Sumitomo SH460LHD-5 SH480LHD-5 SH500LHD-5 Excavator Troubleshooting Manual WLST4605TS-00W – PDF DOWNLOAD
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Sumitomo SH460LHD-5 SH480LHD-5 SH500LHD-5 Excavator Troubleshooting Manual WLST4605TS-00W – 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 6UZ1 type engine.
(SH460HD/480LHD-5, SH500LHD-5)
Extensive use of this manual is useful for performing accurate and quick maintenance procedures
TABLE OF CONTENTS:
Sumitomo SH460LHD-5 SH480LHD-5 SH500LHD-5 Excavator Troubleshooting Manual WLST4605TS-00W – 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
Terminology explanation 17
Comprehensive diagnosis operations of component parts monitoring 17
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 24
Breaker Box Inspection Procedure 25
Engine Control System 28
Engine Control (common rail) System Functions and Operation Explanation 28
Engine Control Module (ECM) 34
Engine Component Parts Layout Diagram 36
Engine Control Module (ECM) Wiring Diagram 52
Engine Control Module (ECM) Pin Layout 53
Circuit Diagram 57
Engine Harness Routing Diagram 66
Connector List 71
Function Inspection List 74
Function Inspection List 74
Trouble Diagnosis by Service Support 75
Checking the Start Circuit System 76
Checking the Start System 80
Checking the Fuel System 82
Checking the Intake Air System 84
Checking the Exhaust System 85
Checking the EGR Control System 86
2
目次は本文校了後作成します。
TST-10-00-005EN
Troubleshoot
Engine-side Trouble 88
Engine-side DTC List 88
Trouble Recovery 96
Screen Display Details 97
Abnormality Display 99
DTC: 0087 Abnormally Low Common Rail Pressure (supply pump not sending pressure) 100
DTC: 0088 Abnormally High Common Rail Pressure (1st stage or 2nd stage) 106
DTC: 0089 Common Rail Pressure Abnormality (supply pump sending too much pressure) 109
DTC: 0090 PCV (pressure control valve) Circuit Fault (PCV1 open circuit or GND short circuit) 113
DTC: 0092 PCV (pressure control valve) Circuit Fault (PCV1 + B short) 118
DTC: 0107 Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage) 123
DTC: 0108 Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage) 129
DTC: 0112 IAT (intake air temperature) Sensor Abnormality (abnormally low voltage) 134
DTC: 0113 IAT (intake air temperature) Sensor Abnormality (abnormally high voltage) 138
DTC: 0117 ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) 143
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) 162
DTC: 0192 Common Rail Pressure Sensor Abnormality (abnormally low voltage) 169
DTC: 0193 Common Rail Pressure Sensor Abnormality (abnormally high voltage) 175
DTC: 0201 No 1 Cylinder Injector Drive System Disconnection 181
DTC: 0202 No 2 Cylinder Injector Drive System Disconnection 186
DTC: 0203 No 3 Cylinder Injector Drive System Disconnection 191
DTC: 0204 No 4 Cylinder Injector Drive System Disconnection 196
DTC: 0205 No 5 Cylinder Injector Drive System Disconnection 201
DTC: 0206 No 6 Cylinder Injector Drive System Disconnection 206
DTC: 0219 Overrun 211
DTC: 0237 Boost Pressure Sensor Abnormality (abnormally low voltage) 213
DTC: 0238 Boost Pressure Sensor Abnormality (abnormally high voltage) 219
DTC: 0335 CKP (crank position) Sensor Abnormality (no signal) 225
DTC: 0336 CKP (crank position) Sensor Abnormality (signal abnormality) 230
DTC: 0340 G Sensor Abnormality (no signal) 235
DTC: 0341 G Sensor Abnormality (signal abnormality) 241
DTC: 0380 Glow Relay Circuit Abnormality 246
DTC: 0487 EGR Position Sensor Abnormality 251
DTC: 0488 EGR Valve Control Abnormality 256
DTC: 0522 Engine Oil Pressure Sensor Abnormality (abnormally low voltage) 261
DTC: 0523 Engine Oil Pressure Sensor Abnormality (abnormally high voltage) 266
DTC: 0601 ROM Abnormality 272
DTC: 0603 EEPROM Abnormality 273
DTC: 0606 CPU Abnormality 274
DTC: 0611 Charge Circuit Abnormality (bank 1) 275
DTC: 0612 Charge Circuit Abnormality (bank 2) 277
DTC: 1093 No Pump Pressure Send (2nd stage) 279
DTC: 1095 Pressure Limiter Open 285
DTC: 1112 Boost Temperature Sensor Abnormality (abnormally low voltage) 292
DTC: 1113 Boost Temperature Sensor Abnormality (abnormally high voltage) 298
DTC: 1173 Overheat 304
DTC: 1261 Injector Common 1 Drive System Abnormality 309
DTC: 1262 Injector Common 2 Drive System Abnormality 317
DTC: 1291PCV(pressure control valve)Abnormality(PCV2 open circuit, ground short) 325
3
TST-10-00-005EN
Troubleshoot
DTC: 1292 PCV(pressure control valve)Abnormality(PCV2+B short circuit) 330
DTC: 1345 G Sensor Out of Phase 335
DTC: 1625 Main Relay System Abnormality 337
DTC: 1630 A/D Conversion Abnormality 343
DTC: 1632 5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) 344
DTC: 1633 5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) 348
DTC: 1634 5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) 353
DTC: 1635 5 V Power Supply 5 Voltage Abnormality
(common rail pressure sensor, EGR position sensor power supply) 357
DTC: 2104 CAN Bus Abnormality 362
DTC: 2106 CAN Time-out Abnormality 366
Main Unit-side Trouble 370
Main Unit-side DTC List 370
DTC: 7000 P1 Pressure Sensor Signal Abnormality 373
DTC: 7001 P2 Pressure Sensor Signal Abnormality 375
DTC: 7002 N1 Pressure Sensor Signal Abnormality 377
DTC: 7003 N2 Pressure Sensor Signal Abnormality 379
DTC: 7004 Overload Pressure Sensor Signal Abnormality 381
DTC: 7020 Upper Pressure Sensor Signal Abnormality 383
DTC: 7021 Swing Pressure Sensor Signal Abnormality 385
DTC: 7022 Travel Pressure Sensor Signal Abnormality 387
DTC: 7040 Fuel Level Sensor Signal Abnormality 389
DTC: 7041 Oil Temperature Sensor Signal Abnormality 391
DTC: 7045 Monitor Thermistor Signal Abnormality 393
DTC: 7063 Return Filter Clogging Pressure Switch Signal Abnormality 394
DTC: 7200 Swing Brake Solenoid Signal Abnormality 398
DTC: 7201 Travel High-speed Solenoid Signal Abnormality 400
DTC: 7202 Pressure Boost Solenoid Signal Abnormality 402
DTC: 7203 Travel Alarm Buzzer Signal Abnormality 405
DTC: 7209 Air Conditioner Coolant Temperature Signal Abnormality 407
DTC: 7211 Beacon, Bucket Lock Signal Abnormality 408
DTC: 7240 Pump Horsepower Proportional Valve Signal Abnormality 410
DTC: 7241 P1 Flow Control Proportional Valve Signal Abnormality 413
DTC: 7400 Abnormally High Coolant Temperature (105 ℃ or higher)
7401 Abnormally High Coolant Temperature (110 ℃ or higher)
7402 Abnormally High Coolant Temperature (120 ℃ or higher) 416
DTC: 7404 Abnormally High Oil Temperature (95 ℃ or higher) 417
DTC: 7405 Abnormally High Boost Temperature (80 ℃ or higher)
7406 Abnormally High Boost Temperature (90 ℃ or higher) 418
DTC: 7420 Abnormally Low Alternator Voltage 419
DTC: 7421 Coolant Level Reduction 421
DTC: 7422 Abnormally Low Engine Oil Pressure 422
DTC: 7423 Air Cleaner Clogging 423
DTC: 7424 Return Filter Clogging (breaker specifications) 425
DTC: 7600 CAN Bus Abnormality 426
DTC: 7601 Monitor Communication Abnormality 428
DTC: 7602 ECM Communication Abnormality 429
DTC: 7604 Computer S Communication Abnormality 430
DTC: 7605 ECM Mismatch 431
DTC: 7606 EEPROM Data Abnormality 432
4
TST-10-00-005EN
Troubleshoot
Problem Symptom List 433
Problem Symptom List 433
Engine Start Problem 434
Engine Stalling 437
Engine Hunting, Rough Idling 440
Engine Output Deficiency 443
Excessive White Smoke in Exhaust Gas 446
Excessive Black Smoke in Exhaust Gas 448
Abnormal Noise 450
High Fuel Consumption 451
High Oil Consumption 454
Tech 2 Data Reference Values 456
6HK1 (Idol) 456
Unit Conversion Ratio 458
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