2001 Sumitomo SH200-3, SH220-3 Excavator Service Manual

This service manual covers the 2001 Sumitomo SH200-3 and SH220-3 excavators, with SH200GT-3 hydraulic circuit and component-compatibility references and SH120-3 electrical/control coverage. Its focus is NEO control-system operation, fault diagnosis, and hydraulic pressure adjustment.

• Hydraulic circuits: High- and low-speed travel, straight travel, swing parking, boom and arm load holding, and breaker/crusher circuit operation.

• Pressure testing and adjustment: Main, pilot, attachment-port, and swing relief procedures, including measuring points, test conditions, adjustment locations, and required tools.

• Engine and pump control: Electronic governor operation, H/S/L and automatic modes, limp-home control, automatic boosting, preheating, and warm-up functions.

• Electrical diagnosis: Monitor diagnostics, short-circuit auto-detection, troubleshooting flowcharts, and tests for solenoid valves, stop motors, temperature sensors, pressure sensors, and backup sensors.

• Controller setup: Machine-model, territory, and language selection, controller mismatch checks, and service-function settings.

• Component references: Hydraulic schematics, wiring diagrams, pilot hose connections, component layouts, cylinder specifications, bucket and arm dimensions, and parts compatibility tables.

This manual is suited to technicians familiar with excavator hydraulic pressure testing and electrical measurements using a tester and service connectors.

Hydraulic Circuits and Pressure Adjustment

Control valve structural drawings explain straight-travel flow sharing, swing priority, boom-down pressure feedback, and arm regeneration. The pilot hose connection diagrams identify the associated ports and lines, while the breaker and crusher sections distinguish their flow paths and holding-valve functions.

The pressure-adjustment instructions distinguish the SH200-3's shim-adjusted swing relief valves from the SH220-3's screw-adjusted arrangement. SH200-3 coverage includes relief-valve disassembly, reassembly, and tightening specifications. The instructions also address temporary main-relief settings during attachment-port testing and restoration afterward.

The auto-boost section explains the protective cutoff for travel and auxiliary attachment operation: travel motors and crusher actuators cannot operate at the boosted pressure.

Electrical Fault Tracing and Monitor Diagnostics

DIAG1 through DIAG6 separate current engine and machine faults from stored faults and their occurrence times. Procedures cover clearing stored records; the CHK screens provide live operating data, transistor-output status, and short-circuit detection results.

Codes such as E0015 for the water-temperature sensor and M0020 for the oil-temperature sensor connect to troubleshooting charts that distinguish sensor faults from harness, connector, or controller problems. That distinction helps narrow the repair before replacing a component.

Component tests include pump-solenoid current measurements and temperature-dependent sensor resistance tables. Service-connector drawings identify adapters such as WDB0055-5 for solenoid-valve testing and WDB0055-6/-7 for the hydraulic pump proportional valve.

Electronic Governor and Controller Settings

For the ISUZU BB-6BG1T installation, the control descriptions connect throttle input, rack feedback, backup speed sensing, stop-motor operation, and limp-home behavior. Pre-glow time maps, idle-revolution maps, and auto warm-up timing charts explain how operating conditions affect engine control.

Initial controller setup includes model selection and engine-controller mismatch detection. Engine coverage concentrates on specifications and control-system diagnosis; a complete internal engine overhaul procedure is not included.

Parts Compatibility and Hydraulic Oil

Compatibility tables compare SH200-3 components with SH200GT-3 and SH200-2 parts, and SH220-3 components with SH220-2 parts. They distinguish common, different, and directionally interchangeable assemblies. For the GT variant, differences include pump control methods, control-valve settings, and monitor equipment.

Maintenance references cover ball-race greasing changes and IDEMITSU Daphne Super Hydro 46SX hydraulic oil, alongside Nephron system references in the product-concept section. The oil discussion links sludge formation to filter blockage, control-valve malfunction, and accelerated wear, and explains how mixing previous-generation oil into the new fluid reduces its extended-life properties.

Important safety notice: This documentation is provided for reference purposes. Always verify procedures and specifications with a certified heavy equipment technician before initiating repairs or system adjustments.

A Preview of Hydraulic Output and Electrical Test Values

These examples represent a small selection of the manual's performance and diagnostic data.

The hydraulic specifications list SH220-3 piston-pump delivery at 2 × 212 L/min and SH200-3 bucket digging force at 141 kN with boosting.

For electrical testing, the quadruple-solenoid section's lever-lock example specifies 45 Ω at 20°C. The backup speed-sensor test lists 0.7 kΩ at 25°C for SH120-3, SH200-3, and SH220-3; both resistance checks depend on temperature.

PDF Navigation, Diagram Detail, and Page Count

Text search and drawing detail: Text search is available in many sections, but some pages and drawing labels are not searchable. There are no embedded PDF bookmarks. Small hydraulic and electrical schematic labels require zooming; some electrical component-layout labels remain faint or difficult to read.

Supplied as one printable 166-page PDF in English. The total includes six contents pages, four product-concept pages, and a one-page units-conversion appendix.