Sumitomo SH210-5 SH240-5 Engine Type 4HK1 Excavator Troubleshooting Manual – PDF DOWNLOAD
DESCRIPTION:
Sumitomo SH210-5 SH240-5 Engine Type 4HK1 Excavator Troubleshooting Manual – PDF DOWNLOAD
Introduction
This Troubleshooting Manual explains troubleshooting of the engine electronic control fuel injection system (common rail type) and main unit of the hydraulic excavator equipped with 4HK1 type engine (SH210/240-5).
Extensive use of this manual is useful for performing accurate and quick maintenance procedures.
TABLE OF CONTENTS:
Sumitomo SH210-5 SH240-5 Engine Type 4HK1 Excavator Troubleshooting Manual – PDF DOWNLOAD
Reading Flow Charts 1
Diagnostic Trouble Code Number and Problem1
Abbreviation Table 2
About Wiring Colors 3
Reading Block Diagrams 4
Reading Trouble Diagnosis 6
Cautions for Maintenance 12
Electrical System 12
Fuel Injection System 12
How to Proceed with Trouble Diagnosis 13
Trouble Diagnosis Procedure 13
Inquiry 14
Preliminary Inspection 16
Trouble Diagnosis 16
Terminology explanation 17
Diagnostic Trouble Code Reading Procedure 18
Confirmation after Repair 19
Injector Inspection Methods Using A Thermogun 20
Judgment through temperature measurement 20
Sorting Methods Using Noncontact Infrared Thermometer 27
Breaker box connection method 28
Engine Control System 31
Engine Control (common rail) System Functions and Operation Explanation 31
Engine Control Module (ECM) 37
Engine Component Parts Layout Diagram 39
Engine Control Module (ECM) Wiring Diagram 53
Engine Control Module (ECM) Pin Layout 54
Engine Harness Routing Diagram 67
Function Inspection List 75
Function Inspection List 75
Trouble Diagnosis by Service Support 76
Checking the Start Circuit System 77
Checking the Start System 81
Checking the Fuel System 83
Checking the Suction Air System 85
Checking the Exhaust System 86
Checking the EGR Control System 87
Engine-side Trouble 89
Engine-side DTC List 89
Trouble Recovery 97
Screen Display Details 98
Abnormality Display 100
DTC: 0087 Abnormally Low Common Rail Pressure (supply pump not sending pressure) 101
DTC: 0088 Abnormally High Common Rail Pressure (1st stage or 2nd stage) 107
DTC: 0089 Common Rail Pressure Abnormality (supply pump sending too much pressure) 110
DTC: 0090 SCV (suction control valve) Drive System Disconnection, +B Short, or GND Short 114
DTC: 0107 Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage) 119
DTC: 0108 Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage) 125
DTC: 0112 IAT (intake air temperature) Sensor Abnormality (abnormally low voltage) 130
DTC: 0113 IAT (intake air temperature) Sensor Abnormality (abnormally high voltage) 136
2
3 RST-10-00-004EN
Trubleshoot
DTC: 0117 ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) 142
DTC: 0118 ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage) 149
DTC: 0182 FT (fuel temperature) Sensor Abnormality (abnormally low voltage) 156
DTC: 0183 FT (fuel temperature) Sensor Abnormality (abnormally high voltage) 163
DTC: 0192 Common Rail Pressure Sensor Abnormality (abnormally low voltage) 170
DTC: 0193 Common Rail Pressure Sensor Abnormality (abnormally high voltage) 176
DTC: 0201 No 1 Cylinder Injector Drive System Disconnection 182
DTC: 0202 No 2 Cylinder Injector Drive System Disconnection 187
DTC: 0203 No 3 Cylinder Injector Drive System Disconnection 192
DTC: 0204 No 4 Cylinder Injector Drive System Disconnection 197
DTC: 0219 Overrun 202
DTC: 0237 Boost Pressure Sensor Abnormality (abnormally low voltage) 204
DTC: 0238 Boost Pressure Sensor Abnormality (abnormally high voltage) 209
DTC: 0335 CKP (crank position) Sensor Abnormality (no signal) 214
DTC: 0336 CKP (crank position) Sensor Abnormality (signal abnormality) 219
DTC: 0340 CMP (cam position) Sensor Abnormality (no signal) 224
DTC: 0341 CMP (cam position) Sensor Abnormality (signal abnormality) 229
DTC: 0380 Glow Relay Circuit Abnormality 234
DTC: 0487 EGR Position Sensor Abnormality 239
DTC: 0488 EGR Valve Control Abnormality 244
DTC: 0522 Engine Oil Pressure Sensor Abnormality (abnormally low voltage) 249
DTC: 0523 Engine Oil Pressure Sensor Abnormality (abnormally high voltage) 254
DTC: 0601 ROM Abnormality 260
DTC: 0603 EEPROM Abnormality 261
DTC: 0606 CPU Abnormality 262
DTC: 0611 Charge Circuit Abnormality (bank 1) 263
DTC: 0612 Charge Circuit Abnormality (bank 2) 265
DTC: 1093 No Pump Pressure Send 267
DTC: 1095 Pressure Limiter Open 273
DTC: 1112 Boost Temperature Sensor Abnormality (abnormally low voltage) 280
DTC: 1113 Boost Temperature Sensor Abnormality (abnormally high voltage) 286
DTC: 1173 Overheat 291
DTC: 1261 Injector Common 1 Drive System Abnormality 296
DTC: 1262 Injector Common 2 Drive System Abnormality 303
DTC: 1345 CMP (cam position) Sensor Out of Phase 310
DTC: 1625 Main Relay System Abnormality 312
DTC: 1630 A/D Conversion Abnormality 318
DTC: 1632 5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) 319
DTC: 1633 5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) 321
DTC: 1634 5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) 324
DTC: 1635 5 V Power Supply 5 Voltage Abnormality
(common rail pressure sensor, EGR position sensor power supply) 326
DTC: 2104 CAN Bus Abnormality 329
DTC: 2106 CAN Time-out Abnormality 333
Main Unit-side Trouble 337
Main Unit-side DTC List 337
DTC: 7000 P1 Pressure Sensor Signal Abnormality 340
DTC: 7001 P2 Pressure Sensor Signal Abnormality 342
DTC: 7002 N1 Pressure Sensor Signal Abnormality 344
DTC: 7003 N2 Pressure Sensor Signal Abnormality 346
DTC: 7004 Overload Pressure Sensor Signal Abnormality 348
DTC: 7005 Bottom Pressure Sensor Signal Abnormality 350
3
RST-10-00-004EN 4
Trubleshoot
DTC: 7006 Rod Pressure Sensor Signal Abnormality 352
DTC: 7020 Upper Pressure Sensor Signal Abnormality 354
DTC: 7021 Swing Pressure Sensor Signal Abnormality 356
DTC: 7022 Travel Pressure Sensor Signal Abnormality 358
DTC: 7040 Fuel Level Sensor Signal Abnormality 360
DTC: 7041 Oil Temperature Sensor Signal Abnormality 362
DTC: 7045 Monitor Thermistor Signal Abnormality 364
DTC: 7060 Boom Angle Sensor Signal Abnormality 365
DTC: 7061 Arm Angle Sensor Signal Abnormality 367
DTC: 7063 Return Filter Clogging Pressure Switch Signal Abnormality 369
DTC: 7200 Swing Brake Solenoid Signal Abnormality 373
DTC: 7201 Travel High-speed Solenoid Signal Abnormality 375
DTC: 7202 Pressure Boost Solenoid Signal Abnormality 377
DTC: 7203 Travel Alarm Buzzer Signal Abnormality 380
DTC: 7204 Power save solenoid signal fault 382
DTC: 7209 Air Conditioner Coolant Temperature Signal Abnormality 384
DTC: 7210 Liftcrane Buzzer Signal Abnormality 385
DTC: 7211 Rotating Light, Bucket Lock Signal Abnormality 388
DTC: 7240 Pump Horsepower Proportional Valve Signal Abnormality 390
DTC: 7241 P1 Flow Control Proportional Valve Signal Abnormality 393
DTC: 7400 Abnormally High Coolant Temperature (105 ℃ or higher)
7402 Abnormally High Coolant Temperature (110 ℃ or higher)
7403 Abnormally High Coolant Temperature (120 ℃ or higher) 396
DTC: 7404 Abnormally High Oil Temperature (95 ℃ or higher) 397
DTC: 7405 Abnormally High Boost Temperature (80 ℃ or higher)
7406 Abnormally High Boost Temperature (90 ℃ or higher) 398
DTC: 7420 Abnormally Low Alternator Voltage 399
DTC: 7421 Coolant Level Reduction 401
DTC: 7422 Abnormally Low Engine Oil Pressure 402
DTC: 7423 Air Cleaner Clogging 403
DTC: 7424 Return Filter Clogging (breaker specifications) 405
DTC: 7600 CAN Bus Abnormality 406
DTC: 7601 Monitor Communication Abnormality 408
DTC: 7602 ECM Communication Abnormality 409
DTC: 7603 Computer B Communication Abnormality 410
DTC: 7604 Computer S Communication Abnormality 411
DTC: 7605 ECM Mismatch 412
DTC: 7606 EEPROM Data Abnormality 413
Problem Symptom List 414
Problem Symptom List 414
Engine Start Problem 415
Engine Stalling 418
Engine Hunting, Rough Idling 421
Engine Output Deficiency 424
Excessive White Smoke in Exhaust Gas 427
Excessive Black Smoke in Exhaust Gas 429
Abnormal Noise 431
High Fuel Consumption 433
High Oil Consumption 436
Tech 2 Data Reference Values 438
Unit Conversion Ratio 439
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