Sumitomo SH210LC-5 SH210LC-5LR Excavator Service Text Manual WLST2105-02W – PDF DOWNLOAD
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Sumitomo SH210LC-5 SH210LC-5LR Excavator Service Text Manual WLST2105-02W – PDF DOWNLOAD
Language : English
Pages : 666
Downloadable : Yes
File Type : PDF
Size: 100 MB
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TABLE OF CONTENTS:
Sumitomo SH210LC-5 SH210LC-5LR Excavator Service Text Manual WLST2105-02W – PDF DOWNLOAD
Main Body Section
Changes from Model 3
Overall Specifications 1
1 Specifications Comparison Table 1
2 Performance Improvements 4
Hydraulic-related Changes 5
1 Use of High-performance Return Filter
(nephron filter and breaker filter eliminated) 5
2 Use of Add-on Valve 7
3 Multi Purpose Circuit Switched to One-touch Operation
(breaker ⇔ crusher) 8
Hydraulic Pump 9
1 Hydraulic Pump Changes 9
2 Appearance Changes 9
3 Circuit Changes 9
4 Reduced Flow Force 10
5 Straight Travel Valve 11
6 Heat Circuit 12
Lower-section Related Changes 14
1 Center Joint Installation Section Notch Dimensions 14
2 Grease Bath Seal 14
3 Center Joint Rotation Stopper Installation Surface 14
4 Lower Roller 15
5 Upper Roller 16
6 Track Guard 16
Cab-related Changes 17
1 Cab Shape 17
2 Irregularly Shaped Steel Line Structure 17
3 Beefed Up Equipment 18
4 Interior Equipment 19
5 Front Window Lock Mechanism 22
Upper Swing Body Changes 23
1 High-rigidity Platform 23
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Contents
Attachment Changes 24
1 Boom 24
2 Arm 25
3 Coupler Pin Fastening 26
4 Line Clamp 26
5 Bucket Edge Bushing 26
6 Use of Plastic Shims 26
7 Reduced Boom Foot Section Play 26
Attachment Plate Thickness Comparison Table 27
Boom 27
Arm 27
ROPS Judgment Method
ROPS Judgment Method 28
Specifications
Overall 30
1 Main Data 30
2 Performance 30
3 Main Body Dimensions 30
4 Engine 31
5 Cooling System 31
6 Upper Side Work System 32
7 Operating Device 33
8 Swing Units 34
9 Travel Lower Body 34
Hydraulic Equipment 34
1 Hydraulic Device 34
2 Control Valve, Cylinder 35
Capacities, Filters 35
1 Coolant and Oil Capacities 35
2 Hydraulic Oil Filters 35
3 Fuel Filter 35
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator 36
Lifting Capacities 37
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Overall View
Overall View (SH210-5 / SH210LC-5) 44
1 Standard Arm (2 94 m) 44
2 Short Arm (2 40 m) 44
Overall View (SH240-5) 45
1 Standard Arm (3 00 m) 45
2 Short Arm (2 50 m) 45
3 Long Arm (3 52 m) 46
Work Range Diagram
Work Range Diagram (SH210-5 / SH210LC-5) 47
1 Standard Arm (2 94 m) 47
2 Short Arm (2 40 m) 48
Work Range Diagram (SH240-5) 49
1 Standard Arm (3 00 m) 49
2 Short Arm (2 50 m) 50
3 Long Arm (3 52 m) 51
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Summary Section
Main Equipment Table
Lower Component 1
1 Travel Unit 1
2 Take-up Roller 1
3 Upper Roller 1
4 Lower Roller 1
5 Recoil Spring 2
6 Shoe 2
Upper Component 3
1 Swing Unit 3
Engine-related 4
1 Engine 4
2 Muffler 5
3 Air Cleaner (double element) 5
4 Radiator 5
Hydraulic Device 6
1 Hydraulic Pump 6
2 Pump P-Q Diagram 7
Control-related 9
1 Control Valve 9
2 Solenoid Valve (5 stack) 9
3 Remote Control Valve (left/right, travel operations) 10
4 Remote Control Valve Characteristic Diagram 11
5 Cushion Valve (heat circuit, with shuttle valve) 12
6 Center Joint 12
Backhoe Attachment 13
1 Cylinder 13
2 Attachments 14
Equipment Layout Diagram
Main Equipment Layout 15
Consumable Part Layout 16
Standard Machine Option List
List of Optional Components 17
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Hydraulics Section
Hydraulic Equipment Layout
Overall View 1
Pump Chamber Hydraulic Equipment Layout 2
Swing Body Center Section Hydraulic Equipment Layout 3
Housing Left Side Hydraulic Equipment Layout 4
Layout of Hydraulic Equipment in Cab 5
Port Diagram
Pump 6
1 Hydraulic Pump (standard model) 6
Valves 7
1 Control Valve 7
2 5 Stack Solenoid Valve 10
3 2 Stack Solenoid Valve 11
4 Remote Control Valves (upper, travel) 12
5 Cushion Valve 13
6 3-direction Valve / Shut-off Valve (Option) 14
7 HBCV (Option) 15
Manifolds 16
1 Manifold Under Cab 16
2 Manifold (accumulator section) 16
3 Manifold (hydraulic oil tank section) 17
Motors 18
1 Swing Motor 18
2 Travel Motor 20
3 Center Joint 21
Pilot Hose Connection Diagram
Pilot P and T Lines 22
Pilot Control Line 24
Function List
Function Table 26
Explanation of New Functions 28
1 Swing Relief Cut-off Control 28
2 Swing Speed Limit Control 30
3 Negative Control Power Save Control 31
4 Option Line Flow Adjustment Control 32
5 Multi Purpose Circuit (breaker ⇔ crusher) One-touch Switching Control 33
6 Bucket-close Regenerative Circuit 34
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Contents
Explanation of Hydraulic Circuit and Operations (standard model)
Travel Circuit 35
Travel Low-speed Circuit 35
Travel High-speed Circuit 37
Straight Travel Circuit (with / without HBCV) 39
Swing Circuit 42
Swing Speed Limit Control Circuit 42
Swing Relief Cut-off Control Circuit 44
Swing Priority Circuit (with / without HBCV) 46
Swing Brake Circuit 49
Swing Parking Circuit (lever in neutral) 51
Swing Parking Circuit (brake release) 53
Swing Parking Circuit (machine stop) 55
Boom Circuit 57
Boom-up Circuit (single operation) 57
Boom-up Circuit (single operation) (with HBCV) (Option) 59
Boom-up Circuit (compound boom-up + arm-in) (with / without HBCV) 61
Boom-down Regenerative Circuit (without HBCV) 64
Boom-down Regenerative Circuit (with HBCV) (Option) 66
Boom-down Tilting Prevention Circuit (with / without HBCV) 68
Boom-down Load Hold Valve Circuit (with / without HBCV) 71
Arm Circuit 74
Arm-out Circuit (with / without HBCV) 74
Arm-in Forced Regenerative Circuit (with / without HBCV) 77
Arm-in Load Hold Valve Circuit (without HBCV) 80
Arm-in Load Hold Valve Circuit (with HBCV) (Option) 82
Bucket Circuit 84
Bucket-open Circuit 84
Bucket-close Regenerative Circuit 86
Negative Control Circuit 88
Negative Control Circuit (power save solenoid OFF) 88
Negative Control Power Save Circuit (power save solenoid ON) 90
Negative Control Circuit (bucket close, power save solenoid OFF) 92
Horsepower Boost Circuits 94
Arm-in Horsepower Boost Circuit 94
Travel Horsepower Boost Circuit 96
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Other Circuits 98
Cushion Circuit (arm-out operation) 98
Cushion Circuit (arm-out operation stopped) 100
Cushion Circuit (arm-out → arm-in operation) 102
Heat Circuit(lever in neutral) 104
Auto Pressure Boost Circuit (bucket close) 106
Explanation of Hydraulic Circuit and Operations (option)
Option Circuits 108
Breaker Circuit (single operation) 108
Shuttle Circuit (hydraulic fork) 110
Multi Purpose Circuit (breaker Q control) 112
Multi Purpose Circuit (2 pumps flow crusher) 114
2nd Option Circuit (hydraulic rotation fork) 116
Main Equipment Structure and Operation Explanation
Pump 118
1 Hydraulic Pump 118
2 Regulator 120
3 Gear Pump 126
Motor 127
1 Travel Motor 127
2 Swing Motor 146
Valve 156
1 Control Valve 156
2 5 stack Solenoid Valve Operation Explanation 189
3 Upper Side Pilot Valve (remote control valve) 191
4 Travel Pilot Valve (remote control valve) 196
5 Cushion Valve 200
6 3-direction Valve 204
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Electrics Section
Explanation of New Functions
Work Mode Select Switch 1
The Throttle Volume and Work Mode Select Switch are Linked!! 1
Computer Connection Method 4
Monitor Changes 5
Pilot Pressure Switch Changed to Pressure Sensor 8
Pump Electromagnetization Proportional Valve 10
1 Horsepower Control Proportional Valve 10
2 P1 Flow Control Proportional Valve 10
System Control for Energy Saving 11
1 Reduced Fuel Consumption Through Transient Load Reduction Control 11
2 Reduced Fuel Consumption Through Swing Relief Cut Control 13
3 Reduced Fuel Consumption Through Power Save Control 15
Swing Speed Limit Control 17
Electrical Equipment Layout Diagram
Overall View 19
1 Main Unit Left Side Layout Diagram (radiator chamber) 20
2 Engine Section Layout Diagram 21
3 Main Unit Right Side Layout Diagram (pump chamber) 22
4 Main Unit Center Section Layout Diagram 23
5 Cab Layout Diagram 1 24
6 Layout Around Operator’s Seat 26
Stand Alone Parts Diagram 27
Main Equipment Structural Diagrams
Connection Connector Pin Layout 45
1 Computer A 45
2 Monitor 46
Electrical Circuit Diagram
Overall View 47
Sequence Circuit Diagram 47
Block Diagram 48
1 Computer A 48
2 Computer S 49
3 ECM 50
4 Monitor Display 51
5 Air Conditioner 52
6 Lever Lock 53
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Contents
7 Horn 53
8 Working Light 54
9 Option 54
10 Others 55
11 Electrical Symbol List 56
Electrical Connector Wiring Diagram
Wire Harness 57
1 Main Frame Harness 57
2 Cab Main Harness 58
3 Cab Sub Harness 59
4 In Cab 60
5 Engine Harness 61
6 Console Right Harness 62
7 Console Left Harness 62
Electrical Parts and Wiring Assembly Diagram
Main Frame 63
Cab 64
Explanation of Functions and Operations
Explanation of Electrical Functions 65
Engine Speed Control 67
1 Throttle Control 67
2 Idling Control (auto / one-touch) 71
3 Idling Start 72
4 Idle Up 73
5 Auto warm up 73
Engine Start / Stop Control 75
1 Engine Start / Stop Judgment 75
2 Power-cut Delay 76
3 Engine Emergency Stop 77
4 Neutral Start 79
Pump Control 80
1 Work Mode Control 80
2 Pump Horsepower Boost Control 81
3 Pump Horsepower Cut Control 82
4 Power Save Control 83
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Swing 85
1 Swing Brake 85
2 Swing Free Swing (Option for North America) 86
3 Swing Lock (for maintenance) 87
4 Swing Relief Cut 88
5 Swing Speed Limit 89
Travel 91
1 Travel Speed Switchover 91
2 Travel Alarm 92
Valve Control 94
1 Lever Lock 94
2 Solenoid Sticking Prevention 95
3 Pressure Boost Control 96
Monitor Control 98
1 Bar Graph
(coolant temperature gauge, oil temperature gauge, fuel gauge) 98
Accessories 105
1 Horn 105
2 Working Light 106
3 Wiper and Washer 107
4 Room Lamp 109
5 Radio Mute 111
Others 112
1 Anti-theft 112
2 Battery Save Function 113
3 Alternator Power Generation Detection 114
4 Overload Alarm (Option for Europe) 115
Options 117
1 Option Line Control 117
2 Option Line Control 120
3 Feed Pump Automatic Stop 122
4 Return Filter Clogging Detected 125
5 Beacon 126
Service Support
Screen Operations 127
1 Screen Shift 127
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Screen Display List 129
1 CHK (status display) Screen List 129
2 DIAG (trouble diagnosis) Screen 142
3 HR (usage log) Screen List 144
4 CFG (setting change) Screen 152
5 CAL (troubleshooting support) Screen 155
6 Check the Monitor Switch (self-diagnosis function) 159
7 Option Flow Setting 161
8 Anti-theft Setting 163
9 Model Setting 165
10 Engine Screen Information 167
Screen Display Details 169
1 Message Display List 169
Trouble Display 171
1 Diagnostic Trouble Code Display 171
2 Main Unit Diagnostic Trouble Code List 172
3 Diagnostic Trouble Code (monitor display) 175
4 Sensor Trouble Operation Table 180
5 EPF (Engine Protection Feature) 181
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Engine Section
Engine Summary
Main Data Table (changes from model 3) 1
Overall Appearance Diagram 3
Sensor and Auxiliary Equipment Layout (left) 4
Sensor and Auxiliary Equipment Layout (rear) 5
Engine System Diagram 5
Fuel System Diagram 6
Detailed Parts Diagrams 7
1 ECM (engine control module) 7
2 Supply Pump / SCV (suction control valve) 8
3 Common Rail / Flow Damper 8
4 Common Rail Pressure Sensor / Pressure Limiter 9
5 Injector 9
6 Engine Coolant Temperature Sensor 10
7 Engine Oil Pressure Sensor 10
8 Cam Position Sensor (CMP sensor) 11
9 Crank Position Sensor (CKP sensor) 11
10 Atmospheric Pressure Sensor 12
11 Suction Air Temperature Sensor 12
12 Boost Pressure Sensor 13
13 Boost Temperature Sensor 13
14 Charge Fuel Pump 14
15 EGR Cooler 14
16 Lead Valve (check valve) 15
17 EGR Valve 15
Engine Control Summary 16
Explanation of Engine Terms
Function Explanation Table 17
Explanation of Engine Structure
Technology for Exhaust Gases 19
1 Common Rail System 19
2 Multi Stage Fuel Injection (multiple injection) 20
3 Inter Cooler 22
4 EGR (exhaust gas recirculation) 23
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Contents
Explanation of Engine Operation
Engine Overall 25
1 Comparison of 6BG1 and 4HK1 25
Fuel Unit 26
1 Common Rail System Summary 26
2 Change Points for Injection Method (governor, common rail) 27
3 Explanation of Injector Operation 28
4 Explanation of Supply Pump Operation 31
5 Supply Pump Disassembly Diagram 32
6 Explanation of Flow Damper Operation 33
7 Pressure Limiter 34
8 Cautions for Maintenance 35
Explanation of Engine Control 38
1 Fuel Injection Quantity Correction 38
2 Starting Q Correction 38
3 Preheat Control (QOS quick on start) 38
4 Atmospheric Pressure Correction (high altitude correction) 38
5 Control for Overheating 39
6 Control for Boost Temperature Rise 40
7 Control for Engine Oil Pressure Drop 40
8 Start Control (coolant temperature monitoring) 40
9 Long Cranking Control 41
10 Starting Control for Reduced Number of Cylinders 41
11 Normal Stop (key switch OFF operation) 41
12 Engine Start / Stop Judgment 42
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Engine Maintenance Standards
Engine Information Screen 43
Purpose 43
How to Go to This Screen 43
Engine Start Restriction 43
Screen 43
Monitor Operation Method 44
View Mode 44
Edit Mode 44
Engine Information
(Q resistance, QR code, engine serial number) Copying Method 45
Rewriting Injector QR Codes 46
When Replacing Computer A at the Same Time 48
Engine Information Acquisition Timing 48
Redoing Engine Information Acquisition 48
Trouble Display 48
Engine Equipment Table
Exhaust Gas 3rd Accessory Electrical Parts Compatibility (Isuzu part number) 49
Exhaust Gas Regulations
Features of Materials Subject to Exhaust Gas Regulation 50
Exhaust Gas Regulation Values 50
Cautions for Fuel Used
Engine Fuel and Maintenance of Fuel Filters 52
1 Fuel to be applied 52
2 Maintenance of fuel filters 54
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Air Conditioner Section
Changes from Model 3
Change List 1
Layout Diagram
Air Conditioner Overall Diagram 2
1 Frame 2
2 Cab 4
Equipment Layout Diagram 5
Circuit Diagram
Air Conditioner Circuit Diagram 6
Explanation of Functions
Explanation of Control 7
1 Air Mix Motor Actuator Control 8
2 Blow Mode Motor Actuator Control 8
3 Refresh / Recirculate Switch Motor Actuator Control 9
4 Blower Amp Control 10
5 Compressor Clutch Control 13
6 COOLMAX Control and HOTMAX Control 14
7 Trouble Detection and Control after Trouble Detected 15
8 Monitor Mode 17
9 Door Switch Control 19
10 Inside Air Filter Clogging Detection Control 19
Actuator Inspection
Air Mix Motor Actuator Inspection 21
Refresh / Recirculate Motor Actuator Inspection 23
Mode Motor Actuator Inspection 25
Self-diagnosis Function with Panel Display
Abnormality Display and Self-check Procedures 27
1 Abnormality Display Position 27
2 Explanation of Abnormality Display 27
3 Explanation of Monitor Mode 29
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Contents
Part Function and OK/NG Judgment
Control Panel and Control Unit 38
Blower Amp 38
Relay 39
Air Mix Actuator 39
Refresh / Recirculate Actuator 39
Blow Mode Actuator 40
Evaporator Sensor 40
Dual Pressure Switch 40
Solar Radiation Sensor 41
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New Machine Performance Section
New Machine Performance
Performance Evaluation Check Sheet 1
Performance Evaluation Recording Sheet 2
New Machine Performance Judgment Standards
Reference Values (210) 3
Reference Values (240) 5
Measurement Method and Main Unit Posture
Engine Speed 7
Measurement method 7
Pressure in Each Section 7
Cylinder Falling Amount 7
Attachment Speed 8
Swing Speed 9
Swing (180°) Brake Angle 9
Travel Speed 9
Off Travel Amount 10
Travel Sprocket Speed 10
Shoe Tension Amount 10
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount 11
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Maintenance Section
Pressure Measurement and Adjustment Procedures
Procedures for Pressure Measurement from the Monitor Display 1
1 Pressure Measurement Method 1
2 Operating Method 1
Procedures for Measuring Hydraulic Oil Temperature from the Monitor Display 2
1 Hydraulic Oil Temperature Measurement Method 2
2 Operating Method 2
Procedures for Pressure Measurement by Installing Pressure Gauge 3
1 Preparations 3
2 Items to prepare 3
Pressure Measuring Ports 4
Control Valve 5
1 Location of Relief Valves 5
Pressure Measurement Preparations 6
Pressure Measurement and Adjustment Procedures 9
1 Main Pressure Measurement 9
2 Pilot Pressure Measurement 13
3 Negative Control Pressure Measurement 14
Pressure Adjustment 16
1 Main Pressure Adjustment 16
2 Pilot Pressure Adjustment 22
Hydraulic Pump Flow Measurement Procedure
Preparations 23
1 Items to Prepare 23
Work Preparations 24
Flow Measurement 27
Drain Volume Measurement Procedure
Preparations 28
Travel Motor Drain Volume Measurement 28
Swing Motor Drain Volume Measurement 31
Air Bleed Procedure
Hydraulic Pump 32
Travel Motor 33
Swing Motor 34
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Contents
HBCV (Option for Europe) 36
1 Boom Cylinder HBCV 36
2 Arm Cylinder HBCV 36
Procedures for Replacing Consumable Parts
Air Conditioner Belt and Fan Belt Replacement 37
1 Air Conditioner Belt Replacement 37
2 Fan Belt Replacement 39
Fuel Filter Replacement 42
1 Filter Replacement 42
2 Air Bleeding 46
Engine Oil Filter and Engine Oil Replacement 47
1 Engine Oil Replacement 47
2 Engine Oil Filter Replacement 49
Radiator Coolant Replacement 50
Air Cleaner Cleaning and Replacement 51
Hydraulic Oil Filter Replacement 53
1 Return Filter Replacement 53
2 Suction Filter Replacement 54
3 Air Breather Element Replacement 55
4 Pilot Oil Filter Replacement 55
5 Hydraulic Oil Replacement 56
Others 59
1 Coolant Filling 59
2 Washer Fluid Filling 59
Periodic Maintenance Procedures
Maintenance Every 250 Hours 60
1 Battery Inspection and Replacement 60
Maintenance after First 250 Hours for New Machine
/ Every 1000 Hours from Then on 61
1 Swing Reduction Gear Oil Replacement 61
2 Gear Oil Filling 64
Replace the Flange Packing at the Bottom of the Fuel Tank 65
Bolt Size and Torque Table
Bolt and Nut Tightening 66
Retightening Torque Table 67
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Data Section
Main Unit Weight
Major Component Weight (standard specifications) 1
Individual Part Weight 2
Dry weight for each part is shown in the table below 2
Shoe Weight (one side) 2
Arm Weight 2
Bucket Weight 3
Interchangeability
Interchangeability 4
1 Main Part Interchangeability Table (SH210-5) 4
2 Main Part Interchangeability Table (SH210LC-5) 5
3 Main Part Interchangeability Table (SH240-5) 6
4 Main Part Interchangeability Table (SH210 / SH240-5) 7
Attachment Installation Methods
Attachment Dimensions 8
Paint Colors
Paint Colors 9
Unit Conversion Ratio
Unit Conversion Ratio 10
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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