Sumitomo SH235X-6 Hydraulic Excavator Repair Service Manual

Sumitomo Excavator SH235X-6 Format: PDF Manual Identification: WLSM2356-00T, WDL2356-1T English Jan. 2015 Sumitomo SH235X-6 Hydraulic Excavator Repair Service Manual – 1370 Pages Operators Manual – 270 Pages Parts Catalog –  642 Pages Description Sumitomo Excavator SH235X-6 Format: PDF Manual Identification: WLSM2356-00T, WDL2356-1T English Jan. 2015 Sumitomo SH235X-6 Hydraulic Excavator Repair Service Manual – 1370 Pages Operators Manual – 270 Pages Parts Catalog –  642 Pages Sumitomo SH235X-6 Manual TABLE OF CONTENTS Safety………………………………………………………………………………………………………………… 3 Safety, general information and standard torque data…………………………………………… 4 General Information…………………………………………………………………………………………. 5 Standard Torque Data For Cap Screws And Nuts………………………………………………. 12 Specifications And Special Torque Settings………………………………………………………. 13 Abbreviation………………………………………………………………………………………………….. 14 Specifications………………………………………………………………………………………………… 22 Main Equipment Table……………………………………………………………………………………. 32 Overall View………………………………………………………………………………………………….. 49 WORK RANGE DIAGRAM……………………………………………………………………………… 53 Main Unit Weight…………………………………………………………………………………………… 61 FLUIDS AND LUBRICANTS……………………………………………………………………………. 80 Circuits and Operation explanation…………………………………………………………………… 83 Main Equipment Structure and Operation Explanation………………………………………… 86 Hydraulic Pump…………………………………………………………………………………………….. 87 Travel Motor………………………………………………………………………………………………… 102 Swing Motor………………………………………………………………………………………………… 115 Control Valve………………………………………………………………………………………………. 121 5 Stack Solenoid Valve Operation Explanation………………………………………………… 156 Upper Pilot Valve (remote control valve)…………………………………………………………. 158 Travel Pilot Valve (remote control valve)…………………………………………………………. 163 Cushion Valve …………………………………………………………………………………………….. 168 3 Stack Proportional Valve (for pilot)………………………………………………………………. 174 Engine Summary…………………………………………………………………………………………. 178 Hydraulic Equipment Layout………………………………………………………………………….. 248 Overall view………………………………………………………………………………………………… 249 Port Diagram……………………………………………………………………………………………….. 254 Hydraulic Device………………………………………………………………………………………….. 279 Electrical and Engine Functions and Service Support……………………………………….. 280 Basic Functions…………………………………………………………………………………………… 281 Service Support…………………………………………………………………………………………… 356 Cautions for Maintenance……………………………………………………………………………… 397 Electrical Equipment Layout Diagram……………………………………………………………… 409 Connection Connector Pin Layout………………………………………………………………….. 439 Sequence Circuit Diagram…………………………………………………………………………….. 442 Removal / Installation and Assembly / Disassembly………………………………………… 457 Pressure Bleeding Operations……………………………………………………………………….. 464 Removal and Installation of Track………………………………………………………………….. 465 Removal and Installation of Shoe Assembly……………………………………………………. 466 Removal and Installation of Shoe Plate…………………………………………………………… 469 Removal and Installation of Roller………………………………………………………………….. 470 Removal and Installation of Upper Roller………………………………………………………… 471 Assembly and Disassembly of Upper Roller…………………………………………………….. 473 Removal and Installation of Lower Roller………………………………………………………… 480 Assembly and Disassembly of Lower Roller…………………………………………………….. 482 Removal and Installation of Drive Sprocket……………………………………………………… 488 Removal and Installation of Take-up Roller……………………………………………………… 490 Assembly and Disassembly of Take-up Roller…………………………………………………. 492 Removal and Installation of Grease Cylinder…………………………………………………… 500 Assembly and Disassembly of Tension Shock Absorber…………………………………… 502 Removal and Installation of Center Joint…………………………………………………………. 505 Assembly and Disassembly of Center Joint…………………………………………………….. 509 Removal and Installation of Travel Motor………………………………………………………… 516 Assembly and Disassembly of Travel Motor…………………………………………………….. 521 Removal and Installation of Swing Unit…………………………………………………………… 570 Assembly and Disassembly of Swing Motor…………………………………………………….. 574 Assembly and Disassembly of Swing Unit……………………………………………………….. 588 Removal and Installation of Hydraulic Pump……………………………………………………. 593 Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit……………. 599 Pump Main Unit Maintenance Standards………………………………………………………… 604 Removal and Installation of Control Valve……………………………………………………….. 630 Procedures for Assembly and Disassembly of Control Valve……………………………… 635 Removal and Installation of Engine Assembly………………………………………………….. 657 Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler………………………………………………………………………………………………………… 663 Removal and Installation of Turbo Charger……………………………………………………… 674 Removal and Installation of EGR Valve…………………………………………………………… 678 Removal and Installation of Top Cover……………………………………………………………. 682 Removal and Installation of Muffler………………………………………………………………… 683 Removal and Installation of Cylinder Head Cover…………………………………………….. 685 Removal and Installation of Cylinder Block……………………………………………………… 727 Lubrication System………………………………………………………………………………………. 777 Cooling System……………………………………………………………………………………………. 816 Removal and Installation of Exhaust Manifold………………………………………………….. 824 Disassembly, Removal and Installation of DPD Assembly…………………………………. 831 Removal and Installation of Fuel Supply Pump………………………………………………… 836 Removal and Installation of Common Rail Assembly………………………………………… 840 Removal and Installation of Injector………………………………………………………………… 847 Removal and Installation of Starter Motor……………………………………………………….. 856 Removal and Installation of Alternator…………………………………………………………….. 858 Preheating System………………………………………………………………………………………. 860 Removal and Installation of Fuel Tank……………………………………………………………. 872 Removal and Installation of Hydraulic Tank…………………………………………………….. 875 Removal and Installation of Pilot Blocs……………………………………………………………. 879 Removal and Installation of Travel Remote Control Valve…………………………………. 880 Procedures for Assembly and Disassembly of Travel Remote Control Valve……….. 883 Removal and Installation of Operation Remote Control Valve……………………………. 896 Procedures for Assembly and Disassembly of Operation Remote Control Valve….. 904 Removal and Installation of Blade Remote Control Valve………………………………….. 915 Assembly and Disassembly Procedures…………………………………………………………. 918 Removal and Installation of 5 Stack Solenoid………………………………………………….. 926 Removal and Installation of Cushion Valve……………………………………………………… 930 Assembly and Disassembly of Cushion Valve………………………………………………….. 933 Removal and Installation of Operator's Seat……………………………………………………. 937 Removal and Installation of Cab Assembly……………………………………………………… 938 Removal and Installation of Wiper………………………………………………………………….. 942 Removal and Installation of Wiper Controller…………………………………………………… 943 Removal and Installation of Wiper Motor…………………………………………………………. 944 Removal and Installation of ECM…………………………………………………………………… 946 Removal and Installation of Computer A…………………………………………………………. 947 Removal and Installation of Computer B…………………………………………………………. 948 Removal and Installation of Monitor……………………………………………………………….. 949 Removal and Installation of Cab Front Glass…………………………………………………… 951 Window Lock Adjustment Procedures…………………………………………………………….. 953 Tightening torque…………………………………………………………………………………………. 955 Removal and Installation of Counterweight……………………………………………………… 956 Removal and Installation of Bucket………………………………………………………………… 960 Removal and Installation of Bucket Link………………………………………………………….. 962 Removal and Installation of Arm…………………………………………………………………….. 964 Removal and Installation of Boom………………………………………………………………….. 966 Removal and Installation of Blade………………………………………………………………….. 971 Removal and Installation of Bucket Cylinder……………………………………………………. 974 Removal and Installation of Arm Cylinder………………………………………………………… 977 Removal and Installation of Boom Cylinder……………………………………………………… 981 Removal and Installation of Blade Cylinder……………………………………………………… 986 Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder (made by KYB)……………………………………………………………………………………………. 990 Removal and Installation of HBCV……………………………………………………………….. 1025 List of special tools…………………………………………………………………………………….. 1028 Maintenance standards and Measurement procedures………………………………….. 1051 Pressure Measurement and Adjustment Procedures………………………………………. 1052 Hydraulic Pump Flow Measurement Procedures……………………………………………. 1068 Drain Volume Measurement Procedures……………………………………………………….. 1072 Air Bleed Procedure……………………………………………………………………………………. 1075 Maintenance Standards………………………………………………………………………………. 1079 Bolt Size and Torque Table…………………………………………………………………………. 1095 New Machine Performance Judgment Table………………………………………………….. 1100 Air Conditioning…………………………………………………………………………………………… 1109 Air Conditioner Overall Diagram…………………………………………………………………… 1110 Assembly and Disassembly of Unit………………………………………………………………. 1152 Removal and Installation of Compressor……………………………………………………….. 1157 Removal and Installation of Condenser…………………………………………………………. 1158 Removal and Installation of Receiver Dryer…………………………………………………… 1160 Work Precautions………………………………………………………………………………………. 1162 Troubleshooting…………………………………………………………………………………………… 1173 Engine-side Diagnostic Trouble Code List……………………………………………………… 1177 Main Unit-side Diagnostic Trouble Code List………………………………………………….. 1179 Engine-side Trouble……………………………………………………………………………………. 1181 Main Unit-side Trouble………………………………………………………………………………… 1254 Symptom…………………………………………………………………………………………………… 1345 Data Reference Values……………………………………………………………………………….. 1359 The Sumitomo Manual Preface The purpose of this Sumitomo Excavator manual is to assist dealers and repair serviceman in efficient repair and maintenance of their machinery. Carrying out the procedures as detailed, together with the use of any special tools needed. Using the Sumitomo SH235X-6 Manual To make information easier to find, there is an index at the beginning of each section listing the various parts in that section. At the beginning of each part there is a table of contents which should also be used as a guide to locate information. To assist with locating information, each section of the manual is preceded by a contents page listing the repair operations, Each instruction within an operating has a sequence number. To complete the operation in the minimum time is possible follow the manual guideline and repair instructions. When parts have to be replaced in either the SH235X-6 Hydraulic Excavator , it is essential that only genuine Sumitomo parts should be used. Special attention should be paid to the following points concerning repairs and the fitting of replacement parts and accessories. Indexing For convenience the manual is divided into section and parts, each page bearing a section and part number. The sections are subdivided into numbered operation. This simplifies cross referencing and enable the subject to be found easily.