Sumitomo SH300-5 Hydraulic Excavator Troubleshooting Manual WLST3305TS-01W – PDF DOWNLOAD
DESCRIPTION:
Sumitomo SH300-5 Hydraulic Excavator Troubleshooting Manual WLST3305TS-01W – 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 6HK1 type engine.
(SH300-5 and SH330/330LC/350HD/350LHD-5)
Extensive use of this manual is useful for performing accurate and quick maintenance procedures.
TABLE OF CONTENTS:
Sumitomo SH300-5 Hydraulic Excavator Troubleshooting Manual WLST3305TS-01W – PDF DOWNLOAD
Reading Flow Charts 1
Diagnostic Trouble Code Number and Problem 1
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
Diagnostic Trouble Code Reading Procedure 18
Confirmation after Repair 19
Final Confirmation Items List 19
Diagnostic Trouble Code Deletion Method 19
Injector Inspection Methods Using A Thermogun 20
Sorting Methods Using Noncontact Infrared Thermometer 27
Breaker Box Inspection Procedure 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
Circuit Diagram 58
Engine Harness Routing Diagram 67
Connector List 72
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) 135
DTC: 0117 ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) 141
2
SST-10-00-007EN
Troubleshoot
DTC: 0118 ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage) 147
DTC: 0182 FT (fuel temperature) Sensor Abnormality (abnormally low voltage) 154
DTC: 0183 FT (fuel temperature) Sensor Abnormality (abnormally high voltage) 160
DTC: 0192 Common Rail Pressure Sensor Abnormality (abnormally low voltage) 167
DTC: 0193 Common Rail Pressure Sensor Abnormality (abnormally high voltage) 173
DTC: 0201 No 1 Cylinder Injector Drive System Disconnection 179
DTC: 0202 No 2 Cylinder Injector Drive System Disconnection 184
DTC: 0203 No 3 Cylinder Injector Drive System Disconnection 189
DTC: 0204 No 4 Cylinder Injector Drive System Disconnection 194
DTC: 0205 No 5 Cylinder Injector Drive System Disconnection 199
DTC: 0206 No 6 Cylinder Injector Drive System Disconnection 204
DTC: 0219 Overrun 209
DTC: 0237 Boost Pressure Sensor Abnormality (abnormally low voltage) 211
DTC: 0238 Boost Pressure Sensor Abnormality (abnormally high voltage) 216
DTC: 0335 CKP (crank position) Sensor Abnormality (no signal) 221
DTC: 0336 CKP (crank position) Sensor Abnormality (signal abnormality) 226
DTC: 0340 CMP (cam position) Sensor Abnormality (no signal) 231
DTC: 0341 CMP (cam position) Sensor Abnormality (signal abnormality) 237
DTC: 0380 Glow Relay Circuit Abnormality 242
DTC: 0487 EGR Position Sensor Abnormality 247
DTC: 0488 EGR Valve Control Abnormality 252
DTC: 0522 Engine Oil Pressure Sensor Abnormality (abnormally low voltage) 257
DTC: 0523 Engine Oil Pressure Sensor Abnormality (abnormally high voltage) 262
DTC: 0601 ROM Abnormality 268
DTC: 0603 EEPROM Abnormality 269
DTC: 0606 CPU Abnormality 270
DTC: 0611 Charge Circuit Abnormality (bank 1) 271
DTC: 0612 Charge Circuit Abnormality (bank 2) 273
DTC: 1093 No Pump Pressure Send 275
DTC: 1095 Pressure Limiter Open 281
DTC: 1112 Boost Temperature Sensor Abnormality (abnormally low voltage) 288
DTC: 1113 Boost Temperature Sensor Abnormality (abnormally high voltage) 294
DTC: 1173 Overheat 299
DTC: 1261 Injector Common 1 Drive System Abnormality 305
DTC: 1262 Injector Common 2 Drive System Abnormality 312
DTC: 1345 CMP (cam position) Sensor Out of Phase 319
DTC: 1625 Main Relay System Abnormality 321
DTC: 1630 A/D Conversion Abnormality 327
DTC: 1632 5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) 328
DTC: 1633 5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) 332
DTC: 1634 5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) 337
DTC: 1635 5 V Power Supply 5 Voltage Abnormality
(common rail pressure sensor, EGR position sensor power supply) 341
DTC: 2104 CAN Bus Abnormality 346
DTC: 2106 CAN Time-out Abnormality 350
Main Unit-side Trouble 354
Main Unit-side DTC List 354
DTC: 7000 P1 Pressure Sensor Signal Abnormality 357
DTC: 7001 P2 Pressure Sensor Signal Abnormality 359
DTC: 7002 N1 Pressure Sensor Signal Abnormality 361
DTC: 7003 N2 Pressure Sensor Signal Abnormality 363
DTC: 7004 Overload Pressure Sensor Signal Abnormality 365
DTC: 7005 Bottom Pressure Sensor Signal Abnormality 367
DTC: 7006 Rod Pressure Sensor Signal Abnormality 369
DTC: 7020 Upper Pressure Sensor Signal Abnormality 371
3
SST-10-00-007EN
Troubleshoot
DTC: 7021 Swing Pressure Sensor Signal Abnormality 373
DTC: 7022 Travel Pressure Sensor Signal Abnormality 375
DTC: 7040 Fuel Level Sensor Signal Abnormality 377
DTC: 7041 Oil Temperature Sensor Signal Abnormality 379
DTC: 7045 Monitor Thermistor Signal Abnormality 381
DTC: 7063 Return Filter Clogging Pressure Switch Signal Abnormality 382
DTC: 7200 Swing Brake Solenoid Signal Abnormality 386
DTC: 7201 Travel High-speed Solenoid Signal Abnormality 388
DTC: 7202 Pressure Boost Solenoid Signal Abnormality 390
DTC: 7203 Travel Alarm Buzzer Signal Abnormality 393
DTC: 7204 Power save solenoid signal fault 395
DTC: 7209 Air Conditioner Coolant Temperature Signal Abnormality 397
DTC: 7240 Pump Horsepower Proportional Valve Signal Abnormality 398
DTC: 7241 P1 Flow Control Proportional Valve Signal Abnormality 401
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) 404
DTC: 7404 Abnormally High Oil Temperature (95 ℃ or higher) 405
DTC: 7405 Abnormally High Boost Temperature (80 ℃ or higher)
7406 Abnormally High Boost Temperature (90 ℃ or higher) 406
DTC: 7420 Abnormally Low Alternator Voltage 407
DTC: 7421 Coolant Level Reduction 409
DTC: 7422 Abnormally Low Engine Oil Pressure 410
DTC: 7423 Air Cleaner Clogging 411
DTC: 7424 Return Filter Clogging (breaker specifications) 413
DTC: 7600 CAN Bus Abnormality 414
DTC: 7601 Monitor Communication Abnormality 416
DTC: 7602 ECM Communication Abnormality 417
DTC: 7603 Computer B Communication Abnormality 418
DTC: 7604 Computer S Communication Abnormality 419
DTC: 7605 ECM Mismatch 420
DTC: 7606 EEPROM Data Abnormality 421
Problem Symptom List 422
Problem Symptom List 422
Engine Start Problem 423
Engine Stalling 426
Engine Hunting, Rough Idling 429
Engine Output Deficiency 432
Excessive White Smoke in Exhaust Gas 435
Excessive Black Smoke in Exhaust Gas 437
Abnormal Noise 439
High Fuel Consumption 441
High Oil Consumption 444
Tech 2 Data Reference Values 446
Unit Conversion Ratio 448
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