显示屏上显示水温高达 98℃。

Symptom: Displayed coolant temperature of SY215 is 98℃ after working one hour.
故障分析：1、查清发动机水温是否是实际水温高，排除水温虚高；
2、查看冷却系统保养情况；
3、分清是否是电器故障与机械故障。
Failure analysis:
1. The actual coolant temperature is high or not.
2. Check the cooling system maintenance record.
3. Failure is caused by electric failure or mechanic failure.
故障原因：1、发动机冷却水不足；
2、发动机风扇皮带松动；
3、发动机水温传感器故障；
4、发动机节温器故障
5、散热器阻塞；
6、控制器故障及线路故障。
1. Coolant level is lower than specification.
2. Fan belt is loosed.
3. Coolant temperature sensor is failed.
4. Regulator failed.
5. Radiator blocked.
6. Controller malfunctioned or circuit failure.
排故方法：1、检查发动机水箱冷却液位，用温度计查清冷却水温是否是虚高；
2、检查发动机风扇皮带张紧度；
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3、测量水温传感器电阻排除传感器故障；
4、用容器装 100℃左右的水将节温器放人，查看节温器是否正常伸张，
排除节温器故障；
5、查看散热器滤网是否阻塞严重，清洗散热器滤网；
6、检查控制器，以及 106 号线是否正常。

Troubleshooting:
1. Check the coolant level and the actual coolant temperature by the thermometer.
2. Check the belt tension.
3. Measure the reistance of the coolant temperature sensor.
4. Tested regulator with water. The opening temperature and opening distance is normal or not.
5. Radiator is blocked or not. Clean the radiator core.
6. Check the controller. Wir 106# is normal or not.
排故体会：认真分析故障，弄清楚故障发生的真正原因，提高排故效率。
Experience: Figure out the root cause of the failure. Solve the problem efficiently.
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19、SY75C高水温 SY75C engine overheated
故障现象：一台SY75C机，在工作中发动机经常容易水温过高。
Symptom: SY75C engine overheated during the work.
故障分析：1、发动机水温高，可以从液压负载和发动机本身散热系统分析；
2、发动机因受液压负载影响，超负荷工作，容易产生水温高的现象；
3、发动机本身散热系统因水泵不工作风扇皮带松，水箱散热水道堵塞，
散热器外围被堵等现象，也会产生水温高的故障；
4、机油散热器堵塞，机油温度过高引起水温过高。
Failure analysis:
1. Engine overheating may be caused by excessive hydraulic load or cooling system problems.
2. If the engine is overloaded, will cause engine overheating.
3. Failure will be caused by cooling system failure, such as water pump failed, fan belt loosed, radiator
blocked by scale, radiator blocked by forein material, and so on.
4. Oil cooler is blocked.
故障原因：水箱散热器堵塞。 Machine photo
Root cause of the failure: Radiator blocked.
排故方法：1、先试机，使液压溢流产生最高压力
观察发动负载：无发动过载情形；
2、观察风叶皮带，水泵、水循环管情 Radiator
况，发现水箱散热外围被干枯的树
叶，杂草等堵塞，其它无异常；
3、拆卸水箱用带有一定压力的水，清
洗水箱散热器外围，组装、试机、观察过两三小时后，水温不高，故
障消除。
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Troubleshooting:
1. Checked and found engine is not overloaded by operating machine to let the main relief valve open.
2. Double check the cooling system components, such as water pump, fan belt, coolant hoses, and so on.
It is found the radiator is blocked by the dry leaf and weed. Others are normal.
3. Clean t he r adiator core t horoughly, t ested for t hree hour s a nd found c oolant t emperature i s nor mal.
problem solved.
排故体会：小挖因受工作环境影响，经常有异物掉进机罩内，最好是经常清理异物。
Experience: Foreign material usually enters into the engine hood due to the working environment of the
small size excavator. Suggest the operator clean the foreign material frequently.
——提供者：孟进 Service engineer: Men Jin
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20、SY360-8 全车动作迟缓无力 All actions of SY360-8 have a long cycle time
故障现象：一台川崎控制器 SY360-8 挖掘机全车动作迟缓无力。

Symptom: SY360-8, equipped with Kawasaki controller, has all actions a long cycle time.
故障分析： 1、液压油箱油位不足；
2、主泵内泄严重导致供油不足；
3、伺服压力过低；
4、系统安全阀压力过低；
6、液压油滤清器堵塞；
7、发动机滤清器堵塞。
Failure analysis:
1. Hydraulic oil level is lower than specification.
2. Main pump has severe internal leakage.
3. Servo pressure is too low.
4. Hydraulic system pressure is too low.
5. Engine speed is lower than specification.
6. Hydraulic oil filter blocked. Fuel is dirty, fuel filter is blocked.
7. Engine filter blocked.
故障原因：发动机燃油脏导致滤清器堵塞。
Root cause of the failure: Fuel filter is dirty and causes the fitler blocked.
排故方法： 1、测量该机器主压力正常 35MPa；
2、测量该机器先导压力正常 3.9MPa；
3、检查液压油位标尺，液压油油量正常；
4、检查发动机转速正常，H 模式 11 档 2230 转；
5、检查前后泵比例阀电流异常 400mA 左右，检查燃油滤清器，发现滤

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清器堵塞，由于川崎控制器有失速保护功能，当发动机功率下降，控
制器会将主泵排量减少，导致动作缓慢无力。
Troubleshooting:
1. Measured main pressure is 35Mpa, which is normal.
2. Measured pilot pressure is 3.9Mpa, it is normal.
3. Checked and found hydraulic oil level is correct.
4. Checked engine speed is normal. It is 2230rpm when at 11th position.
5. Checked and found current of main pump PSV is 400mA, it is abnormal. Fuel filter is blocked.
Note: Kawasaki controller has the protection function of engine speed droop. When the engine derated,
controller will reduce the pump output flow, which causes the slow action.
排故体会：了解川崎控制器这一特性，对排故有一定帮助。

Experience: If you know this feature of Kawasaki controller, it will be helpful to the troubleshooting.
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21、发动燃油消耗大 Fuel consumption is excessive
故障现象：SY215 挖机配的 6D34 发动机，在使用 660 小时发现柴油消耗率为 25L/h。

Symptom: 6D34 engine of SY215 consumed 25 liters fuel one hour when working hour is 660H.
故障分析：1、低压油路漏油；
2、发动机高压油路漏油；
3、高压油泵机油冷却处密封圈损坏；
4、喷油器喷油量过大，有后喷现象。
Failure analysis:
1. Low pressure circuit leaked fuel.
2. High pressure circuit leaked fuel.
3. O-ring seal of fuel pump damaged.
4. Fuel injector failed, and cause excessive fuel leaked intor combustion chamber.
故障原因：喷油器喷油量过大，有后喷现象，喷的过量柴油经刮油环刮到油底壳内，
导致柴油量消耗过高。
Root cause of the failure: Fuel injector failed and caused fuel leaked into oil pan through combustion
chamber.
排故方法：1、检查柴油箱及低压油路，没有发现任何漏油现象；
2、挖机无憋车现象，发动机无掉功率现象，如果高压油路漏油，功率会
下降。排除发动机高压油路问题；
3、仔细观察，发现发动机机油高度每天会上升一点，取些机油样品，发
现为柴油。放出油底壳内多余机油，使机油刻度线在上下刻度线中间，
但冷机停放一晚，到第二天早上又发现机油没有上升。因此认为喷油
泵内部无故障；
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Replace injector Replace injector
4、观察发现发动机会有很轻黑烟，更换发动机喷油器后故障消失。
Troubleshooting:
1. Checked and found fuel tank and low pressure circuit did not leak fuel.
2. Engine speed and power were normal. If the high pressure circuit leaked fuel, engine will derated. It is
sure the high pressure circuit did not leak fuel.
3. Double checked and found oil level increased a little day by day. Analyze the oil sample and found
fuel in it. Shut down machine for a whole night, and found oil level not increased. It is sure that fuel
was not leaked through the fuel pump.
4. Tested and found engine has a slight black smoke. Replace the fuel injectors, tested and proved
problem solved
排故体会：由易到难，认真分析。从发动机的基本构造原理和基本故障判断知识，
层层分析，找出故障原因。
Experience: Troubleshoot carefully and step by step. Be familiar with the basic strucure of engine will
help to figure out the root cause of the failure.
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22、机油油面升高 Engine oil level increased
故障现象：SY215 挖机配的 6D34 发动机，在使用 385H 发现机油超过油标尺上刻线。

Symptom: SY215, equipped with 6D34 engine, oil level is above the “H” mark after using 385 hours.
故障分析：1、冷却液内漏；
2、燃油内漏。
Failure analysis:
1. Coolant leaked into oil.
2. Fuel leaked into oil.
故障原因：喷油泵油封损坏使燃油和机油混合，导致上述故障。
Root cause of the failure: Fuel pump seal damaged, and fuel leaked into oil.
排故方法：1、根据先易后难原则，抽出机油标尺，把标尺上油滴在排气支管的高温
处。有柴油味飘出，说明有燃油。
2、看热车带负荷作业，黑烟正常，同时用测温仪检测各个缸排气温度相
差值在 30 度以内，排除喷油器故障。
Engine
机油进
3、放出油底壳内多余机油，使机油刻度线在上下刻度线中间。但冷机停
放一晚，到第二天早上又发现机油上升。因此认为喷油泵内部故障。
4、将燃油泵拆下修理，试车正常，故障排除。
Troubleshooting:
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1. Pull out the dipstick, and let a drop of oil drop onto the high temperature exhaust manifold. Fuel odor
is smelled. It is sure that fuel leaked into the oil.
2. Checked a nd f ound engine smoke i s nor mal at full lo ad. Measured exhaust t emperature difference
between cylinders is within 30℃. It is sure the fuel injector is normal.
3. Drain engine oil to normal level, and shut down the engine. Engine oil increased again after waiting
for a night. It is sure that fuel leaked into oil through the fuel pump.
4. Rebuild the fuel pump, tested and proved oil level is normal. Problem solved.
排故体会：由易到难，认真分析。从发动机的基本构造原理和基本故障判断知识，
层层分析，找出故障原因。
Experience: Troubleshoot carefully and step by step. Be familiar with the basic strucure of engine will
help to figure out the root cause of the failure.
——提供者：卢浩 Service engineer: Lu Hao
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23、SY75 发动机有异响 SY75 engine has abnormal noise
故障现象：一台 SY75 挖机工作 304H 客户反映发动机有异响，其它工况正常。

Symptom: SY75 engine has abnormal noise at 304H. Others are normal.
故障分析：1、水泵皮带、空调皮带干燥打滑的声响；
2、水泵轴承、风扇轴承内部缺油干摩擦的声响；
3、气门间隙过大的声响；
4、连杆瓦、主轴瓦润滑不良，间隙过大的声响；
5、液压泵和发动机之间的声响。
Experience:
1. Abnormal noise is caused by loosed fan belt or air conditioner belt.
2. Water pump bearing has insufficient grease.
3. Abnormal noise is caused by excessive valve lash.
4. Con-rod bearing or main bearing is worn and has excessive clearance.
5. Abnormal noise sounded between engine and the hydraulic pump.
故障原因：气门螺栓松动，气门间隙过大导致发动机异响。
Root cause of failure: Valve lash adjusting screw is loosed, excessive valve lash causes abnormal noise.
Abnormal noise is obvious Valve lash is excessive. Lock nut

when the engine is cold started. of the adjusting screw is loosed.
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Adjust the valve lash
to specified value of
Isuzu engine.
排故方法：1、检查皮带松紧度正常；
2、拆下风扇皮带，启动试车 5 分钟故障依存，排除水泵轴承、风扇轴承
内部缺油干摩擦的声响；
3、用螺丝刀监听缸盖进排气门、缸体、油底壳，发现发动机刚启动后声
响很大，随发动机转速增大而变大，水温正常后声响没有了；
4、打开气门罩室，调整气门间隙后，故障排除。
Troubleshooting:
1. Checked and found the belt tension is normal.
2. Remove the fan belt, start the engine and run for 5 minutes. Problem still existed. It is sure failure not
caused by the water pump bearing or fan bearing.
3. Use a screwdriver to detect the source of abnormal noise on the valve cover, cylinder block, and oil
pan. It i s f ound t he noi se i s bi g w hen e ngine i s started. The hi gher t he s peed, t he bi gger t he noi se.
Abnormal noise became faint when the coolant temperature is normal.
4. Adjust the valve lash, tested and proved abnormal noise disappeared. Problem solved.
排故体会：首先要找到声响的源头，然后再进行排故。
Experience: Find out the source of the noise first, and then do the troubleshooting.
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24、SY135C 冒白烟 SY135C emitted white smoke
故障现象：一台 SY135C 小挖挖使用 113 小时，发动机严重冒白烟，特别熏眼睛，机
油消耗量较大。刚刚启动着车的 3 分钟内，冒大量白烟，同时排气管有
“突突”的声音。
Symptom: SY135C emits heavy white smoke at 113H, which fumes eyes obviously. More oil is consumed.
A large amount of white smoke emits out within 3 minutes engine is started. At the same time, abnormal noise
comes from the exhaust pipe.
故障分析：1、燃油里面有水；
2、喷油泵柱塞磨损，供油量不均匀；
3、气缸压力过低，燃烧不良；
4、气门有异物卡死，气门不工作。
Failure analysis:
1. There is water in the fuel.
2. Fuel pump plunger is worn. Delivered fuel of each cylinder is uneven.
3. Cylinder pressure is too low to combust fuel completely.
4. Valve is seized and failed to work normally.
故障原因：喷油器滴油，柴油燃烧不完全造成上述故障。
Root cause of the failure: Fuel injector leaked, and cause fuel can not be combusted completely.
Engine emits white smoke and blue Injector nozzle is wet. Tested on the
smoke which fumes eyes obviously. work bench and found it leaked fuel.
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排故方法：1、检查柴油滤清、油水分离器；
2、在进行4#缸断缸实验，发现颜色没有，也没有“突突”声响。
3、更换喷油器后，故障排除。
Troubleshooting:
1. Checked and found fuel filter and fuel water separator are normal.
2. Do cut out test for each cylinder one by one. When No.4 cylinder is cut out, the smoke is normal and
no abnormal noise.
3. Replace the injector of No.4 cylinder, tested and proved problem solved.
排故体会：用断缸法来判别哪一缸故障，然后进行故障分析排故。
Experience: Using the cut out method to determine which cylinder is failed. And then troubleshoot the
root cause of the failure.
——提供者: 卢浩 Service engineer: Lu Hao
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25、发动机增压器有异响 Turbocharger has abnormal noise
故障现象：一台 SY230C8 发动机五十铃 6BG1TRP 在调试场调试，发动机低速有异响，
高速不明显，排烟正常，转速正常。
Symptom: SY230C8 with Isuzu engine 6BG1TR was tested in the factory. Abnormal noise was detected
at low engine speed. It is not obvious at high engine speed. Smoke and speed are normal.
故障分析：1、空气管路卡箍松动或进气管路松开，但会伴随冒黑烟现象；
2、增压器内有异物或机油供油系统不通；
3、增压器转子碰到壳体发出不正常声音。
Failure analysis:
1. Clamp of air hose or inlet hose is loosed, but will have black smoke phenomena.
2. Foreign material enters into turbocharger or oil supply to turbo is blocked
3. Turbo wheel contacts with its housing, and causes abnormal noise.
故障原因：增压器转子叶轮碰到壳体发出的尖锐声音。
Root cause of the failure: Compressor wheel contacts with its housing, causing the sharp noise.
Blades bended severely Clamp is loosed
排故方法：1、松开增压器上的进气卡箍；
2、发现进气端叶轮被异物敲打变现，更换新增压器后故障排除。
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Troubleshooting:
1. Clamp of the turbocharger inlet hose is loosed.
2. Remove the turbo inlet hose, it it found that the blades compressor wheel is impacted bended. Replace
the turbocharger, problem solved.
排故体会：1、增压器在未安装前，一定要检查是否在运输、装卸过程中受到损伤。
2、装配过程中一定加少量机油在增压器进油口保证在刚刚启动时候有机
油润滑。
Experience:
1. Before the turbocharger is installed, check it for damage during transportation or handling.
2. After turbocharger is installed, feed oil to the its oil inlet port. So there i s oil lubrication during t he
initial start.
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26、发动机抱瓦 Engine bearing seized
故障现象：反挖配置五十铃发动机工作 708 小时，客户在 2010 年 3 月 16 日反映发动
机有异响，拉回代理商维服务站拆解分析。
Symptom: Isuzu engine of the excavator has abnormal noise on 16Mar10. Working hour is 708H. Engine
was sent to dealer’s workshop to dismantle and analysis.
故障分析：1、油底壳内有大量铁屑；
2、3#缸内机油冷却喷嘴损坏；
3、3#缸的连杆弯曲，活塞被冷却喷嘴打坏；
4、1#缸连杆轴颈磨损严重；
5、主轴瓦全部磨损严重；
6、缸盖上凸轮轴轴瓦磨损严重。
Failure analysis:
1. A large amount of metal chip is found in the oil pan.
2. Cooling jet of No.3 cylinder is damaged.
3. Con-rod of No.3 cylinder is bended. Piston is impacted and damaged by the cooling jet.
4. Con-rod bearing journal of No.1 cylinder is worn severely.
5. All the main bearings were worn severely.
6. Camshaft bearing in the cylinder head is worn severely.
Con-rod journal A large amount of Heavy dust found on the

is seized severely metal chip in oil pan valve. Poor maintenance
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Main bearing & con-rod Cooling jet is damaged
bearing are worn severely bythe bended con-rod
Oil pump gear Liner is Piston oil deposit

is not worn. scratched indicated poor lubrication
Con-rod bended severely
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故障原因：操作手在发动机启动前没有按31挖机使用说明书上要求（冷机起动应先
空负荷下运转3分钟-5分钟）去做，造成每天冷机起动时都会造成瞬间轴
瓦磨损，日复一日就导致烧瓦抱轴最终连杆轴承受巨大压力和一定的扭矩
后，使活塞销油孔处于硬力集中，强度下降，引起连杆弯曲打坏机油冷却
喷嘴。
Cause of f ailure: Operator did not start t he machine according t o Sany Operation and Maintenance
manual w hich requires t he m achine l ow i dle running f or t hree t o five m inutes w hen i t i s c old s tarted.
Bearing worn occurred everyday when engine is cold started, and finally caused the b earing seized.
Con-rod suffered high temperature, soften, and bended. Cooling jet is impacted by bended con-rod.
排故方法：从上排的照片中分析，这是典型“烧瓦抱轴故障现象”，其原因有：
1、从机油泵齿上看没有发现磨损痕迹，排除机油保养不当或机油更换周
期过长，机油过脏或机油油路受阻轴。
2、缸套只是轻微拉伤说明柴油质量低、喷油器雾化不良、燃烧不完全使
柴油和机油混合稀释，机油润滑粘度降低，造成缸套轻微的拉痕。
3、从缸盖的气门底部积碳和活塞环槽上面黄色机油表明客户冷车起动后
没有预热机器就急于高速带载工作，使机油在低温较粘稠状态时流速
较慢不能及时润滑轴瓦，使其表面形成瞬时高温而相互烧熔。
Troubleshooting: Failure photos indicated this is a typical bearing seizure. Probable cause listed below:
1. Engine oil pump is not worn. Engine oil should not be dirty, poor maintain, or change i nterval
prolonged. Engine oil passage should not be blocked.
2. Liner is s cratched s lightly. It m eans t he f uel qua lity i spoor, atomized poorly, a nd not c ombustioned
completely. Oil is diluted by the fuel and oil viscosity reduced.
3. Carbon built up on t he cylinder head and yellow oil deposit in the ring groove indicate that machine
works w ith l oad on ce i t i s s tarted w ithout w arm up. Oil ha s bi gger vi scosity w hen m achine i s n ot
warmed up, and flow slowly that bearing can not get sufficient lubrication. Heat built up rapidly on
the surface and bearing was seized finally.
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排故体会：
（1）提高操作手技术素质，加强对三一保养手册使用说明书阅读和执行其内
各项操作规则，随时监察设备技术状况，发现异常及时处理，不能判
别的问题要及时向三一服务人员汇报，就能大大地减少这类事故发生，
减少客户停机时间；
（2）该故障发生前会有机油压力低和保养放机油时会发现铁碎屑现象发
生，而服务没有及时采取措施和上报三一服务技术部，导致事故发生，
处理棘手。
Experience:
1. Give the operator m ore t raining t o i mprove hi s t echnical s kill. Reand, unde rstand, a nd ope rate t he
machine according to the maintenance and operation manual. Inspect the machine timely. If abnormal
phenomena i s de tected a nd not c lear t he c ause o f f ailure, ope rator m ust s hut dow n t he m achine a nd
report to sany service engineer. So that, this kind of failure will be reduced to minimum, and reduce the
user’s downtime.
2. Before this failure occurred, there should be low oil pressure phenomena and metal chip can be found
in the oil dur ing t he m aintenance. Unfortunately, not hing w as r eport t o S any s ervice de partment a nd
nothing was done to prevent this failure occurred.
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27、发动机烧机油 Engine oil consumption is excessive
故障现象： 08SY23270750 挖机每小时机油消耗量 150 毫升，下排气滴机油。

Symptom: 08SY23270750 consumes 150ml oil per hour. Oil drops can be found blowby.
故障分析：大量灰尘进入气缸，残留在气缸壁上的机油在高温燃气作用下，有的被
燃烧，有的随废气一起排出或在气缸内形成积碳，在发动机温度过高时还
有部分机油油蒸汽汽化排到曲轴箱外，出现下排气滴机油现象。
Failure analysis: A large amount of dust enters into combustion chamber. Some of the oil remains on the
line wall was combusted and formed heavy carbon. Others are vaporized due to high temperature and
form oil drops in the blowby.
故障原因：1、活塞与汽缸壁的配合间隙过大；
2、活塞环对口或卡死在环槽内失去弹性；
3、增压器密封失效，回油不通；
4、发动机拉缸。
1. Clearance between piston and liner is excessive.
2. Piston ring is seized in the ring groove.
3. Turbocharger seal damaged. Return oil blocked.
4. Line scratch.
排故方法：首先检查空气进气道，发现进气道大量灰尘。拆检增压气时发现增压器
内壁残留很厚尘土。初步断定为，发动机气缸磨损严重。拆除发动机拿
到5铃指定维修站拆检发动机发现进排气门有大量的氧化物，活塞顶部有
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大量的机油氧化物和灰尘的混合物，活塞环磨损严重。更四配套及滤芯、
机油试机正常。
Troubleshooting: Checked and found a large amount of dust in the air inlet hose, and heavy dust in the
turbocharger compressor wheel. It is sure that the liner was worn severely. Remove the engine and sent it
Isuzu specified service shop. After dismantling, a large amount of carbon is found built up on the valves.
Heavy c arbon a nd dus t built up on t he p iston t op s urface. Pistion r ing w as w orn s everely. Replace t he
failed parts and related parts, tested and proved problem solved.
排故体会：遇到发动机早期磨损故障时，一定仔细检查每一个环节，分析故障原因。
找出故障点。以备区分责任。
Experience: When the premature wear occurred, double check each detail to figure out the root cause of
the failure. Make clear who should take the responsibility of the failure.
----提供者：王超 Service engineer: Wang Chao
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28、发动机后油封漏油 Engine oil leaks out from the rear crankshaft seal
故障现象：SY65 设备使用 936 小时，客户于 2010 年 1 月 28 号报修反映后油封漏油，
代理商服务人员予以更换新油封。但设备运转不到 1000 小时，后油封再
次漏油，而且比未更换前漏油更严重。
Symptom: Customer complained SY65 leaks engine oil from rear crankshaft seal at 936H on 28J an10.
1000H later after replaced by dealer service engineer, the failure repeats again and it is much more severe.
故障分析：1、后油封没有装好或装配过程中损坏；
2、曲轴油封衬套磨损或装配过程中变形；
3、气门罩盖上 PCV 阻塞或曲轴箱油蒸汽过大；
4、飞轮壳与油封密封处被损坏。
Failure analysis:
1. Rear crankshaft is installed improperly or damaged during the installation.
2. Sleeve of the rear crankshaft seal is worn or deformed during the installation.
3. Breather on the valve cover is blocked and the crankcase pressure is excessive.
4. The seal seat of the flywheel housing is damaged.
故障原因：1、曲轴油封衬套没有更换而且在更换油封时候被损坏；
2、油封没有装配好。
1. Sleeve of the old rear crankshaft seal is not moved and damaged during the new seal installed.
2. New seal is not installed properly.
Rear crankshaft s eal

is found damaged.
Remove the flywheel
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Before the new seal od installed, clean the Do not apply sealant
flywheel housing, especially the seal groove. when the seal is inatlled.
排故方法：1、打开加油口盖检查汽缸的密封性比较好；
2、拆下气门罩室盖上的 PCV 呼吸气管，检查 PCV 正常；
3、检查后油封发现没有装好，而且油封损坏了。所以再一次更换后油封，
故障排除。
Troubleshooting:
1. Remove the filler cap. Tested and found the cylinder pressure is normal.
2. Remove the breather, checked and found breather and its hose are normal.
3. Checked and found t he rear c rankshaft s eal i s not i nstalled properly and damaged. Replace t he r ear
crankshaft seal again, tested and proved problem solved.
排故体会：更换后油封要看漏油位置，分析漏油的原因，找准新油封的安装位置。
而不是盲目的换油封。
Experience: Before the rear crankshaft seal is removed, make sure where the oil leaked out. Find out the
cause of oil leakage and then installed new seal properly. Do not replace the seal blindly.
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29、SY210C 挖机发动机偶尔憋车 SY210C engine stalled occasionally
故障现象：设备工作大约两小时左右，出现憋车症状，如不立即停止动作设备可能
憋熄火。马上把手柄回中位停止动作后，等发动机转速恢复正常后又能
继续工作两小时左右。
Symptom: Engine s peed dr ops obviously after w orking a bout t wo hour s. Engine will s hut down i f t he
operation not stopped immediately. Engine speed restored after all the pilot valve lever returns to neutral
position, and then machine can work about another two hours normally.
故障分析：1、燃油油路故障；
2、高压油泵、油嘴故障；
3、发动机内损故障；
4、发动机涡轮增压器故障；
5、空气滤芯进气不足。
Failure analysis:
1. Fuel circuit has failure occurred.
2. Fuel injection pump and/or injector failed.
3. Engine internal parts worn.
4. Turbocharger failed.
5. Air inlet is insufficient.
故障原因：该设备滤芯座与燃油滤芯接触面处有一极细小裂纹导致进空气。
Root cause of failure: There is a small crack on the filter base mating face with the filter, air enters.
排故方法：1、首先更换柴油滤芯。
2、开始排查供油系统。
3、检查手高压油泵上手油泵是否内泄，油泵、油嘴供油是否正常。
4、更换燃油滤芯座。
Troubleshooting:
1. Replace the fuel filter first.
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2. Inspect the fuel system.
3. Priming pump has internal leakage or not. Fuel pump and injector works normally or not.
4. Replace the fuel filter base.
排故体会：按照发动机供油原理逐步分析，排除每一个环节点是否正常。
Experience: Troubleshoot step by step according to the fuel system operation. Determine each
component of fuel system works normal or not.
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30、发动机自动熄火 Engine shut down automatically
故障现象：SY360负流量挖掘机，工作1小时左右发动机自动熄火，伴有“突突突”
声。停机5分钟后启动发动机能正常启动能正常工作。
Symptom: SY360 N FC excavator shut down automatically after working about one hour , and has
abnormal noise. Five minutes later, machine can be started normally and worked normally.
故障分析：根据故障现象：造成发动机自动熄火的应该为发动机燃油低压油路，因
为在发动机熄火时伴有“突突突”声音。这种声音在发动机燃油系统出
现堵塞，有空气进入燃油低压油路造成
供油不畅才会出现。造成燃油油路堵塞，
进空气的原因：
1、使用柴油不清洁，燃油油箱脏。
2、柴油滤芯堵塞，连接油管松动破裂。
3、输油泵损坏。
Failure analysis: As per failure phenomena described, failure should be caused by the low pressure fuel
circuit. Abnormal noise sounds likc machine gun when the engine is shut down. This noise is caused by
fuel blocked and air enters into fuel system. Probable cause of air enters into fuel system listed below:
1. Used fuel is not clean, fue tank is dirty.
2. Fuel filter is blocked. Fuel hoses are loosed or broken.
3. Fuel transfer pump failed.
故障原因：燃油油水分离器滤芯进油滤网被丝状物堵塞。
Root cause of the failure: Small strainer of fuel water separator is blocked by fibroid material.
排故方法：1、根据发动机熄火现象首先燃油滤芯是否污染堵塞，必要时进行更换。
2、检查燃油油路中是否有空气存在，同时检查输油泵泵油是否正常。
3、必要时采用直流方式供油，以排除管路中有堵塞现象。
4、将输油泵出油管直接连接到喷油泵上，以便排查包括柴油滤芯器盖在
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内的管路连接点。
5、拆检油水分离器，发现油水分离器座内
小滤网被丝状物堵塞，造成供油节流，
致使供油不畅。
6、将滤网拆洗后试机，工作正常，故障排除。
Troubleshooting:
1. Check the fuel filter is blocked or not. Replace the fuel filter if required.
2. Check the fuel system has air or not. Transfer pump works normally or not.
3. If required, using by-pass method to troubleshoot whether fuel circuit is blocked or not.
4. Connect the output hose of transfer pump to the fuel pump directly to troubleshoot the circuit between
transfer pump and fuel pump is normal or not.
5. Check the fuel water separator, and found a small strainer is blocked by the fibrid material.
6. Clean the small strainer. Tested and proved machine works normally. Problem solved.
排故体会：根据故障现象，结合柴油发动机燃油系统油路，逐一将各故障点排除。
Experience: As per failure phenomena described, troubleshoot the suspected parts step by step according
to fuel system operation.
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31、SY235C-8 发动机无法启动 SY235C-8 engine can not be started
故障现象：五十铃 6BG1T-AA 发动机无法启动。

Symptom: Isuzu engine 6BG1T-AA can not be started.
故障分析：1、检查电路是否正常；
2、检查启动机是否正常；
3、检查发动机的涡轮增压器是否正常；
4、检查柴油泵是否工作正常；
5、检查发动机自身是否正常。
Failure analysis:
1. Electric circuit works normally or not.
2. Starting motor works normally or not.
3. Turbocharger is normal or not.
4. Fuel pump works normally or not.
5. Engine is normal or not.
故障原因：发动机第一缸排气门断落在燃烧室里并且发动机一缸拉缸严重，拆下发
动机整体分解后大修，更换新件修复。
Root c ause of failure: Exhaust va lve of N o.1 c ylinder b roken a nd d ropped i nto c ombustion c hamber.
No.1 cylinder is seized severely. Replace the failed parts, rebuilt the engine.
Impacted and damaged by valve Valve spring is broken

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排故方法：1、检查电路：钥匙打开，启动电路正常。
2、检查启动机正常。
3、检查柴油泵：经校正柴油泵工作正常。
4、空气滤芯上的杂物和泥土太多，外部异物进入柴油机，打坏了增压器。
5、手动盘动飞轮盘不能盘整圈，打开发动机缸盖检查发现 1 缸排气门断
落在燃烧室里并且发动机 1 缸拉缸严重。
6、更换损坏的零件，大修后试机正常。
Troubleshooting:
1. Check the electric circuit. Starting circuit is normal tested by the start switch.
2. Checked and found starting motor is normal.
3. Checked and found fuel pump works normally.
4. A large amount of foreign material and dust was foun in the air filter and enters into engine,
turbocharger was impacted and damaged.
5. Engine can not be cranked a whole turn manually. Remove the cylinder head, and found the exhaust
valve of No.1 cylinder was broken and dropped into combustion chamber. Engine seized severely.
6. Replace the failed parts and related parts, rebuilt the engine. Tested and proved problem solved.
排故体会：1、机器的寿命取决于对机器的正常保养和维护。作为一个修理工应当指
导用户正确的保养和维护自己的机器；
2、发动机自身卡死，可直接认定为发动机自身故障。
Experience:
1. Service life of the machine is relied on the proper operation and maintenance. Service engineer should
instruct the operator or user how to operate and maintained his machine properly.
2. If the engine is seized, it is mostly caused by internal mechanical failure.
——提供者：储学敏 Service engineer: Chu Xue Min
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32、发动机冒蓝烟 Engine emitted blue smoke
故障现象：发动机冒蓝烟，从涡轮增压器和机油标尺处窜机油。
Symptom: Engine emits blue smoke. Engine oil leaks out from dipstick and turbocharger.
故障分析：发动机冒蓝烟，一般是发动机烧机油产生的，通常可以下几个方面检查：
1、发动机机油油位过高；
2、涡轮增压器窜机油；
3、发动机四配套磨损；
4、气门油封损坏。
Failure analysis: Engine emits blue smoke is usually the phenomenon of engine oil burned.
1. Too much engine oil is filled into the oil pan.
2. Turbocharger leaks engine oil.
3. Engine liner and piston ring are worn.
4. Valve seal damaged.
故障原因：活塞偏磨，机油进入燃烧室，造成了蓝烟的现象；且气缸内的混合气窜
入曲轴箱，致使 1 定压力的气体从油标尺和涡轮增压器窜出。
Root cause of failure: Piston is worn. Oil enters into combustion chamber and blue smoke emits. At the
same time, gas in combustion chamber enters into crankcase, causes oil leaks from turbo and dipstick.
Piston worn Liner scratched
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排故方法：1、拆下涡轮增压器进气管和消音器,检查发现其轴向和径向间隙均正常；
2、机油从机油标尺、涡轮增压器处窜出，说明曲轴箱内部压力过大造成。
3、拆去下排气管和呼吸器，故障仍然存在，说明造成此故障原因在发动
机内部。
4、拆检发动机发现第 5 缸活塞偏磨，第 5 缸连杆小瓦磨损，更换故障零
件后正常。
Troubleshooting:
1. Remove the inlet hose and exhaust mulfler from turbocharger, checked and found the axial and radial
clearance are normal.
2. Engine oil leaks out from dipstick and turbocharger. It means the pressure is crankcase is excessive.
3. Remove the exhaust pipe and breather, proble still existed. Failure occurred inner the engine.
4. Dismantle the engine a nd f ound N o.5 pi ston a nd c on-rod be aring i s w orn. Replace t he f ailed pa rts,
tested and proved problem solved.
排故体会：发现故障后，要从现象到本质，逐步推进，从简到难，从外到内。要仔
细分析，认真观察。
Experience: After failure occurred, service engineer should do the troubleshooting step by step. Observe
and analysis carefully to figure out the root cause of the failure.
——提供者：刘远鹏 Service engineer: Liu Yuan Peng
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33、SY65C冷车时启动困难 SY65C engine is hard to start when it is cold
故障现象：SY65C冷车时启动困难。
Symptom: SY65 is hard to start when the engine is cold.
故障分析：1、发动机故障；
2、燃油系统故障；
3、启动电路故障；
4、配气系统故障。
Failure analysis:
1. Engine failure occurred.
2. Fuel system problems.
3. Starting circuit problems.
4. Air inlet system problems.
故障原因：发动机预热塞损坏。
Root cause of the failure: Glow plug of the engine is failed.
排故方法：1、用万用表测量电瓶电压为24.6伏，正常；
2、仔细检查熄火拉线，启动继电器，启动马达，均正常；
3、检查预热塞，预热塞不工作，更换后正常。
Troubleshooting:
1. Measured battery voltage is 24.6V which is normal.
2. Checked and found the shut down cable, start relay, and starting motor are all normal.
3. Checked and found glow plug fails to work. Replace the failed glow plug, problem solved.
Glow plug
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排故体会：该车工作50小时，设备采用的是单色监控器WDKSY60-60控制的,与启动困
难没关系。显示屏里的故障信息会给维修带来方便，最后判断是预热方面
问题, 减少诊断时间。
Experience: Working hour is 50H when the failure occurred. Machine is controlled by black and white
monitor WDKSY60-60, which has nothing to do with the engine hard starting. Displayed information in
the monitor is helpful to the troubleshooting which shortened the troubleshooting time.
——提供者：黄军 Service engineer: Huang Jun
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34、设备憋车 Engine stalled
故障现象：设备工作大约两小时左右，出现憋车症状，如不立即停止动作设备可能
熄火。立即把手柄回中位，等发动机转速恢复正常后又能继续工作两小时。
Symptom: Engine s peed dr ops obviously after w orking a bout t wo hour s. Engine will s hut down i f t he
operation not stopped immediately. Engine speed restored after all the pilot valve lever returns to neutral
position, and then machine can work about another two hours normally.
故障分析：1、柴油滤芯故障；
2、手油泵故障；
3、燃油管路漏气；
4、燃油箱及吸油滤芯堵塞。
Failure analysis:
1. Fuel filter has failure occurred.
2. Priming pump failed.
3. Fuel circuit leaks air.
4. Fuel tank and fuel filter blocked.
故障原因：经检查发现该滤芯座与燃油滤芯接触面处有一极细小裂纹导致上述故障。
Root cause of failure: There is a small crack on the filter base mating face with the filter, air enters.
排故方法：1、首先更换柴油滤芯症状依旧；
2、检查手油泵发现外漏严重，更换新手油泵试车故障依然存在；
3、开始排查供油系统，更换所有燃油管路无效；
4、清洗燃油箱及吸油滤芯依然无效；
5、更换 1 滤芯座，故障消除。
Troubleshooting:
1. Replace the fuel filter, problem still existed.
2. Priming pump leaked fuel severely. Replace it, tested and proved problem still existed.
3. Replace all the hoses and tubes of fuel system, tested and proved problem still existed.
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4. Double check and found there is a small crack on the mating surface of the filter b ase. Replace t he
fuel filter base, tested and proved problem solved.
Experience: Grasp the system operation and use the proper method. Obey the rule of easy first and then
complex. Troubleshoot along the road sign of the failure. All the problems will be readily solved.
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35、SY135 冒黑烟，动力不足 SY135 emits black smoke, power insufficient
故障现象：SY135 发动机工作无力，冒黑烟，机器工作时间为 380 小时。

Symptom: SY135 has insufficient power and emits black smoke. Working hour is 380H.
故障分析：挖掘机使用仅 380 小时,基本可排除发动机本身故障及液压系统负载过大
的故障；可以从以下简单处着手：
1、比例电磁阀不工作，造成憋车现象；
2、空气滤芯堵塞，造成进气不足；
3、涡轮增压器损坏；
4、进气管路漏气；
5、燃油滤芯是否堵塞，造成进油不足。
Failure an alysis: Working hour is only 380H, engine mechanic failure and excessive hydraulic load
should not be suspected. Troubleshooting should be started from the following simpleness:
1. Main pump PSV fails to work normally, and causes the engine speed drops obviously.
2. Air filter blocked, air supply is insufficient.
3. Turbocharger damaged.
4. Air inlet circuit leaked.
5. Fuel filter blocked. fuel supply is insufficient.
故障原因：1、进气软管堵塞；
2、涡轮增压进气管松动。
1. Air inlet hose is blocked.
2. Clamp of the turbocharger inlet hose is loosed.
排故方法：1、空滤检查无堵塞现象；
2、主泵压力为 340kg,证明系统压力正常；先导压力为 39kg 证明先导压
力正常；
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3、更换油水分离器及燃油滤芯，并检查手油泵的进油滤网，无堵塞现象；
故可排除燃油油路的问题；
4、检查涡轮增压器进气软管发现卡箍松动，紧固后故障排除。
Troubleshooting:
1. Checked and found air filter is not blocked. It is normal.
2. Hydraulic system pressure is 340kg which is normal. Pilot pressure is 39kg which is normal.
3. Replace the fuel f ilter a nd f uel w ater s eparator. Checked a nd found t he strainer in t he i nlet por t of
priming pump is not blocked. Fuel circuit is normal.
4. Checked and found the clamp of turbocharger inlet hose is loose. Tighten it properly, problem solved.
排故体会：发动机冒黑烟原因很多，进气不足是其主要原因之一，检查进气系统比较
简单，应先从此入手，然后再检查电、油路。
Experience: There are so many probable cause of black smoke. Insufficient air is one of them. It is easy
to do the air inlet system inspection, so do the troubleshooting started from the air inlet system. And then
check the electric circuit and fuel circuit.
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36、发动机冒黑烟，憋车 Engine emits black smoke and speed drops obviously
故障现象：发动机冒黑烟，憋车，涡轮增压器附近有异响。
Symptom: Engine speed drops obviously with heavy black smoke. Turbocharger has abnormal noise.
故障分析：由于此故障的现象较明确，有黑烟憋车且有明确部位的异响；基本可以
从涡轮增压器有关的部位查找。
Failure an alysis: Failure phenomena are clear. Black smoke, engine speed drops obviously, and
abnormal noise from turbocharger. Troubleshooting should be started from the turbocharger.
故障原因：涡轮增压器废气旁通阀损坏。
Root cause of failure: Wastegate of the turbocharger is failed.
排故方法：
1、清洗燃油油路，更换燃油滤芯，故障依旧；
2、清洗空气滤芯，故障依旧；
3、发动机运转过程中涡轮增压器附近有“吱吱”的响声；
4、检查涡轮增压器正常，用手触摸涡轮增压器废气旁通阀有震动感。将旁
通阀管路断开声音消失，但故障依旧；
5、更换涡轮增压器废气旁通阀，故障排除。
Troubleshooting:
1. Clean the fuel circuit and replace the fuel filter, tested and proved problem still existed.
2. Clean the air filter properly, tested and proved problem still existed.
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3. Tested and found turbocharger has abnormal noise when engine is running.
4. Checked t he t urbocharger b y t ouching t he wastegate of t he t urbocharger w ith ha nd, a nd f ound i t i s
vibrated. Remove the hose of the wastegate, abnormal noise disappeared but the problem still existed.
5. Replace the turbocharger wastegate, tested and proved problem solved.
排故体会：废气旁通阀可保持增压压力避免由于压气机压缩空气的压力超出规定标
准而造成发动机过载。此故障为旁通阀始终为开启状态，增压器动力不
足，进气量不够，造成冒黑烟，憋车。
Experience: Wastegate i s us ed t o ke ep pr oper b oost pr essure, which can p revent f rom excessive b oost
pressure and engine overload. In this failure case, wastegate is always i n open status. Boost pressure is
lower specification, which casues black smoke and engine speed drops obviously.
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37、发动机转速下降800转 Engine speed drops 800 rpm
故障现象： SY215C挖掘机发动机工作一小时后转速从2200转掉800多转，重新启动正
常,一小时以后再次掉速。
Symptom: Engine speed of SY215 drops more than 800rpm after working for one hour. Shut down the
engine and then restarted, machine works normally. But failure repeats again one hour later.
故障分析：由于熄火后重新启动能工作正常一小时,从这一现象来看故障基本定位在电
气或燃油系统的故障。
1、油门控制器故障；
2、燃油回油溢流阀故障,燃油回油不畅；
3、水或其它杂质堵塞燃油滤清器；
Failure an alysis: Machine can work normally for one hour after it is restarted. Root c ause s hould be
focused on the fuel system or electric system.
1. Governor actuator failure.
2. Fuel return check valve failed, which causes the fuel return difficutly.
3. Water or sediment blocked the fuel filter.
故障原因：燃油品质差,杂质多,含水量高,造成滤芯堵塞,从而造成发动机掉速严重。
Root cause of failure: Fuel quality is poor. Sediment blocked fuel filter. Engine speed drops obviously.
排故方法：1、检查发现燃油品质差，很脏，杂质多，造成滤芯堵塞从而供油不畅；
2、清洗燃油箱，更换所有燃油滤芯。故障排除。
Troubleshooting:
1. Checked and found fuel quality is poor. Sediment blocked the fuel filter. Fuel supply is insufficient.
2. Clean the fuel tank, replace all the fuel filters. Tested and proved problem solved.
排故体会：1、做好挖机用户知识的培训，使其能正确使用与保养挖机；
2、排除故障中要做到胸有成竹，循序渐进的工作方式。
Experience:
1. Give the user or operator professional training to let them use and maintain the machine properly.
2. Troubleshoot with confidence and step by step to figure out root cause of the failure.
——提供者：夏刚 Service engineer: Xia Gang
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38、发动机正常熄火后打不着车 Engine can not be started after shut down normally
故障现象：SY200 挖掘机工作 4700 小时，熄火后无法再启动。

Symptom: Working hour of SY200 is 4700H. Engine can not be restarted after normal shut down.
故障分析：1、电路故障；
2、熄火装置故障；
3、燃油是否洁净；
4、油路故障（堵塞或有空气进入）；
5、发动机本身故障。
Failure analysis:
1. Electric circuit failure.
2. Shut down motor failed.
3. Fuel has much more sediment or not.
4. Fuel circuit failure. Fuel is blocked or air enters into the fuel system.
5. Engine mechanical failure.
排故过程：1、检查冷却液，机油正常。
2、检查熄火装置在启动位置，正常。
3、放油检查燃油，目测正常。
4、手动泵油从高压泵进油处观察，无气泡，出油正常，证明低压油路没
有问题。
5、松开喷油器进油高压管，启动发动机，高压出油，但觉得力度不够。
松开高压泵高压油管螺栓，手动泵油发现有油浸出，判断出油阀密封
不严。
6、更换出油阀后，发动机正常。
Troubleshooting：
1. Checked and found coolant and engine oil is normal.
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2. Checked and found the shut down cable is in the fuel on position when engine is cranked.
3. Drain out some fuel, and visual inspect it is normal.
4. Priming fuel and and found no air bulb bled out from the fuel. It means low pressure fuel circuit is ok.
5. Loose the injection pipe from the injector and crank engine. Fuel overflows out but is weak. Loose the
injection pipe from the fuel i njection pum p. Operate the priming pum p and fuel flows out from the
loosed pipe. It is suspected that delivery valve can not seal the fuel properly.
6. Replace the delivery valve, tested and proved engine can be started normally. Problem solved.
Delivery valve
Experience: Grasp the system operation and use the proper method. Obey the rule of easy first and then
complex. Troubleshoot along the road sign of the failure. All the problems will be readily solved.
---提供者：郭长存 Service engineer: Guo Chang Cun
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39、发动机抱瓦 Engine bearing seized
故障现象：SY75C 挖机配 4JG1 型发动机,在使用到 842 小时出现异响,服务工程师到
现场检查发现,连杆轴瓦拉瓦。
Symptom: 4JG1 engine of SY75C has abnormal noise at the 842 th hours. Service engineer checked and
found on the jobsite that the con-rod bearing seized.
故障分析：1、操作人员不规范操作；
2、发动机机油量过少；
3、喷油器损坏造成机油粘度不够(雾化不良或不能雾化)；
4、机油被污染(被水或其他油品污染,进气道进入颗粒粉尘或金属粉末；
5、发动机机油泵损坏或机油吸油管与缸体进油口密封不严；
6、机油的等级不适合挖机工作环境要求。
Failure analysis:
1. Improper operation causes the failure.
2. Engine oil level is low excessively.
3. Injector failed and causes the engine oil diluted.
4. Engine oil is contaminated by coolant or fuel. Dust or metal power enters into air inlet passage.
5. Engine oil pump damaged or suction pipe seal of oil pump is damaged.
6. Oil grade misfits the working condition of the excavator.
故障原因: 天气冷，机油牌号不对，粘度过高，在冷机启动时机油短时间难以及时
经过滤清器到达机件内部，运动机件得不到机油润滑，造成干摩擦。
Root cause of the failure: Engine oil viscosity is incorrect which is high excessively in the cold weather.
Oil is hard to arrive moving parts timely during cold start. Adhesive wear occurred without lubrication.
排故方法:1、测量从发动机内放出来的机油在 9.5 升左右,排除机油过少；
2、放出来的机油,任何异味；检查机油喷嘴,喷油正常；
3、检查空滤,进气道干净无水渍,排除进气系统故障；
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4、检查机油泵正常，无磨损或损坏痕迹。取 300 毫升机油放在发动机舱，
8 小时后,机油被冻,且很稠；
5、现场询问用户挖机操作手得知挖机用的是壳牌 15W-40 机油.对照壳牌机
油的使用说明,使用的机油不符合当地的环境温度.现场试验证明机油
粘度较高.综合以上分析,在冷机启动时机油对机件相对阻力过大,短时
间内运动机件得不到机油润滑,导致上述故障。
Troubleshooting:
1. Drain out the engine oil completely. It is about 9.5 liters. It means oil is sufficient.
2. Checked and found used oil has no odor. Injector works normally.
3. Checked and found air filter and air inlet passage is clean and no water vestige. Air inlet is normal.
4. Checked and found oil pump is normal. It is not worn and no pa rts damaged. Put 0.3 liters oil in the
engine room, tested and found it is very thick and frozen 8 hours later.
5. Operator said that Shell brand 15W-40 oil was used. This oil misfit the local ambient temperature as
per its use guide. This is also proved by the test on the jobsite as described in step 4. Based on above
analysis, the oil flow resistance is excessively high during the cold start. The moving parts can not get
oil lubrication and adhesive wear occurred.
排故体会: 排除故障应该结合工作环境、挖机、操作人员等相关条件考虑,越细越好。
Experience: Think about the environment, the machine, the operator, and so on to do the troubleshooting.
The more the factor you considered, the better the result.
——故障诊断人:卢浩 Service engineer: Lu Hao

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40、发动机憋车、掉速熄火 Engine stalled
故障现象：SY330 发动机工作时掉速熄火，熄火后再次启动机器无法启动，需排除燃
油管路中空气后能正常启动，工作半小时左右故障再次出现。
Symptom: SY330 engine speed drops till shut down during the work. It can not be restarted unless bleed
air from the fuel system. Failure repeats again half an hour later.
故障分析：根据故障现象，再次启动发动机需排除燃油管路中的空气，可以锁定故
障为燃油低压油路阻塞引起。
Failure an alysis: As p er the failure phenomena, i t needs t o bl eed air from fuel circuit before i t c an be
restarted. It is clear that the failure is caused by the low pressure fuel circuit block.
故障原因：
1、燃油箱内杂质过多，阻塞燃油输出油管；
2、燃油粗滤芯堵塞；
3、R90P 油水分离器阻塞；
4、输油泵进油管接头内滤网堵塞；
5、燃油精滤芯阻塞；
6、燃油各低压油管与管接头阻塞或破裂以及管接头松动工作时进入空气。
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1. Fuel tank has much sediment which blocked the fuel hose.
2. Primary fuel filter is blocked.
3. R90P fuel water separator is blocked.
4. Strainer in the joint bolt of the transfer pump inlet hose is blocked.
5. Secondary fuel filter is blocked.
6. Hose connector of low pressure circuit is blocked, broken, or loose which cause air enters into fuel.
排故方法：1、检查燃油低压油管有无松动、破裂漏油等；
2、打开燃油箱排污阀，放出油箱内杂质，拆开燃油箱底部出油管查看出
油管有无杂质阻塞；
3、检查燃油粗滤芯进油管接头处滤网与输油泵进油滤网有无阻塞；
4、更换滤芯。
Troubleshooting:
1. Checked and found low pressure fuel circuit is normal. No loose, no broken, and no fuel leakage.
2. Open the fuel tank drain valve to drain the sediment from the tank. Remove the fuel hose from the tank
bottom, and check whether the hose has sediment blocked or not.
3. Inspect the strainer in the inlet hose of primary filter and transfer pump, it is blocked or not.
4. Repalce the fuel filters.
排故体会：认真检查故障的每一个细节, 逐步排除每个故障点。
Experience: Inspect the failure phenomena detailedly, troubleshoot step by step.
- 398 -
41、发动机可以转动但不能着车 Engine can be cranked but can not be started
故障现象： SY215C挖掘机当启动钥匙转动到启动位置，发动机可以正常转动但不能
着车，排气管无烟排出。
Symptom: Engine of SY215 can be cranked by start switch but can not be started. No smoke emitted.
故障分析：1、油箱无燃油；
2、电气或手动燃油切断阀未打开；
3、发动机长期未使用或更换燃油系统部件后燃油系统有空气；
4、燃油回油不畅；
5、燃油回油溢流阀故障；
6、水或其它杂质堵塞燃油滤清器；
7、柴油发动机高压油泵磨损；
8、柴油发动机喷油嘴故障。
Failure analysis:
1. No fuel in the tank.
2. Electric or manual fuel cut off valve is not opened.
3. Engine not started for a long time or air in fuel after replacing fuel system parts.
4. Fuel return is not smooth.
5. Fuel return check valve failed.
6. Water or other foreign material blocked the fuel filter.
7. Fuel injection pump was worn.
8. Injector failure.
故障原因：检查发现油路不畅，回油管油路堵塞。
Root cause of the failure: Fuel return is not smooth since the return fuel hose is blocked.
排故方法：1、检查电瓶的盘车时电压是否有 24V；
2、检查电线是否松动、证实电磁阀功能是否正常、确定手动切断杆是否
位于运行的位置；
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3、检查回油管油路、及回油溢流阀；
4、泄放油水分离器或更换燃油滤清器；
5、松开两个喷油器的高压油管和在转动发动机时目测检查燃油输送，如
果燃油不能输送，更换喷油泵；
6、检查喷油泵正时是否正常。
Troubleshooting:
1. Battery voltage is higher than 24V or not during the cranking.
2. Electric wire connector is loose or not. Solenoid valve is normal or not. Make sure the manual fuel cut
off valve is opened or not.
3. Inspect the fuel return circuit and fuel return check valve.
4. Drain the fuel water separator or replace the fuel filter.
5. Loose two injection pipes from injector and crank engine. If no fuel found, replace the fuel pump.
6. Fuel timing is normal or not.
Fuel return
check valve
排故体会：1、定期做好挖机保养维护工作，清洗油路。
2、排除故障要谨慎加小心，不能忽视细节方面的故障。
Experience:
1. User should carry out routine maintenance and clean fuel circuit timely.
2. Troubleshoot carefully and patiently. Do not ignor each detail of the failure phenomena.
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第4节空调系统 Air conditioner
01、空调制冷不良 A/C has a poor refrigeration.
故障现象：空调在使用两个小时后不制冷，关掉空调两小时后又可正常工作一段时间。
Symptom: Air conditioner has no r efrigeration effect after using two hours. It can work normally for a
period of time after two hours break.
故障分析：1、温度传感器损坏或者插装位置不正确，造成感温信号不对，从而自动
切断压缩机的电源；
2、膨胀阀结冰；
3、冷媒加注太多或者太少或者残留空气；
4、干燥筒饱和；
5、冷凝器散热不良，造成空调系统保护压缩机，自动切断电源。
Failure analysis:
1. Temperature sensor failed or installed in an improper position, which cause the incorrect temperature
signal and cut off the electric power of the compressor automatically.
2. Expantion valve is frozen.
3. Refrigerant is less or much excessively. Or much air remained in the air conditioning system.
4. Receiver-dryer is saturated.
5. Condenser is cooled poorly. System cut off the electric power automatically to protect the compressor.
排故原因：此类故障多为系统中有空气、杂质或水份造成冰堵形成。
1、空调能正常工作两小时，说明冷媒加注量正常，但不排除真空是否抽好；
2、检查继电器是否损坏不能脱开引起膨胀阀结冰；
3、是否膨胀阀开度太小引起结冰堵塞；
4 、温度传感器损坏不能给信号或者和蒸发器接触不好引起；
5、干燥筒饱和。
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Probable c ause of t he f ailure: Most of t his ki nd of f ailure i s c aused b y a ir, s ediment, or w ater in t he
system. The frozen material blocked circuit.
1. A/C work normally for two hours. It means refrigerant amount is normal, but vacuum is suspected.
2. Relay is failed which causes the expansion valve frozen.
3. Opening of the expansion valve is small and cause the ice block.
4. Temperature sensor failed or evaporator is opened intermittently.
5. Receiver-dryer is saturated.
排故方法：1、重新抽真空，查泄漏，正常后加注冷媒（低压1-2kg，高压14-16kg）；
2、检查压缩机离合器能正常离合；
3、发现膨胀阀结冰，调节膨胀阀开度到最大，继电器正常，故障依旧。
4、打开蒸发器发现温度传感器被包在固定插销内，拔出两厘米装好在蒸发
器外，试车，空调能正常工作。
Troubleshooting:
1. Vacuumize, check for leakage, and fill refrigerant. Low pressure is 1-2kg & high pressure is 14-16kg.
2. Check the clutch of compressure can be engage and disengaged normally or not.
3. Checked and found expansion valve is frozen. Adjust its opening to maximum. Relay works normally
but problem still existed.
4. It is found t hat t emperature sensor of t he evaporator i s wrapped in t he f ix pin. Pull i t 2c m out and
installed at the outside of evaporator properly. Tested and proved A/C can work normally.
排故体会： 1、空调温度传感器安装位置很重要，不能随意乱插；不能插的太深,也
不能太浅,否则感应的温度不准,造成制冷不良。
2、一步一步从最简单的去排除，耐心的去处理一个问题。
Experience:
1. The installed position of A/C temperature sensor is very important. It must be installed properly in the
correct position. Otherwise, the detected temperature will be incorrect and cause poor refrigeration.
2. Service engineer should do troubleshooting step by step patiently to solve each problem.
---提供者:李纪平 Service engineer: Li Ji Ping
- 402 -
02、215C-8 空调不制冷 215C-8 a/c fails to refrigerate
故障现象：一台 215C-8 空调不制冷。

Symptom: A/C of 215C8 is failed to refrigerate.
故障分析：
1、空调压缩机不通电；
2、空调压缩机继电器，鼓风机继电器通电不良；
3、控制面板坏；
4、空调滤清很脏。
Failure analysis:
1. Air compressor has no power supplied.
2. Power supplied to relay of air compressor and blower is opened intermittently.
3. A/C control panel is failed.
4. Air filter of the a/c system is dirty.
故障原因：
1、控制面板坏了，导致电路不通电；
2、压缩机继电器坏。
1. A/C control panel is failed. No electric power supplied.
2. Relay of air compressor is failed.
排故方法：
1、用电线短接压缩机继电器时，听不到压缩机有吸合的声音，继电器也不吸；
2、更换新的继电器能听到压缩机的声音；
3、检查发现鼓风机的继电器正常；
4、接通控制面板仍然没反应；
5、更换控制面板，故障消除。
- 403 -
Troubleshooting:
1. Use a wire to short the air compressor relay, it is found air compressure not engaged. Also that relay
has no action.
2. Replace with a new relay, tested and found air compressor clutch can be engaged.
3. Checked and found the blower relay works normally.
4. Power on the a/c, but the control panel fails to work.
5. Replace the control panel, tested and proved a/c works normally. Problem solved.
排故体会; 先检查简单的，然后再由浅入深。
Experience: Troubleshoot the simple firstly and then step by step to figure out root cause.
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03、135C8 机器空调不制冷 135C8 a/c fails to refrigerate
故障现象：用户空调不制冷，空调控制面板没有电，风机不转。
Symptom: User’s a/c fails to refrigerate. Control panel of the a/c has no power. Blower fails to work.
故障分析：
1、空调保险丝因过载损坏；
2、空调控制面板损坏；
3、线路断路；
4、空调制冷系统缺冷媒，压力不够，空调无法启动。
Failure analysis:
1. Fuse of a/c system is failed.
2. Control panel failed.
3. Circuit opened.
4. Refrigerant is insufficient. Pressure is too low to start the a/c.
排故过程：
1、电源正常，检测空调冷媒压力，正常。检查F8号空调保险丝，正常；
2、更换空调控制面板，空调控制面板仍然没有电，单独接电源测试空调压缩
机和空调鼓风机电机，均正常；
3、对照三一厂135型挖掘机电路图，未发现其它部位有保险丝，测量空调控制
面板与机体的连接线束，所有接头均无电压。
4、经仔细检查空调线束，发现控制面板与车身连接线束中有一个套着白色护
套的玻璃管式保险丝断路，检查线路无其他磨损短路处后，更换新的5A保
险管，试车正常。
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Troubleshooting:
1. Power source is normal. Pressure of refrigerant is normal. Fuse F8 of a/c system is normal.
2. Replace the control panel, it still has no pow er. Supply power to air compressor and blower directly,
tested and found air compressor and blower are normal.
3. No more fuses can be found in the SY135 electric schematic. Checked and found the wires of control
panel which connects to the frame have no voltage.
4. Double check the a/c harness, and found a tube type fuse with a white jacket in the wires of control
panel. Checked and found the wires are normal. Replace the 5A tube type fuse. Problem solved.
排故体会：空调系统通常会有两个保险，1路保护控制部分如控制面板，一路保护电
机如压缩机、鼓风机。而控制面板的保险是随空调系统一起的，故在电路图中没有标
明出来。这就要求服务工程师对系统部件的工作原理，零部件的结构与布置应该有一
定的了解，才能更好更快的排除挖机故障。
Experience: Usually, there are two fuses in a/c system. One fuse is use to protect the control part, such as
control panel, and another one is used to protect air compressor and blowers. The fuse of control panel is
shipped with air conditioner, so it is not labeled in t he schematic. Service engineer should grasp t he
system operation, the component structure, and layout of the a/c system to figure out root cause of failure.
----提供者：合肥湘元 Service enigneer: He Fei Xiang Yuan
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04、空调制冷不良 Air conditioner refrigerates poorly
故障现象：一台 SY215 的挖掘机空调制冷效果很差，但是其他各项工作正常。

Symptom: Air conditioner of SY215 refrigerates poorly. Machine works normally.
故障分析：压缩机不工作，鼓风机不工作，氟利昂缺失，冷凝器原因，空调滤芯。
Failure analysis: Air compressor and lower fails to work. Freon lost. Condenser fails or filter blocked.
故障原因：首先想到是可能以下原因造成空调不凉：
1、压缩机不工作；
2、鼓风机不工作；
3、不制冷的原因氟利昂缺失；
4、冷凝器原因；
5、空调滤芯。
Probable cause of the failure: Following causes are most possible to cause the failure.
1. Compressor fails to work.
2. Blower fails to work normally.
3. Freon lost.
4. Condenser related failure.
5. Filter of air conditioner system.
排故方法：
1、检查空调压缩机是否工作，检查其正常；
2、其次看看鼓风机，有风送出鼓风机，工作正常；
3、检测空调内是否缺失氟利昂，经检查不缺；
4、冷凝器散热正常；
5、检查空调滤芯是否堵塞。经检查有大量尘土堵塞滤芯。更换空调滤芯后
试车正常。
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Troubleshooting:
1. Checked and found the air compressor works normally.
2. Checked and found the blower works normally.
3. Checked and found Freon is sufficient.
4. Checked and found condenser is normal. Refrigerant is cooled normally.
5. Checked and found the filter of air conditioner system is blocked by large amount of dust. Replace the
filter, tested and proved a/c works normally. Problem solved.
排故体会：
1、做为一名技术服务人员，首先要掌握机器性能及其所有零部件的用途；
2、当机器出现故障时，应按步骤一点一点仔细检查排除。
Experience:
1. To be a professional service engineer, you should grasp the machine performance and parts function.
2. When failure occurred, troubleshoot step by step carefully to figure out the root cause of failure.
----提供者：陈欣 Service engineer: Chen Xin
- 408 -
05、空调不制冷 A/C fails to refrigerate
故障现象：SY205 挖机在工作时，空调控制面板正常工作，但空调不制冷。
Symptom: A/C control panel works normally, but a/c fails to refrigerate when machine is working.
故障分析：1、压缩机是否吸合，其工作是否正常；
2、系统压力是否正常，高压低压是否在正常的范围之内；
3、膨胀阀是否冰堵或脏堵；
4、干燥瓶上高低压开关是否正常，高低压转换是否正常；
5、温度传感器是否正常。
Failure analysis:
1. Air compressor works normally or not. Its clutch can be engaged normally or not.
2. Refrigerant pressure is normal or not. High and low pressure is within specification or not.
3. Expansion valve is blocked by ice, sediment or not.
4. Pressure switch on the dryer bottle is normal or not. High/low pressure can be shifted normally or not.
5. Temperature sensor is normal or not.
故障原因：空调温度传感器损坏。
Root cause of the failure: Temperature sensor of a/c is failed.
Location of temperature sensor

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排故方法：1、打开空调控制面板，检查压缩机离合器是否吸合，检查保继电器 K2
是否正常，发现正常；
2、用压力表检测系统压力，高低压的压力都在正常范围之内，排除冷媒
泄漏，膨胀阀冰堵、脏堵； Temperature sensor
3、检查高低压开关，能正常通断；
4、检查蒸发器安装的温度感应传感器，拔下传感
器检测后发现感应器被冻坏，失效，更换新的
温度传感器后系统运常。
Troubleshooting:
1. Power on the air conditioner. Checked and found relay K2 and air compressor work normally.
2. Measured s ystem hi gh and l ow pr essure i s w ithing s pecification. Refrigerant a mount i s normal.
Expansion valve is not blocked by ice or sediment.
3. High/Low pressure switch works normally.
4. Checked and found the temperature sensor on the evaporator is failed. Replace with a new temperature
sensor, tested and proved a/c works normally. Problem solved.
排故体会：先要根据故障现象分析可能出现的原因，然后由简到难逐步排除。
Experience: Analysis probable causes of the failure as per the failure phenomena, and then troubleshoot
step by step started from easy inspection.
- 410 -
06、空调系统不制冷 A/C fails to refrigerate
故障现象：空调系统不制冷，无故障代码。
Symptom: A/C fails to refrigerate. No failure code displayed.
故障分析：
1、该机压缩机电磁阀离合器不吸合，压缩机不工作；
2、压缩机内泄，无法建立起高、低压；
3、检查温控器，工作是否正常；
4、压力开关是否常开；
5、控制器（空调器）电源电压是否正常，空调风机转速控制是否正常;
6、空调控制器线路是否正常，有无断路、短路。
Failure analysis:
1. Clutch of the air compressor can not be engaged. air compressor not work.
2. Air compressor has internal leakage. High pressure and low pressure can not buid up.
3. Temperature control switch works normally or not.
4. Pressure switch is always opened or not.
5. Power source voltage of the a/c controller is normal or not. Blower speed control is normal or not.
6. A/C circuit is normal or not. Circuit is opened or shorted?
故障原因：控制器控制压缩机离合器端的信号不正常，导致压缩机不能正常工作，
空调系统不制冷。
Air compressor Controller

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Root cause of failure: Signal to the clutch of air compressor is abnormal, which causes air compressor
fails to work normally.
排故方法：
1、用压力表测试高、低压均为 0；证明压缩机没工作；
2、检查电磁阀离合器控制继电器，工作正常，工作电压 24V，能正常闭合、
断开；
3、检查温控器，工作正常，能正常通断；
4、检查控制器（空调器）电源电压 24V,正常，空调风机转速控制正常；
5、空调控制器线路正常，无断路；
6、更换控制器后，空调工作正常。
Troubleshootin:
1. Measured high pressure and low pressure are zero. It means air compressor fails to work.
2. Checked and found the relay of the air compressor clutch is normal. Its voltage is 24V.
3. Checked and found the temperature control switch works normally.
4. Measured power source voltage of the a/ c controller i s 2 4V which is no rmal. Speed control of a/c
blower is normal.
5. Wire of a/c controller is normal. Circuit is not opened.
6. Replace the a/c controller, tested and proved a/c works normally. Problem solved.
排故体会：首先分清是机械问题还是电气问题，再进一步检测，可以少走弯路。
Experience: Make sure it is a mechanical problem or a electrical problem first, and then troubleshoot to
same your time and energy.
- 412 -
第5节操作保养 Operation and maintenance
01、动臂销轴异响 Boom root pin has abnormal noise
故障现象：动臂销轴异响。
Symptom: Boom root pin has abnormal noise.
故障分析：1、没有使用纯正的黄油；
2、没有按时打黄油；
3、黄油嘴是否堵死；
4、轴套、密封圈磨损。
Failure analysis:
1. Genuine grease is not used during the daily maintenance.
2. Bearing is not grease lubricated according to the maintenance interval.
3. Grease nipple is failed.
4. Bearing sleeve and dustproof seal are failed.
故障原因：动臂销轴得不到润滑导致销轴干磨异响。
Root cause of the failure: Boom root pin is not grease lubricated and causes abnormal noise.
排故方法：1、检查动臂销轴黄油嘴完好，销轴部位的黄油较干，将铲斗油缸、斗杆
油缸全部收回，铲斗趴在地上；
2、用吊车轻轻起吊动臂，拆下动臂平台连接的管路、线路，拆下动臂油
缸与动臂连接的销轴，用拔销器将动臂销轴拔出；
3、起吊动臂，更换轴套；
4、更换密封圈、销轴，将动臂安装到机架上；
5、安装动臂油缸杆肖，连接油管、线路、加注黄油，故障排除。
Troubleshooting:
1. Checked and found the grease fitting is normal and the grease near the pin is dry. Retract arm cylinder
- 413 -
and bucket cylinder completely and lower the bucket to the ground.
2. Remove the hoses and wires between the boom and upper structure. Remove the boom cylinder rod
pin. Use a truck crane to suspend the boom properly and remove boom root pin with special tool.
3. Lift the boom, replace the bearing sleeve.
4. Replace dustproof seal and boom root pin. Install the boom to the upper structure.
5. Install boom cylinder rod pin. Connect the hoses and wires between boom and upper structure.
Lubribcate boom root pin properly. Tested and proved abnormal noise disappeared. Problem solved.
排故体会：此类问题属于保养不当导致的，在平时的服务过程中抓住每次机会，对
操作手进行日常维护保养的培训，要求客户使用纯正配件。
Experience: This failure is caused by improper maintenance. Service engineer should instruct operator to
do daily maintenance with genuine parts during the service.
——提供者：黄旦 Service engineer: Huang Dan
- 414 -
02、挖机无法回转 Excavator can not swing
故障现象：挖机无法回转。
Symptom: Excavator can not swing.
故障分析：1、回转减速机损坏；
2、回转马达制动解除阀发卡；
3、回转先导阀故障；
4、回转阀芯故障等；
5、回转支承与回转马达驱动齿中有异物发卡。
Failure analysis:
1. Swing drive failed.
2. Swing brake release valve seized.
3. Swing pilot valve failed.
4. Swing valve spool failed.
5. Swing drive is blocked by foreign material.
故障原因：回转支承与回转马达驱动齿中有异物发卡。
Root cause of the failure: Foreign material is found between the ring gear and the swing drive.
排故方法：1、做回转动作有溢流，先导阀、回转主阀芯完好；
2、检查回转马达制动解除阀无发卡，滤网无堵塞；
3、检查发现黄油盘有凸起变形，拆下回转马达，回转支承与回转马达驱
动齿中有异物发卡；
4、更换黄油盘及齿圈全部螺栓、垫片后，机器正常。
Troubleshooting:
1. Do swing operation, and the relief pressure is normal. Pilot valve and main valve spool are normal.
2. Checked and foun the swing brake release valve spool not seized. Strainer not blocked.
3. Checked and found the grease cover of swing bearing is hunched and deformed. Remove the swing
unit. A foreign material is found between the swing drive gear and the ring gear of swing bearing.
- 415 -
4. Replace grease chamber, ring gear bolts, and washers. Tested and proved machine swings normally.
排故体会：此类故障属操作手操作不当导致，要对操作手加强挖机规范操作规范培
训，避免此类故障的发生，确保机器的正常工作。
Experience: This f ailure i s c aused b y i mproper op eration. It i s n ecessary t o i nstruct t he o perator to
prevent this kind of failure occurs again in the future, and make sure that machine can work normally.
——提供者：时宏国 Service engineer: Shi Guo Hong
- 416 -
第6节结构件 Structure
01、托链轮漏油 Carrier roller leaks oil
故障现象：托链轮漏油（有渗油现象）。
Symptom: Lubricant seeps out from carrier roller.
故障分析：1、长时间、长距离行驶；
2、拖链轮轴磨损；
3、拖链轮油封老化。
Failure analysis:
1. Machine travels a long distance in a long time continually.
2. Shaft of carrier roller is worn.
3. Dual cone seal of carrier roller failed.
故障原因：拖链轮内部浮动油封损坏。
Root cause of the failure: Dual cone seal of the carrier roller is failed.
排故方法：更换托轮总成，故障排除。
Troubleshooting: Replace the carrier roller. Problem solved.
排故体会：此类问题可能是客户长时间长距离行走或有尘土进入油封导致磨损造成，
建议客户避免长时间长距离行走，经常对挖机进行清洁作业。
Experience: This failure may be caused by travelling long time or long distance continually, or dus t
enters which result in dual cone seal worn. Suggest the user clean machine usually, and not travel long
time or long distance continually.
——提供者：孙挺 Service engineer: Sun Ting
- 417 -
02、履带张不紧 Track can not be tensioned
故障现象：履带无法张紧，行走时存在跑偏现象。
Symptom: Track can not be tensioned. Travel offset is out of specification.
故障分析：1、黄油嘴堵塞；
2、张紧油缸活塞或杆锈蚀卡滞。
Failure analysis:
1. Grease nipple failed.
2. Rod of the track tension cylinder is rusted and seized.
排故原因：履带张紧油缸已很长时间没有打过黄油，由于黄油中含有水分,张紧油缸
活塞长期停留在一个位置导致与缸筒锈死不能活动，将黄油阀松开直至
完全卸下,油缸中黄油始终不能溢出,履带也不会松弛。
Failure cause: Grease is not pumped into the track tension cylinder for a long time. Rod of track tension
cylinder is hold in the same position for a long time and seized. Loose the grease valve gradually till it is
removed. No grease flows out from the track tension cylinder, and track tension not changed.
排故方法：首先将铲斗着地，将一侧履带支起悬空，用高压黄油枪一边打黄油一边
转动履带，如上述方法无效，则必须对涨紧油缸进行拆卸维修，具体方
法如下：
1、打开履带轨链节（借助氧气烤红打出活销），取出导向轮及张紧装置总
成并将两部分分离；
2、借助工装及两个千斤顶将张紧油缸活塞杆拉出；
3、仔细将活塞及缸筒内的锈蚀除净并清洗干净，更换新的密封组件后将
活塞装回缸筒；
4、将张紧装置与导向轮进行组合后装回 X 架，并将轨链节及履带等零部
件还原重新张紧履带，维修工作完成。
- 418 -
Troubleshootin: Jack up one s ide t rack b y l owering buc ket t o t he ground. P ump g rease i nto t he t rack
tension cylinder when this track is doing travel operation. If the track still can not be tensioned, remove
and repair it as the method described following:
1. Heating t he m aster pi n with w elding t orch, and remove i t to open the t rack l ink. Pull o ut th e tr ack
tension assembly. Separate the cylinder from the track tension assembly.
2. Pull out the rod from the track tension cylinder by using jig and two jacks.
3. Clean the dry grease and rust of bot the cylinder and the rod. Replace seals and failed parts. Rebuild
the track tension cylinder.
4. Restore the track tension assembly. Close the track link and install the master pin. Problem solved.
排故体会：该故障是由于涨紧油缸长期未保养引起锈蚀，要求对涨紧油缸每 500 小
时进行泄油和重新涨紧的保养。
Experience: This failure is caused by track tension cylinder not maintained for a long time. As required,
grease of the track tension cylinder should be drained out and refilled with new grease every 500 hours.
——提供者：王新伟 Service engineer: Wang Xin Wei
- 419 -
03、斗杆油缸与斗杆连接耳板开裂 Stick cracks at the nose the stick cylinder rod pin installed
故障现象：斗杆油缸与斗杆连接的耳板处开裂。
Symptom: Stick is cracked at the nose where the stick cylinder rod pin installed.
故障分析：1、操作手的操作是否粗暴；
2、工况是否恶劣；
3、材质是否合格。
Failure analysis:
1. Improper operation of the machine.
2. Work condition is serious.
3. Material defection.
故障原因：焊缝开裂，系焊接工艺问题。
Root cause of the failure: Cracked at the welding seam, it is the workmanship defection of the welding.
排故方法：1、经询问客户是按照标准作业，没有不良操作习惯；
2、经现场观察，工矿为土方作业，符合作业要求；
3、将旧斗杆拆下，更换新斗杆，故障处理完毕。
Troubleshooting:
1. Talked with the operator, it is sure that machine is operated properly.
2. Machine is used to excavate soil in the jobsite, which is the normal application of the excavator.
3. Replace with a new stick, problem solved.
排故体会：该故障属于制造问题，建议公司改善制造工艺，对焊接件焊缝进行探伤，
100%全检。
Experience: This failure is caused by workmanship defection. Suggest factory to improve workmanship,
and examine all the sticks for defection before it is assembled.
- 420 -
04、座椅扶手无法固定 Armrest of the seat can not be fixed
故障现象：座椅扶手向前倾，无法固定，压在操纵箱上。
Symptom: Armrest can not be fixed. It drops down on the console.
故障分析：1、座椅扶手调节螺母螺纹滑丝；
2、座椅扶手调节推杆磨损；
3、座椅扶手安装轴磨损。
Failure analysis:
1. Thread of the armrest adjusting nut is ruined.
2. Adjusting rod of the seat armrest is worn.
3. The shaft of seat armrest is worn.
故障原因：座椅扶手安装轴磨损，扶手放下时推杆无法固定。
Root cause of failure: Shaft of seat armrest is worn. The adjusting rod of armrest can not be fixed.
排故方法：1、打开轴盖，检查调节螺母、推杆完好；
2、调节扶手，将扶手放下，推杆到位无法固定，检查扶手安装轴磨损，
3、更换座椅，故障完成。
Troubleshooting:
1. Remove the cover, checked and found the adjusting nut and rod is normal.
2. Adjust the armrest, release the armrest. It can not be fixed. Shaft of the armrest is worn.
3. Replace the seat assembly, problem solved.
排故体会：大多数情况下，是由于用户使用不当所导致，提醒用户使用时避免上下
反复调整，禁止坐在扶手上。
Experience: This kind of failure is usually caused by users’ improper usage. Service engineer should
instruct the operator do not adjust the armrest frequently and repeatly, and do not sit on the armrest.
----提供者：章宏运 Service engineer: Zhang Hong Yuan
- 421 -
05、机顶罩锁无法正常关闭 Engine hood can not be locked normally
故障现象：机顶罩锁无法正常关闭。
Symptom: Engine hood can not be locked normally.
故障分析：1、机顶罩锁锁芯磨损；
2、锁扣调整不合适；
3、顶机罩锁弹簧断裂。
Failure analysis:
1. The core of engine hood lock is worn.
2. Lock is installed improperly.
3. Spring of the lock is broken.
故障原因：经现场检查，顶机罩锁弹簧断裂，导致无法正常关闭。
Root cause of failure: Spring of the engine hood lock is broken. Engine hood can’t be locked normally.
排故方法：1、用手提砂轮机将机顶罩锁与顶机罩的连接焊点除去，取下机顶罩锁；
2、将表面打磨平整；
3、将新锁对好位置并点焊，确认锁闭可靠后再段焊；
4、补油漆以防止生锈。
Troubleshoot:
1. Grinding the welding seam of the engine hood lock, and remove the lock from the engine hood.
2. Polish the engine hood where the lock installed.
3. Spot welding the lock to the engine hood proper position. And then weld it engine hood tightly.
4. Paint the lock and the welding seam to prevent rust.
排故体会：这类机械性故障在处理时是很明显的可以看出的，但是在处理的过程中
应该细心，不要再次机械性的伤到别的位置。
Experience: Root cause of this kind of failure is obvious. Service engineer should be careful during the
repair process to avoid other parts damaged.
——提供者：宋红星 Service engineer: Song Hong Xing
- 422 -
06、回转支承间隙过大 Swing beraing has excessive clearance
故障现象：旋挖钻机工作时桅杆晃动，使旋挖钻头无法定位开孔。
Symptom: Drilling rod of the rotary drill shakes which causes the drill can not located on the hole.
故障分析：1、桅杆与连杆销轴间隙大，连杆与平台销轴间隙大；
2、回转支承内部磨损，轴向间隙大。
Failure analysis:
1. Clearance between the drilling rod and linkage is excessive. Clearance between the linkage and upper
structure is excessive.
2. Swing bearing is worn, which causes excessive axial clearance.
故障原因：回转支承轴向间隙大。
Root cause of the failure: Swing bearing has excessive axial clearance.
排故方法：1、检查旋挖钻机桅杆，油缸等连接部位销轴间隙正常，钻头工作正常；
2、在开孔定位时上车部分有点头现象，定位后加压垂直角度有偏移，检
查回转支承部位有5毫米明显的轴向间隙；
3、更换回转支承总成，故障现象消除。
Troubleshooting:
1. Checked and found the pin clearance of the drilling rod and cylinders are normal. Drill is connectly
properly and works normally.
2. The upper structure nods when machine starts to drill a hole. The drilling rod shakes in a small angle
during the work. Measured swing bearing axial clearance is 5mm which is obvious.
3. Replace the swing bearing assembly, tested and proved problem solved.
排故体会：挖机底盘做旋挖钻，旋挖钻整车重量要比挖机重1倍，上车架重量要相差
2倍左右，所以对回转支承之类的关键部件要采用加强件。
Experience: Rotary drill is based on t he hex chassis. The weight of rotary drill is two times of hex, and
the weight of rotary drill upper structure is three times of hex. Swing bearing should be strengthened.
——提供者：邵锏波 Service engineer: Shao Jian Bo
- 423 -
07、动臂与平台连接销处间隙过大。Clearance between boom and platform is excessive
故障现象：动臂异响。
Symptom: Boom has abnormal noise.
故障分析：整机工作300小时左右，动臂与平台间、动臂油缸与平台间调整隔垫损坏，
导致间隙过大，工作时动臂轴向摆动，产生异响。
Failure analysis: Boom root shims and boom cylinder root shims are damaged when the working hour is
about 300H, which causes excessive clearance. Boom shakes during the work and has abnormal noise.
故障原因：新机出厂时，工厂使用的调整隔垫为塑胶调整隔垫，不耐磨、易损坏。
Root cause of failure: Resin shims are used in new machine which is not anti-wear and easy damaged.
排故方法：1、检查动臂与平台间连接销是否正常；
2、检查动臂油缸与与平台连接销是否正常；
3、检查该两地方销垫是否异常，有磨损现象；
4、更换钢件调整隔垫片。
Troubleshooting:
1. Check the boom root pin is normal or not.
2. Check the boom cylinder root pins are normal or not.
3. Checked and found boom root shims and boom cylinder root shims are worn.
4. Replace with the steel shims. Tested and proved problem solved.
排故体会：建议在新机装配时，该部位使用钢件调整隔垫片。
Experience: Steel shime is suggested to be used on the new machine.
- 424 -
08、张紧油缸打不进黄油 Grease can not be pumped into track tension cylinder
故障现象：SY230 挖机在工作 1500 小时后，履带松弛，张紧油缸打不进黄油。

Symptom: SY230 track can’t be tensioned at 1500H. Grease can’t be pumped into track tension cylinder.
故障分析：
1、没有按时的更换黄油；
2、张紧油缸生锈；
3、黄油阀损坏；
4、使用劣质黄油。
Failure analysis:
1. Grease is not changed according to maintenance interval.
2. Track tension cylinder is rusted.
3. Grease valve is failed.
4. Poor quality grease is used.
故障原因：使用劣质黄油，造成黄油干裂凝固。
Root cause of the failure: Poor quality grease is used, which is found dried and hardened.
排故过程：
1、检查发现黄油阀完好；
2、检查发现张紧油缸完好；
3、检查是否因为黄油时间太长，粘度下降，干裂凝固导致黄油道堵塞，从
而打不进黄油，检查结果正常；
4、经检查客户使用劣质黄油，导致黄油管路不畅通。
5、清洗张紧油缸，更换成三一指定的黄油，故障排除。
Troubleshooting:
1. Checked and found the grease valve is normal.
2. Checked and found the track tension cylinder is normal.
- 425 -
3. Whether the grease is not changed for a long time, which casues it dried and blocked the grease
passage. It is found that this is not the root cause of the failure.
4. Checked and found the poor quality grease is used, which causes the grease passage blocked.
5. Clean t he parts o f t rack tension cylinder, replace related seals, and replace w ith t he S any specified
grease. Tested and proved problem solved.
排故体会：新机交机时1定要向客户交代使用什么样的油品和保养件，操作手要不定
期的检查各润滑件及管路的畅通情况。
Experience: Service engineer should instruct end user or operator using Sany genuine pa rts o r S any
specified parts to do the maintenance during the new machine delivery. Operator should inspect the
grease lubrication as required.
——提供者:永恒利 Service engineer: Yong Heng Li
- 426 -
09、动臂上升、下降出现抖动、发涩 Boom operation has interference
故障现象：1、动臂提升的时候，平台耳板（靠驾驶室）往外涨；
2、斗杆油缸档板螺栓断裂；
3、动臂上升、下降出现抖动、发涩现象（热机时明显）。
Symptom:
1. Boom root pin bore plate of the upper structure deformed toward the cab when boom up operated.
2. Stick cylinder pin bolt is broken.
3. Machine vibrated during boom up and boom down operation, especially after machine is warmed up.
故障分析：1、可能是平台底座不同心导致；
2、轴向间隙或径向间隙过大引起；
3、轴与轴套之间的间隙过小；
4、油缸挡板与固定支座不平行，导致挡板螺栓断裂；
5、油缸排不出气，动臂阀芯发卡或出现拉痕；
6、动臂节流阀堵，压力传感器受损。
Failure analysis:
1. Two boom root pin bores of the upper structure are not aligned.
2. Axial clearance or radial clearance is excessive.
3. Clearance between the boom root pin and boom root sleeve is small excessively.
4. Cylinder pin plate is not paralleled to its base, which causes the pin bolt broken.
5. Boom cylinder fails to bleed air. Boom valve spool seized or scratched.
6. Boom holding valve is blocked. Pilot pressure sensor is failed. Bolt is broken
故障原因：1、轴向间隙与径向间隙过大，引起平台耳
板造成弹性变形；
2、档板支座不平行，工作时，径向受力过大导致螺栓断裂；
3、阀芯发卡，转速与电压值不对。
- 427 -
Root cause of failure:
1. Axial and radial clearance is excessive, which causes the bore plate of upper structure deformed.
2. Two bases of cylinder pin bolt is not paralleled, excessive radial force causes the bolt broken.
3. Valve spool seized. Engine speed and voltage is incorrect.
排故方法：1、测量的间隙不在正常范围内。更换轴与轴套，调整双边间隙；
2、检查挡板与固定支座是否同 1 平行线上，更换销轴，挡板螺栓加垫；
3、抽出回油滤芯看是否有密封杂质；
4、测试先导压力在 37 公斤；
5、标定转速、去掉动臂节流阀；
6、更换先导压力传感器； Boom sleeve
7、电控改液控，清洗阀。
Troubleshooting:
1. Measured clearance is abnormal. Replace boom root pin and boom sleeve. Adjust the axial clearance.
2. Make sure the plate is paralleled to its base. Replace cylinder pin, replace bolts and washer.
3. Pull out the hydraulic return oil filter to check whether there is damaged seal or not.
4. Measured pilot oil pressure is 37kg.
5. Calibrate engine speed. Clean the boom holding valve.
6. Replace the pilot pressure sensor.
7. Set the machine under hydraulic control mode, and clean boom valve spool.
排故体会：仔细观察、加强学习理论、工作原理、加强实践。目前动臂油缸抖动、
发涩轻微直至正常，还需观察跟踪！
Experience: Inspect carefully. Study hard to grasp system operation and get much more exercise. After
repairing, there is a very slight vibration during boom operation. Need to follow up continually.
—— 提供者:张志辉 Service engineer: Zhang Zhi Hui
- 428 -
10、330设备大臂销轴异响 330 Boom pin has abnormal noise
故障现象：大臂销轴异响。
Symptom: Boom boom has abnormal noise.
故障分析：1、没有使用纯正的黄油；
2、没有按时打黄油；黄油嘴是否堵死；
3、销轴轴套是有问题。
Failure analysis:
1. Genuine grease is not used.
2. Boom pin not lubricated timely. Grease fitting is blocked or not.
3. Boom pin and sleeve are failed.
排故过程：1、检查客户使用是否时公司所规定的黄油；
2、询问挖机操作手是否按时打黄油；检查黄油嘴是否堵死；
3、拆下轴套检查是否磨损。
4、经检查为操作手没有定期打黄油，更换销轴，故障排除。
Troubleshooting:
1. Whether the Sany specified grease is used by the user.
2. Whether the pin is grease lubricated timely or not. Grease fitting is failed or not.
3. Boom pin sleeve is worn or not.
4. Checked and found the pin is not grease lubricated timely. Replace the pin, problem solved.
排故体会:此类问题应首先询问是否操作手定期打了黄油，是否用了纯正的黄油，黄
油嘴是否堵塞等问题。
Experience: About t his ki nd of f ailure, s ervice e ngineer s hould e nquiry operator m aintenance record,
genuine grease used or not, the grease fitting is blocked or not, and so on.
——提供者：李茂明 Service engineer: Li Mao Ming
- 429 -
11、挖机回转时异响 Excavator has abnormal noise during swing operation
故障现象： 1台SY215样机，挖机回转时发生“碰碰”异常响声。
Symptom: Not sold new machine SY215 has abnormal impacting noise when machine swings.
故障分析：根据响声可以从以下几方面来考虑:
1、整机部件以及挖机底盖板附件松动；
2、动臂根部销轴、油缸销轴与轴套之间的间隙过大以及润滑不良；
3、回转马达与减速机故障引起回转异响；
4、回转支承故障引起回转异响；
5、上车架平台平行度超差导致回转支承损坏，引起回转异响。
Failure analysis: Troubleshoot in following aspects as per the abnormal noise.
1. Bottom cover of the upper structure or engine is loosed.
2. Boom root pin or cylinder pin has excessive clearance with its sleeve caused by poort lubrication.
3. Swing motor or swing drive failure, which causes the abnormal swing noise.
4. Swing bearing fails and causes the abnormal swing noise.
5. Parallelism degree of the upper frame is excessive, causes swing bearing failed and abnormal noise.
故障原因：检查回转齿轮油，松动回转马达减速机底座与平台连接螺栓，启机回转
异响未改变；将回转马达与减速机总成与上车平台分离，用手推铲斗带
动回转支承转动，回转异响存在，说明此故障点为回转支承损坏。
Cause of the failure:
1. Inspect the gear oil of swing drive. Loose the installation bolts of the swing assembly, tested and
found problem s till existed. Remove the swing assembly. Push the bucket to make upper structure
rotate and abnormal noise still existed. It means the abnormal noise is caused by failed swing bearing.
排故方法：
1、查看整机部件以及挖机底盖板无松动现象，正常；
2、检查销轴与轴套之间的间隙以及润滑情况，正常；
- 430 -
3、检查回转马达与减速机：
a、回转马达减速机油位和油质正常；
b、回转马达底座与平台连接处螺栓紧固情况，正常；
c、减速机驱动轴齿轮磨损以及与回转支承齿轮啮合时发生的异常响声；
d、减速机驱动轴球轴承损坏；
4、检查回转支承故障；
a、查看回转支承齿轮是否损坏；
b、查看回转支承球轴承是否损坏；
5、检查上车架平台平行度是否超差，导致回转支承损坏，引起回转异响。
Troubleshooting:
1. Checked and found bottom covers of upper structure and engine are normal.
2. Checked and found clearance between pins and sleeves is normal. Pins are lubricated normally.
3. Inspect swing motor and swing drive:
A. Oil level and oil quality of the swing drive are normal.
B. Installation bolts of the swing assembly are tightened properly.
C. Shaft gear of swing drive is worn or not. Whether the abnormal noise is caused by it or not.
D. Bearing of the swing drive shaft is worn or not.
4. Inspect the swing bearing:
A. Ring gear of the swing bearing is damaged or not.
B. Ball bearing of the swing bearing is failed or not.
5. Whether the parallelism degree of the upper structure is out of specification, causes swing bearing
failed and abnormal swing noise.
排故体会：采用排除法排故，先易后难，减少故障处理时间。
Experience: Easy first and then difficult. Troubleshoot step by step to reduce the service time.
- 431 -
12、驾驶室晃动 Cab vibrates severely
故障现象：多台09年SY75或65型挖掘机用户，架驶室抖动严重。
Symptom: Several users of SY75 or SY65 made in 2009 complain that cab shakes severely.
故障分析：在挖机的驾驶室与上车体之间安装有减震垫，用以减低挖机工作时产生
的震动，提高驾驶员的操作舒适性。出现异常抖动主要因为减震效果不好
或者产生的震动量太大。
Failure an alysis: Vibration da mper i s i nstalled between t he cab and t he upper structure t o r educe t he
vibration during the work, and improve the comfort of the operator.
故障原因：1、发动机运转时震动量大，发动机减震垫损坏；
2、驾驶室减震垫损坏；
3、驾驶室固定螺栓未紧固；
4、驾驶室没有成水平状态安装，各支点位置高低不平。
排故方法：1、启动机器，发动机工作时，无异常抖动，工作平稳；
2、推动驾驶室，驾驶室各点减震无异常；
3、检查驾驶室固定螺栓和发动机固定螺栓均正常；
4、发动机器后操作挖机，观察到驾驶室相对车身的位移量大，拆卸驾驶
室底板，发现驾驶室左前脚减震垫上装着约6毫米厚的钢垫片，而其
他三个减震垫上没有装，重新调整垫片后试车，故障排除。
排故体会：驾驶室是通过减震垫与上车体连接的，由于驾驶室未水平装好，机器在
不平整的地面上工作时才会出现，故我们解决故障时要结合客户工作时的
状况来分析故障原因，才能更快的处理好故障。
----提供者：合肥湘元
- 432 -
12、驾驶室晃动 Cab vibrates severely
故障现象：多台09年SY75或65型挖掘机用户，架驶室抖动严重。
Symptom: Several users of SY75 or SY65 made in 2009 complain that cab shakes severely.
故障分析：在挖机的驾驶室与上车体之间安装有减震垫，用以减低挖机工作时产生
的震动，提高驾驶员的操作舒适性。出现异常抖动主要因为减震效果不好
或者产生的震动量太大。
Failure analysis: Vibration damper is installed between the cab and the upper structure to reduce the
vibration during the work, and improve the comfort of the operator.
故障原因：1、发动机运转时震动量大，发动机减震垫损坏；
2、驾驶室减震垫损坏；
3、驾驶室固定螺栓未紧固；
4、驾驶室没有成水平状态安装，各支点位置高低不平。
Probalbe cause of the failure:
1. Engine support cushion is damaged due to excessive vibration when engine is running.
2. Cab support cushion is damaged.
3. Mounting bolts of the cab is loosed.
4. Cab is installed improperly.
排故方法：1、启动机器，发动机工作时，无异常抖动，工作平稳；
2、推动驾驶室，驾驶室各点减震无异常；
3、检查驾驶室固定螺栓和发动机固定螺栓均正常；
4、发动机器后操作挖机，观察到驾驶室相对车身的位移量大，拆卸驾驶
室底板，发现驾驶室左前脚减震垫上装着约6毫米厚的钢垫片，而其
他3个减震垫上没有装。
5、重新调整垫片后试车，故障排除。
Troubleshooting:
- 432 -
1. Checked and found no abnormal vibration when engine is running.
2. Push the cab manually, and found the cab cushion is normal.
3. Checked and found the mounting bolts of cab are tightened properly.
4. Double check and found the cab has excessive displacement when the machine is operated. Remove
the bottom plate of the cab. It is found there is a 6mm steel plate installed between the cab and the left
front cushion while other three cushions have not.
5. Remove the steel plate of the left front cushion, tested and proved problem solved.
排故体会：驾驶室是通过减震垫与上车体连接的，由于驾驶室未水平装好，机器在
不平整的地面上工作时才会出现，故我们解决故障时要结合客户工作时的
状况来分析故障原因，才能更快的处理好故障。
Experience: Cab is installed on the upper structure with cushion to reduce vibration. If the cab is not
installed at the same level, it will vibrate when machine is operated on the uneven ground. Therefore,
service engineer should grasp the detailed failure phenomena so as to solve the problem quickly.
----提供者：合肥湘元 Service engineer: He Fei Xiang Yuan
- 433 -

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Quality Changes the World

International Service Department of Sany Heavy Machinery Ltd

第一节 液压系统 Hydraulic System……...…………...……………………………………….……- 8 -

第二节 电气系统 Electrical system .............................................................................................- 169 -

第三节 发动机 Engine ........................................................................................................................- 317 -

第四节 空调系统 Air conditioning system .................................................................- 401 -

01、空调制冷不良 A/C has a poor refrigeration ............................................................................................................. - 401 -

第五节 操作保养 Operation and maintenance ...........................................................- 413 -

01、动臂销轴异响 Boom root pin has abnormal noise .................................................................................................. - 413 -

第六节 结构件 Structure .............................................................................................................- 417 -

01、托链轮漏油 Carrier roller leaks oil .......................................................................................................................... - 417 -

01、整车突然没动作 Machine has no action suddenly

——提供者：刘志刚 Service engineer: Liu Zhi Gang

——提供者：刘志刚 Service engineer: Liu Zhi Gang

——提供者：张小飞 Service engineer: Zhang Xiao Fei

3、测量回转溢流压力为 255 公斤左右--不正常--偏低，将溢流阀压力调

4、测量回转刹车解除 SH 口压力为 Disc of swing

——提供者：刘志刚 Service engineer: Liu Zhi Gang

故障现象：一 台 SY215C8M 型挖掘机，单独左行走或回转时动作速度慢，做复合动作

过仔细分析液压系统原理图，如主控制阀 CSP 单向阀卡在常通位置，就

故障原因：主控阀 CSP 单向阀卡在常通位置。

排故方法：1、测量主溢流压力为 348 公斤，先导压力为 38 公斤--正常；

4、拆检 CSP 单向阀发现卡在常通位置，无法关闭。对主控阀 CSP 单向

左侧主控阀平行油道的液压油可以经 CSP 单向阀供给中心油道。当单

独做左行走或回转动作时 P1 泵既向左行走或回转供油，又由 CSP 单

同时与斗杆或铲斗动作时，由 CSP 单向阀供给中心油道的油被切断无

Fig 1：CSP checke valve Fig 2：CSP check valve

——提供者：唐子光、刘志刚 Service engnineer: Tang Zi Guang, Liu Zhi Gang

——提供者： 刘志刚 Service engineer: Liu Zhi Gang

故障现象：一 台 SY210 型负流量机器，更换主泵，主控制阀后出现小臂回收外扬动作

中位时约 38 公斤，阀芯全行程操作时 1 - 5 公斤。

900mA 左右,手柄全行程操作时电流值为 350mA 左右--正常，将前后

泵比例电磁阀线束 503、504 互换后试机，故障依然存在，证明比例

——提供者：刘志刚 Service engineer: Liu Zhi Gang

故障现象：一 台 07 年 SY210 负流量机器，铲斗在单独动作和复合动作时速度都慢，

the bucket operation performed poorly.

——提供者：刘志刚 Service engineer: Liu Zhi Gang

排故过程：1、通过监控器发现发动机的最高转速 2100 左右(因挖机时间过长,所以

5、拆卸大臂 2 阀芯,大臂 1 主阀芯均无异常.

——提供者：李纪平 Service engineer: Li Ji Ping

故障原因：1、负压传感器故障； Pump adjuster Servo piston of

——提供者：张小亮 Service engineer: Zhang Xiao Liang

故障现象：一 台 SY200C 型负流量机器，在向右回转后，停止转动时出现回转自动滑

不会只出现右回转时异响，故可 Makeup check valve

排除主控制阀故障。 Makeup check valve is

——提供者：刘志刚 Service engineer: Liu Zhi Gang

2、测量先导作业切断开关处 0.85Y 线端电压 24V 正常，电阻 NO-C 断开

3、测量先导作业切断电磁阀处 0.85YG 线端电压 24V 正常，线圈两端电

——提供者：伍锡斌 Service engineer: Wu Xi Bin

故障现象： SY230C8B 启动后动臂自动上升、无法下降。

Root cause of the failure: Boom valve core is choked.

2. Check boom valve cores and core No.1 is found to be choked.

——提供者：张会龙 Service engineer: Zhang Hui Long

Symptom: Here is one unit of SY360C excavator, which has no actions.

2. Oil absorption filter is blocked.

3. Engine coupling is damaged (e.g. plastic plate, flexible plate).

4. Main pump damaged.

5. Servo system pressure is too low or has no pressure.

3. Engine coupling is damaged (e.g. plastic plate, flexible plate).Replace coupling.

2. Check the hydraulic pump, which is found to be damaged.

第一节液压系统 Hydraulic System……...…………...……………………………………….……- 8 -

第二节电气系统 Electrical system .............................................................................................- 169 -

第三节发动机 Engine ........................................................................................................................- 317 -

第四节空调系统 Air conditioning system .................................................................- 401 -

第五节操作保养 Operation and maintenance ...........................................................- 413 -

第六节结构件 Structure .............................................................................................................- 417 -

故障现象：一台 SY215C8M 型挖掘机，单独左行走或回转时动作速度慢，做复合动作

——提供者：刘志刚 Service engineer: Liu Zhi Gang

故障现象：一台 SY210 型负流量机器，更换主泵，主控制阀后出现小臂回收外扬动作

故障现象：一台 07 年 SY210 负流量机器，铲斗在单独动作和复合动作时速度都慢，

故障现象：一台 SY200C 型负流量机器，在向右回转后，停止转动时出现回转自动滑

故障现象：一台 SY210C 挖掘机发动机启动困难，工作时冒黑烟严重，动作慢（工作

排故体会：同样的情况出现在另一台 230C-8 的机器上，很快能排除，这就需要积

——提供者：周书良 Service engineer: Zhou Shu Liang

故障现象：一台 SY65C 挖掘机在工地满负荷工作时突然发生整车无动作故障。

故障现象：一台 SY330 挖掘机，冷车时其工作正常，热车时其憋车、冒黑烟。

排故方法： 1、工作时会一直存在，不分冷车、热车，所以首先排除电气和涡轮增

出现憋车，检查油路并用凉水对图:含有杂质的滤芯 Picture: Filter with impurities

排除方法： 1、.检查行走先导控制油路有无额定压力，压力值正常；

故障现象：一台 SY215 直线前行时会向左转弯,有跑偏现象。

故障现象：一台 SY230 挖掘机行走严重跑偏，在脚踏先导阀同样行程时，行走时转

3、测量两侧行走马达压力，一侧压力为 28Mpa,另一侧为 34Mpa,即可排除单边单