Sumitomo SH160-5 Hydraulic Excavator Troubleshooting Manual – PDF DOWNLOAD

Description

Sumitomo SH160-5 Hydraulic Excavator Troubleshooting Manual – PDF DOWNLOAD

SUMITOMO SH160-5 HYDRAULIC EXCAVATOR TROUBLESHOOTING MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Sumitomo SH160-5 Hydraulic Excavator Troubleshooting Manual – 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 4JJ1 type engine.
(SH130-5, SH160-5)
Extensive use of this manual is useful for performing accurate and quick maintenance procedures.

TABLE OF CONTENTS:

Sumitomo SH160-5 Hydraulic Excavator Troubleshooting Manual – 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
Sorting methods 27
Breaker Box Inspection Procedure 28
Engine Control System 31
Engine Control (common rail) System Functions and Operation Explanation 31
Engine Control Module (ECM) 39
Engine Component Parts Layout Diagram 41
Engine Control Module (ECM) Wiring Diagram 59
Engine Control Module (ECM) Pin Layout 60
Engine Harness Routing Diagram 74
Connector List 78
Function Inspection List 80
Function Inspection List 80
Trouble Diagnosis by Service Support 81
Checking the Start Circuit System 82
Checking the Start System 86
Checking the Fuel System 88
Checking the Suction Air System 92
Checking the Exhaust System 92
Checking the EGR Control System 93
Engine-side Trouble 95
Engine-side DTC List 95
Trouble Recovery 103
Screen Display Details 104
Abnormality Display 106
DTC: 0087 Abnormally Low Common Rail Pressure (supply pump not sending pressure) 107
DTC: 0088 Abnormally High Common Rail Pressure (1st stage or 2nd stage) 113
DTC: 0089 Common Rail Pressure Abnormality (supply pump sending too much pressure) 117
DTC: 0090 SCV (suction control valve) Drive System Disconnection, +B Short, or GND Short 121
DTC: 0107 Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage) 126
DTC: 0108 Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage) 132
3 NST-10-00-006EN
Troubleshoot
DTC: 0112 IAT (suction air temperature) Sensor Abnormality (abnormally low voltage) 137
DTC: 0113 IAT (intake air temperature) Sensor Abnormality (abnormally high voltage) 143
DTC: 0117 ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) 149
DTC: 0118 ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage) 156
DTC: 0182 FT (fuel temperature) Sensor Abnormality (abnormally low voltage) 163
DTC: 0183 FT (fuel temperature) Sensor Abnormality (abnormally high voltage) 170
DTC: 0192 Common Rail Pressure Sensor Abnormality (abnormally low voltage) 177
DTC: 0193 Common Rail Pressure Sensor Abnormality (abnormally high voltage) 183
DTC: 0201 No 1 Cylinder Injector Drive System Disconnection 189
DTC: 0202 No 2 Cylinder Injector Drive System Disconnection 194
DTC: 0203 No 3 Cylinder Injector Drive System Disconnection 199
DTC: 0204 No 4 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) 238
DTC: 0380 Glow Relay Circuit Abnormality 243
DTC: 0487 EGR Position Sensor Abnormality 248
DTC: 0488 EGR Valve Control Abnormality 253
DTC: 0522 Engine Oil Pressure Sensor Abnormality (abnormally low voltage) 258
DTC: 0523 Engine Oil Pressure Sensor Abnormality (abnormally high voltage) 264
DTC: 0601 ROM Abnormality 270
DTC: 0603 EEPROM Abnormality 271
DTC: 0606 CPU Abnormality 272
DTC: 0611 Charge Circuit Abnormality (bank 1) 273
DTC: 0612 Charge Circuit Abnormality (bank 2) 276
DTC: 1093 No Pump Pressure Send 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 303
DTC: 1261 Injector Common 1 Drive System Abnormality 309
DTC: 1262 Injector Common 2 Drive System Abnormality 316
DTC: 1345 CMP (cam position) Sensor Out of Phase 323
DTC: 1625 Main Relay System Abnormality 325
DTC: 1630 A/D Conversion Abnormality 331
DTC: 1632 5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) 332
DTC: 1633 5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) 335
DTC: 1634 5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) 338
DTC: 1635 5 V Power Supply 5 Voltage Abnormality
(common rail pressure sensor, EGR position sensor power supply) 341
DTC: 2104 CAN Bus Abnormality 344
DTC: 2106 CAN Time-out Abnormality 349
Main Unit-side Trouble 353
Main Unit-side DTC List 353
DTC: 7000 P1 Pressure Sensor Signal Abnormality 356
DTC: 7001 P2 Pressure Sensor Signal Abnormality 358
DTC: 7002 N1 Pressure Sensor Signal Abnormality 360
DTC: 7003 N2 Pressure Sensor Signal Abnormality 362
4 NST-10-00-006EN
Troubleshoot
DTC: 7004 Overload Pressure Sensor Signal Abnormality 364
DTC: 7005 Bottom Pressure Sensor Signal Abnormality 366
DTC: 7006 Rod Pressure Sensor Signal Abnormality 368
DTC: 7020 Upper Pressure Sensor Signal Abnormality 370
DTC: 7021 Swing Pressure Sensor Signal Abnormality 372
DTC: 7022 Travel Pressure Sensor Signal Abnormality 374
DTC: 7040 Fuel Level Sensor Signal Abnormality 376
DTC: 7041 Oil Temperature Sensor Signal Abnormality 378
DTC: 7045 Monitor Thermistor Signal Abnormality 380
DTC: 7060 Boom Angle Sensor Signal Abnormality 381
DTC: 7061 Arm Angle Sensor Signal Abnormality 383
DTC: 7063 Return Filter Clogging Pressure Switch Signal Abnormality 385
DTC: 7200 Swing Brake Solenoid Signal Abnormality 389
DTC: 7201 Travel High-speed Solenoid Signal Abnormality 391
DTC: 7202 Pressure Boost Solenoid Signal Abnormality 393
DTC: 7203 Travel Alarm Buzzer Signal Abnormality 396
DTC: 7209 Air Conditioner Coolant Temperature Signal Abnormality 398
DTC: 7210 Liftcrane Buzzer Signal Abnormality 399
DTC: 7211 Rotating Light, Bucket Lock Signal Abnormality 402
DTC: 7240 Pump Horsepower Proportional Valve Signal Abnormality 404
DTC: 7241 P1 Flow Control Proportional Valve Signal Abnormality 407
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) 410
DTC: 7404 Abnormally High Oil Temperature (95 ℃ or higher) 411
DTC: 7405 Abnormally High Boost Temperature (80 ℃ or higher)
7406 Abnormally High Boost Temperature (90 ℃ or higher) 412
DTC: 7420 Abnormally Low Alternator Voltage 413
DTC: 7421 Coolant Level Reduction 415
DTC: 7422 Abnormally Low Engine Oil Pressure 416
DTC: 7423 Air Cleaner Clogging 417
DTC: 7424 Return Filter Clogging (breaker specifications) 419
DTC: 7600 CAN Bus Abnormality 420
DTC: 7601 Monitor Communication Abnormality 422
DTC: 7602 ECM Communication Abnormality 423
DTC: 7605 ECM Mismatch 424
DTC: 7606 EEPROM Data Abnormality 425
Problem Symptom List 426
Problem Symptom List 426
Engine Start Problem 427
Engine Stalling 431
Engine Hunting, Unstable Idling Speed 435
Engine Output Deficiency 439
Excessive White Smoke in Exhaust Gas 443
Excessive Black Smoke in Exhaust Gas 445
Abnormal Noise 447
High Fuel Consumption 449
High Oil Consumption 452
Tech 2 Data Reference Values 454
Unit Conversion Ratio 456

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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