Sumitomo SH300-5 Excavator Service Text Manual WLST3005-00T – PDF DOWNLOAD
FILE DETAILS:
Sumitomo SH300-5 Excavator Service Text Manual WLST3005-00T – PDF DOWNLOAD
Language : English
Pages : 640
Downloadable : Yes
File Type : PDF
Size: 75.7 MB
TABLE OF CONTENTS:
Sumitomo SH300-5 Excavator Service Text Manual WLST3005-00T – PDF DOWNLOAD
Main Unit Section
Changes from Model 3
Overall Specifications 1
1 Specifications Comparison Table 1
2 Performance Improvements 2
Hydraulic-related Changes 3
1 Use of High-performance Return Filter
(nephron filter and breaker filter eliminated) 3
2 Use of Add-on Valve 5
3 Multi Purpose Circuit Switched to One-touch Operation
(breaker ⇔ crusher) 6
Hydraulic Pump 7
1 Hydraulic Pump Changes 7
2 Appearance Changes 7
3 Circuit Changes 7
4 Reduced Flow Force 8
5 Straight Travel Valve 9
6 Heat Circuit 10
Lower-section Related Changes 12
1 Center Joint Installation Section Notch Dimensions 12
2 Grease Bath Seal 12
3 Center Joint Rotation Stopper Installation Surface 12
4 Track Roller 13
5 Carrier Roller 14
6 Track Guard 14
Cab-related Changes 15
1 Cab Shape 15
2 Irregularly Shaped Steel Pipe Structure 15
3 Beefed Up Equipment 16
4 Interior Equipment 17
5 Front Window Lock Mechanism 20
Upper Swing Body Changes 21
1 High-rigidity Platform 21
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Attachment Changes 22
1 Boom 22
2 Arm 23
3 Coupler Pin Fastening 24
4 Pipe Clamp 24
5 Bucket Edge Bushing 24
6 Use of Plastic Shims 24
7 Reduced Boom Foot Section Play 24
Specifications
Overall 25
1 Main Data 25
2 Performance 25
3 Main Body Dimensions 25
4 Engine 26
5 Cooling System 26
6 Upper Side Work System 27
7 Operating Device 27
8 Swing Units 28
9 Travel Lower Body 29
Hydraulic Equipment 29
1 Hydraulic Device 29
2 Control Valve, Cylinder 30
Capacities, filters 30
1 Water and Oil Capacities 30
2 Hydraulic Oil Filters 30
3 Fuel Filter 30
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator 31
Lifting Capacities (Standard Arm) 32
Lifting Capacities (Short Arm) 33
Lifting Capacities (Long Arm) 34
Overall View
Overall View 35
1 Standard Arm (3 18 m) 35
2 Short Arm (2 65 m) 35
3 Long Arm (3 66 m) 36
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Work Range Diagram
Work Range Diagram 37
1 Standard Arm (3 18 m) 37
2 Short Arm (2 65 m) 38
3 Long Arm (3 66 m) 39
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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 Shoes 2
Upper Component 3
1 Swing Unit 3
Engine-related 4
1 Engine 4
2 Muffler 5
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 8
1 Control Valve 8
2 Remote Control Valve (left / right, travel operations) 9
3 Remote Control Valve Characteristic Diagram 10
4 Cushion Valve (heat circuit, with shuttle valve) 12
5 Center joint 12
6 Solenoid Valve (5-stack) 12
Backhoe Attachment 13
1 Cylinder 13
2 Cylinder with HBCV (option) 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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Hydraulic 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 14
6 3-Direction Valve/Shut-off Valve (Option) 15
7 HBCV (Option) 16
Manifolds 17
1 Manifold Under Cab 17
2 Manifold (accumulator section) 17
3 Manifold (hydraulic oil tank section) 18
Motors 19
1 Swing Motor 19
2 Travel Motor 20
3 Center Joint 21
Pilot Hose Connection Diagram
Pilot P and T Lines 22
Pilot Control Line 25
Pilot Control Line (HBCV) 28
Function List
Function Table 30
Explanation of New Functions 32
1 Swing Relief Cut Control 32
2 Negative Control Power Save Control 34
3 Option Line Flow Adjustment Control 35
4 Multi Purpose Circuit (breaker ⇔ crusher) One-touch Switching Control 36
5 Bucket-close Regenerative Circuit 37
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Content
Explanation of Hydraulic Circuit and Operations (standard model)
Travel Circuits 38
Travel Low-speed Circuit 38
Travel High-speed Circuit 40
Straight Travel Circuit (without HBCV) 42
Straight Travel Circuit (with HBCV) (Option) 44
Swing Circuits 46
Swing Relief Cut-off Control Circuit 46
Swing Priority Circuit (without HBCV) 48
Swing Priority Circuit (with HBCV) (Option) 50
Swing Brake Circuit 52
Swing Parking Circuit (lever in neutral) 54
Swing Parking Circuit (brake release) 56
Swing Parking Circuit (machine stop) 58
Boom Circuits 60
Boom-up Circuit (single operation) (without HBCV) 60
Boom-up Circuit (single operation) (wiht HBCV) (Option) 62
Boom-up Circuit (compound boom-up + arm-in) (without HBCV) 64
Boom-up Circuit (compound boom-up + arm-in) (with HBCV) (Option) 66
Boom-down Regenerative Circuit (without HBCV) 68
Boom-down Regenerative Circuit (with HBCV) (Option) 70
Boom-down Tilting Prevention Circuit (without HBCV) 72
Boom-down Tilting Prevention Circuit (with HBCV) (Option) 74
Boom-down Load Hold Valve Circuit (without HBCV) 76
Boom-down Load Hold Valve Circuit (with HBCV) (Option) 78
Arm Circuits 80
Arm-out Circuit (without HBCV) 80
Arm-out Circuit (with HBCV) (Option) 82
Arm-in Forced Regenerative Circuit (without HBCV) 84
Arm-in Forced Regenerative Circuit (with HBCV) (Option) 86
Arm-in Load Hold Valve Circuit (without HBCV) 88
Arm-in Load Hold Valve Circuit (with HBCV) (Option) 90
Bucket Circuit 92
Bucket-open Circuit 92
Bucket -close Regenerative Circuit 94
Negative Control Circuit 96
Negative Control Circuit (power save solenoid OFF) 96
Negative Control Power Save Circuit (power save solenoid ON) 98
Negative Control Circuit (bucket close, power save solenoid OFF) 100
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Horsepower Boost Circuits 102
Arm-in Horsepower Boost Circuit 102
Travel Horsepower Boost Circuit 104
Other Circuits 106
Cushion Circuit 106
Heat Circuit (lever in neutral) 112
Auto Pressure Boost Circuit (bucket close) 114
Explanation of Hydraulic Circuit and Operations (option)
Option Circuit 116
Breaker Circuit (single operation) 116
Multi Purpose Circuit 118
Main Equipment Structure and Operation Explanation
Pump 122
1 Hydraulic Pump 122
2 Regulator 125
3 Gear Pump 133
Motor 134
1 Travel Motor 134
2 Swing Motor 143
Valve 150
1 Control Valve 150
2 5-stack Solenoid Valve Operation Explanation 185
3 Upper Pilot Valve (remote control valve) 187
4 Travel Pilot Valve (remote control valve) 192
5 Option Pilot Valve (remote control valve) 197
6 Cushion Valve 200
7 Selector Valve (3-direction valve) 204
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Electrical 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
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
Electrical Equipment Layout Diagram
Overall View 17
1 Main Unit Left Side Layout Diagram (radiator compartment) 18
2 Engine Section Layout Diagram 19
3 Main Unit Right Side Layout Diagram (pump compartment) 20
4 Main Unit Center Section Layout Diagram 21
5 Cab Layout Diagram 1 22
6 Layout Around Operator Seat 24
Stand-alone Parts Diagram 25
Main Equipment Structural Diagrams
Connection Connector Pin Layout 41
1 Computer A 41
2 Monitor 42
Electrical Circuit Diagram
Overall View 43
1 Sequence Circuit Diagram 43
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Content
Block Diagram 45
1 Computer A 45
2 ECM 46
3 Monitor Display 47
4 Air Conditioner 48
5 Lever Lock 49
6 Horn 49
7 Working Light 50
8 Option 50
9 Others 51
10 Electrical Symbol List 52
Electrical Connector Wiring Diagram
Wire Harness 53
1 Main Frame Harness 53
Cab 56
1 Cab Main Harness 56
2 Cab Sub Harness 59
3 In Cab 61
4 Engine Harness 63
Console 64
1 Console Right Harness 64
2 Console Left Harness 64
3 GPS Harness 65
Electrical Parts and Wiring Assembly Diagram
Main Frame 66
Cab 68
Explanation of Functions and Operations
Explanation of Electrical Functions 70
Engine Speed Control 72
1 Throttle Control 72
2 Idling Control 76
3 Idling Start 77
4 Idle Up 78
5 Auto Warm Up 78
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Engine Start/Stop Control 80
1 Engine Start/Stop Judgment 80
2 Power-cut Delay 81
3 Engine Emergency Stop 82
4 Neutral Start 84
Pump Control 85
1 Work Mode Control 85
2 Pump Horsepower Boost Control 86
3 Pump Horsepower Cut Control 87
4 Power Save Control 88
Swing 90
1 Swing Brake 90
2 Swing Relief Cut 91
Travel 93
1 Travel Speed Switchover 93
2 Travel Alarm 94
Valve Control 96
1 Lever Lock 96
2 Solenoid Sticking Prevention 97
3 Pressure Boost Control 98
Monitor Control 100
1 Bar Graph 100
Accessories 106
1 Horn 106
2 Working Light 107
3 Wiper and Washer 108
4 Room Lamp 110
Others 112
1 Anti-theft 112
2 Battery Save Function 113
3 Alternator Power Generation Detection 114
Options 115
1 Option Line Control 115
2 Option Line Control 118
3 Feed Pump Automatic Stop 120
4 Return Filter Clogging Detected 123
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Service Support
Screen Operations 125
1 Screen Shift 125
Screen Display List 127
1 CHK (status display) Screen List 127
2 DIAG (trouble diagnosis) Screen 139
3 HR (usage log) Screen List 141
4 CFG (setting change) Screen 146
5 CAL (troubleshooting support) Screen 150
6 Check the Monitor Switch (self-diagnosis function) 152
7 Option Flow Setting 154
8 Anti-theft Setting 156
9 Model Setting 158
10 Engine Screen Information 160
Screen Display Details 162
1 Message Display List 162
Trouble Display 164
1 Diagnostic Trouble Code Display 164
2 Main Unit Diagnostic Trouble Code List 165
3 Diagnostic Trouble Code (monitor display) 168
4 Sensor Trouble Operation Table 174
5 EPF (Engine Protection Feature) 176
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Engine Section
Engine Summary
Main Data Table (changes from model 3) 1
Overall Appearance Diagram 2
Sensor and Auxiliary Equipment Layout (left) 3
Sensor and Auxiliary Equipment Layout (rear) 4
Engine System Diagram 4
Fuel System Diagram 5
Detailed Parts Diagrams 6
1 ECM (engine control module) 6
2 Supply Pump/SCV (suction control valve) 7
3 Common Rail/Flow Damper 7
4 Common Rail Pressure Sensor/Pressure Limiter 8
5 Injector 8
6 Engine Coolant Temperature Sensor 9
7 Engine Oil Pressure Sensor 9
8 Cam Position Sensor (CMP sensor) 10
9 Crank Position Sensor (CKP sensor) 10
10 Atmospheric Pressure Sensor 11
11 Suction Air Temperature Sensor 11
12 Boost Pressure Sensor 12
13 Boost Temperature Sensor 12
14 Charge Fuel Pump 13
15 EGR Cooler 13
16 Lead Valve (check valve) 14
17 EGR Valve 14
Engine Control Summary 15
Explanation of Engine Terms
Function Explanation Table 16
Explanation of Engine Structure
Technology for Exhaust Gases 18
1 Common Rail System 18
2 Multi Stage Fuel Injection (multiple injection) 19
3 Inter Cooler 21
4 EGR (exhaust gas recirculation) 22
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Explanation of Engine Operation
Engine Overall 24
1 Comparison of 6BG1T and 6HK1X 24
Fuel Unit 25
1 Common Rail System Summary 25
2 Change Points for Injection Method (governor, common rail) 26
3 Explanation of Injector Operation 27
4 Explanation of Supply Pump Operation 30
5 Supply Pump Disassembly Diagram 31
6 Explanation of Flow Damper Operation 32
7 Pressure Limiter 33
8 Cautions for Maintenance 34
Explanation of Engine Control 37
1 Fuel Injection Quantity Correction 37
2 Starting Q Correction 37
3 Preheat Control (QOS quick on start) 37
4 Atmospheric Pressure Correction (high altitude correction) 37
5 Control for Overheating 38
6 Control for Boost Temperature Rise 39
7 Control for Engine Oil Pressure Drop 39
8 Start Control (coolant temperature monitoring) 39
9 Long Cranking Control 40
10 Starting Control for Reduced Number of Cylinders 40
11 Normal Stop (key switch OFF operation) 40
12 Engine Start/Stop Judgment 41
Engine Maintenance Standards
Engine Information Screen 42
1 Purpose 42
2 How to Go to This Screen 42
3 Engine Start Restriction 42
4 Screen 42
Monitor Operating Method 43
1 View Mode 43
2 Edit Mode 43
Engine Information
(Q resistance, QR code, engine serial number) Copying Method 44
Rewriting Injector QR Codes 45
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When Replacing Computer A at the Same Time 47
Engine Information Acquisition Timing 47
Redoing Engine Information Acquisition 47
Trouble Display 47
Engine Equipment Table
Exhaust Gas Third Regulation Accessory Electrical Parts Compatibility
(Isuzu part number) 48
Exhaust Gas Regulations
Features of Materials Subject to Exhaust Gas Regulation 49
Exhaust Gas Regulation Values 49
Cautions for Fuel Used
Engine Fuel and Maintenance of Fuel Filters 51
1 Fuel to be applied 51
2 Maintenance of fuel filters 53
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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 6
Circuit Diagram
Air Conditioner Circuit Diagram 7
Explanation of Functions
Explanation of Control 11
1 Air Mix Motor Actuator Control 12
2 Blow Mode Motor Actuator Control 12
3 Refresh / Recirculate Switch Motor Actuator Control 13
4 Blower Amp Control 14
5 Compressor Clutch Control 17
6 COOLMAX Control and HOTMAX Control 18
7 Trouble Detection and Control after Trouble Detected 19
8 Monitor Mode 21
9 Door Switch Control 23
10 Inside Air Filter Clogging Detection Control 23
Actuator Inspection
Air Mix Motor Actuator Inspection 26
Refresh/Recirculate Motor Actuator Inspection 28
Mode Motor Actuator Inspection 30
Self-diagnosis Function With Panel Display
Trouble Display and Self-check Procedure 32
1 Trouble Display Position 32
2 Explanation of Trouble Display 32
3 Explanation of Monitor Mode 34
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Part Function and OK/NG Judgment
Control Panel and Control Unit 43
Blower Amp 43
Relay 44
Air Mix Actuator 44
Refresh / Recirculate Actuator 44
Blow Mode Actuator 45
Evaporator Sensor 45
Dual Pressure Switch 45
Solar Radiation Sensor 46
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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 (SH300-5) 3
Measurement Method and Main Unit Posture
Engine Speed 5
Pressure in Each Section 5
Cylinder Falling Amount 5
Attachment Speed 6
Swing Speed 7
Swing (180°) Brake Angle 7
Travel Speed 7
Off Travel Amount 8
Travel Sprocket Speed 8
Shoe Tension Amount 8
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount 9
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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 15
1 Main Pressure Adjustment 15
2 Pilot Pressure Adjustment 18
Hydraulic Pump Flow Measurement Procedure
Preparations 19
1 Items to Prepare 19
Work Preparations 20
Flow Measurement 23
Drain Volume Measurement Procedure
Preparations 24
Travel Motor Drain Volume Measurement 24
Swing Motor Drain Volume Measurement 27
Air Bleed Procedure
Hydraulic Pump 28
Travel Motor 29
Swing Motor 30
HBCV (Option) 31
1 Boom Cylinder HBCV 31
2 Arm Cylinder HBCV 31
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Content
Procedures for Replacing Consumable Parts
Air Conditioner Belt and Fan Belt Replacement 32
1 Air Conditioner Belt Replacement 32
2 Fan Belt Replacement 34
Fuel Filter Replacement 37
1 Filter Replacement 37
2 Air Bleeding 40
Engine Oil Filter and Engine Oil Replacement 41
1 Engine Oil Replacement 41
2 Engine Oil Filter Replacement 42
Radiator Coolant Replacement 44
Air Cleaner Cleaning and Replacement 45
Hydraulic Oil Filter Replacement 47
1 Return Filter Replacement 47
2 Suction Filter Replacement 48
3 Air Breather Element Replacement 49
4 Pilot Oil Filter Replacement 49
5 Hydraulic Oil Replacement 50
Others 53
1 Coolant Filling 53
2 Washer Fluid Filling 53
Periodic Maintenance Procedures
Maintenance Every 250 Hours 54
1 Battery Inspection and Replacement 54
Maintenance after First 250 Hours for New Machine
/ Every 1000 Hours from Then on 55
1 Swing Reduction Gear Oil Replacement 55
2 Gear Oil Filling 56
Replace the Flange Packing at the Bottom of the Fuel Tank 57
Bolt Size and Torque Table
Bolt and Nut Tightening 58
Retightening Torque Table 59
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Data Section
Main Unit Weight
Divided Weight (standard specifications) 1
Stand-alone Part Weight 2
Shoe Weight (per side) 2
Arm Weight 2
Bucket Weight 3
Interchangeability
Interchangeability 4
1 Main Part Interchangeability Table (SH300-5) 4
Attachment Installation Methods
Attachment Dimensions 5
Paint Colors
Paint Colors 7
Unit Conversion Ratio
Unit Conversion Ratio 8
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