Sumitomo SH210LC-5 SH250-5 Excavator Service Text Manual WLST2105-01T – PDF DOWNLOAD
FILE DETAILS:
Sumitomo SH210LC-5 SH250-5 Excavator Service Text Manual WLST2105-01T – PDF DOWNLOAD
Language : English
Pages : 663
Downloadable : Yes
File Type : PDF
Size: 95.4 MB
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sumitomo SH210LC-5 SH250-5 Excavator Service Text Manual WLST2105-01T – PDF DOWNLOAD
Main Body Section
Changes from Model 3
Overall Specifications 1
1 Specifications Comparison Table 1
2 Performance Improvements 3
Hydraulic-related Changes 4
1 Use of High-performance Return Filter
(nephron filter and breaker filter eliminated) 4
2 Use of Add-on Valve 6
3 Multi Purpose Circuit Switched to One-touch Operation
(breaker ⇔ crusher) 7
Hydraulic Pump 8
1 Hydraulic Pump Changes 8
2 Appearance Changes 8
3 Circuit Changes 8
4 Reduced Flow Force 9
5 Straight Travel Valve 10
6 Heat Circuit 11
Lower-section Related Changes 13
1 Center Joint Installation Section Notch Dimensions 13
2 Grease Bath Seal 13
3 Center Joint Rotation Stopper Installation Surface 13
4 Lower Roller 14
5 Upper Roller 15
6 Track Guard 15
Cab-related Changes 16
1 Cab Shape 16
2 Irregularly Shaped Steel Line Structure 16
3 Beefed Up Equipment 17
4 Interior Equipment 18
5 Front Window Lock Mechanism 21
Upper Swing Body Changes 22
1 High-rigidity Platform 22
1
RST-00-00-051EN
Contents
Attachment Changes 23
1 Boom 23
2 Arm 24
3 Coupler Pin Fastening 25
4 Line Clamp 25
5 Bucket Edge Bushing 25
6 Use of Plastic Shims 25
7 Reduced Boom Foot Section Play 25
Attachment Plate Thickness Comparison Table 26
Boom 26
Arm 26
ROPS Judgment Method
ROPS Judgment Method 27
Specifications
Overall 29
1 Main Data 29
2 Performance 29
3 Main Body Dimensions 29
4 Engine 30
5 Cooling System 30
6 Upper Side Work System 31
7 Operating Device 32
8 Swing Units 33
9 Travel Lower Body 33
Hydraulic Equipment 33
1 Hydraulic Device 33
2 Control Valve, Cylinder 34
Capacities, Filters 34
1 Coolant and Oil Capacities 34
2 Hydraulic Oil Filters 34
3 Fuel Filter 34
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator 35
Lifting Capacities (Standard Arm) 36
Lifting Capacities (Short Arm) 37
Lifting Capacities (Standard Arm) 38
Lifting Capacities (Short Arm) 39
Lifting Capacities (Long Arm) 40
2
Contents
RST-00-00-051EN
Overall View
Overall View (SH210LC-5) 41
1 Standard Arm (2 94 m) 41
2 Short Arm (2 40 m) 41
3 S-Short Arm (1 91 m) 42
Overall View (SH250-5) 43
1 Standard Arm (3 00 m) 43
2 Short Arm (2 50 m) 43
3 Long Arm (3 52 m) 44
Work Range Diagram
Work Range Diagram (SH210LC-5) 45
1 Standard Arm (2 94 m) 45
2 Short Arm (2 40 m) 46
3 S-Short Arm (1 91 m) 47
Work Range Diagram (SH250-5) 48
1 Standard Arm (3 00 m) 48
2 Short Arm (2 50 m) 49
3 Long Arm (3 52 m) 50
3
Contents
RST-00-00-051EN
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 4
3 Air Cleaner (double element) 5
4 Pre cleaner (option) 5
5 Radiator 5
Hydraulic Device 6
1 Hydraulic Pump 6
2 Add on Pump (option) 6
3 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 Cylinder with HBCV (option) 14
3 Attachments 15
Equipment Layout Diagram
Main Equipment Layout 16
Consumable Part Layout 17
Standard Machine Option List
List of Optional Components 18
4
Contents
RST-00-00-051EN
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
Pilot Control Line HBCV (option) 26
5
RST-00-00-051EN
Contents
Function List
Function Table 27
Explanation of New Functions 29
1 Swing Relief Cut-off Control 29
2 Swing Speed Limit Control 31
3 Negative Control Power Save Control 32
4 Option Line Flow Adjustment Control 33
5 Multi Purpose Circuit (breaker ⇔ crusher) One-touch Switching Control 34
6 Bucket-close Regenerative Circuit 35
Explanation of Hydraulic Circuit and Operations (standard model)
Travel Circuit 36
Travel Low-speed Circuit 36
Travel High-speed Circuit 38
Straight Travel Circuit (with / without HBCV) 40
Swing Circuit 43
Swing Speed Limit Control Circuit 43
Swing Relief Cut-off Control Circuit 45
Swing Priority Circuit (with / without HBCV) 47
Swing Brake Circuit 50
Swing Parking Circuit (lever in neutral) 52
Swing Parking Circuit (brake release) 54
Swing Parking Circuit (machine stop) 56
Boom Circuit 58
Boom-up Circuit (single operation) 58
Boom-up Circuit (single operation) (with HBCV) (Option) 60
Boom-up Circuit (compound boom-up + arm-in) (with / without HBCV) 62
Boom-down Regenerative Circuit (without HBCV) 65
Boom-down Regenerative Circuit (with HBCV) (Option) 67
Boom-down Tilting Prevention Circuit (with / without HBCV) 69
Boom-down Load Hold Valve Circuit (with / without HBCV) 72
Arm Circuit 75
Arm-out Circuit (with / without HBCV) 75
Arm-in Forced Regenerative Circuit (with / without HBCV) 78
Arm-in Load Hold Valve Circuit (without HBCV) 81
Arm-in Load Hold Valve Circuit (with HBCV) (Option) 83
Bucket Circuit 85
Bucket-open Circuit 85
Bucket-close Regenerative Circuit 87
6
Contents
RST-00-00-051EN
Negative Control Circuit 89
Negative Control Circuit (power save solenoid OFF) 89
Negative Control Power Save Circuit (power save solenoid ON) 91
Negative Control Circuit (bucket close, power save solenoid OFF) 93
Horsepower Boost Circuits 95
Arm-in Horsepower Boost Circuit 95
Travel Horsepower Boost Circuit 97
Other Circuits 99
Cushion Circuit (arm-out operation) 99
Cushion Circuit (arm-out operation stopped) 101
Cushion Circuit (arm-out → arm-in operation) 103
Heat Circuit(lever in neutral) 105
Auto Pressure Boost Circuit (bucket close) 107
Explanation of Hydraulic Circuit and Operations (option)
Option Circuits 109
Breaker Circuit (single operation) 109
Shuttle Circuit (hydraulic fork) 111
Multi Purpose Circuit (breaker Q control) 113
Multi Purpose Circuit (2 pumps flow crusher) 115
2nd Option Circuit (hydraulic rotation fork) 117
Main Equipment Structure and Operation Explanation
Pump 119
1 Hydraulic Pump 119
2 Regulator 121
3 Gear Pump 127
Motor 128
1 Travel Motor 128
2 Swing Motor 147
Valve 157
1 Control Valve 157
2 5 stack Solenoid Valve Operation Explanation 190
3 Upper Side Pilot Valve (remote control valve) 192
4 Travel Pilot Valve (remote control valve) 197
5 Cushion Valve 201
6 3-direction Valve 205
7
Contents
RST-00-00-051EN
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 44
1 Computer A 44
2 Monitor 45
Electrical Circuit Diagram
Overall View 46
1 Sequence Circuit Diagram 46
8
RST-00-00-051EN
Contents
Block Diagram 47
1 Computer A 47
2 Computer S 48
3 ECM 49
4 Monitor Display 50
5 Air Conditioner 51
6 Lever Lock 52
7 Horn 52
8 Working Light 53
9 Option 53
10 Others 54
11 Electrical Symbol List 55
Electrical Connector Wiring Diagram
Wire Harness 56
1 Main Frame Harness 56
2 Cab Main Harness 57
3 Cab Sub Harness 58
4 In Cab 59
5 Engine Harness 60
6 Console Right Harness 61
7 Console Left Harness 61
Electrical Parts and Wiring Assembly Diagram
Main Frame 62
Cab 63
Battery switch 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
9
Contents
RST-00-00-051EN
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
Swing 85
1 Swing Brake 85
2 Swing Lock (for maintenance) 86
3 Swing Relief Cut 88
4 Swing Speed Limit 89
Travel 91
1 Travel Speed Switchover 91
2 Travel Alarm 93
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
Others 111
1 Anti-theft 111
2 Battery Save Function 112
3 Alternator Power Generation Detection 113
Options 114
1 Option Line Control 114
2 Option Line Control 117
3 Feed Pump Automatic Stop 119
4 Return Filter Clogging Detected 122
10
RST-00-00-051EN
Contents
Service Support
Screen Operations 124
1 Screen Shift 124
Screen Display List 126
1 CHK (status display) Screen List 126
2 DIAG (trouble diagnosis) Screen 139
3 HR (usage log) Screen List 141
4 CFG (setting change) Screen 149
5 CAL (troubleshooting support) Screen 152
6 Check the Monitor Switch (self-diagnosis function) 156
7 Option Flow Setting 158
8 Anti-theft Setting 160
9 Model Setting 162
10 Engine Screen Information 164
Screen Display Details 166
1 Message Display List 166
Trouble Display 168
1 Diagnostic Trouble Code Display 168
2 Main Unit Diagnostic Trouble Code List 169
3 Diagnostic Trouble Code (monitor display) 172
4 Sensor Trouble Operation Table 177
5 EPF (Engine Protection Feature) 178
11
Contents
RST-00-00-051EN
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
12
RST-00-00-051EN
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
Engine Maintenance Standards
Engine Information Screen 43
1 Purpose 43
2 How to Go to This Screen 43
3 Engine Start Restriction 43
4 Screen 43
Monitor Operation Method 44
1 View Mode 44
2 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
13
Contents
RST-00-00-051EN
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
14
Contents
RST-00-00-051EN
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
15
RST-00-00-051EN
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
16
Contents
RST-00-00-051EN
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 (250) 5
Measurement Method and Main Unit Posture
Engine Speed 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
17
Contents
RST-00-00-051EN
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
HBCV (Option for Europe) 36
1 Boom Cylinder HBCV 36
2 Arm Cylinder HBCV 36
18
RST-00-00-051EN
Contents
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
19
Contents
RST-00-00-051EN
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 (SH210LC-5) 4
2 Main Part Interchangeability Table (SH250-5) 5
3 Main Part Interchangeability Table (SH210 / SH250-5) 6
Attachment Installation Methods
Attachment Dimensions 7
Paint Colors
Paint Colors 8
Unit Conversion Ratio
Unit Conversion Ratio 9
HYDRAULIC SCHEM DIAGRAM
HYDRAULIC SCHEM DIAGRAM
ELECTRIC CIRCUIT DRAWING
ELECTRIC CIRCUIT DRAWING
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.
S.V