Sumitomo SH75X-6A Hydraulic Excavator Repair Service Manual

Sumitomo Excavator SH75X-6A Format: PDF Manual Identification: WLSM0756-00T, WDL0756-2T, WCL0756-0T English Mar 2014 Sumitomo SH75X-6A Hydraulic Excavator Repair Service Manual – 1252 Pages Operators Manual – 272 Pages Parts Catalog –  528 Pages Description Sumitomo SH75X-6A Hydraulic Excavator Repair Service Manual Sumitomo Excavator SH75X-6A Format: PDF Manual Identification: WLSM0756-00T, WDL0756-2T, WCL0756-0T English Mar 2014 Sumitomo SH75X-6A Hydraulic Excavator Repair Service Manual – 1252 Pages Operators Manual – 272 Pages Parts Catalog –  528 Pages Sumitomo SH75X-6A 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………………………………………………. 11 Specifications And Special Torque Settings………………………………………………………. 12 Abbreviation………………………………………………………………………………………………….. 13 Specifications………………………………………………………………………………………………… 20 Main Equipment Table……………………………………………………………………………………. 29 Overall View………………………………………………………………………………………………….. 40 WORK RANGE DIAGRAM……………………………………………………………………………… 44 Main Unit Weight…………………………………………………………………………………………… 48 FLUIDS AND LUBRICANTS……………………………………………………………………………. 64 Circuits and Operation explanation…………………………………………………………………… 69 Main Equipment Structure and Operation Explanation………………………………………… 72 Hydraulic Pump…………………………………………………………………………………………….. 73 Travel Motor………………………………………………………………………………………………….. 82 Swing Motor………………………………………………………………………………………………….. 97 3 Stack Solenoid Valve Operation Explanation………………………………………………… 111 Upper Pilot Valve (remote control valve)…………………………………………………………. 113 Travel Pilot Valve (remote control valve)…………………………………………………………. 119 Blade Pilot Valve (remote control valve)………………………………………………………….. 124 Option Pilot Valve (remote control valve)………………………………………………………… 126 Cushion Valve …………………………………………………………………………………………….. 129 Reverse Prevention Valve…………………………………………………………………………….. 133 2 Stack Solenoid Valve…………………………………………………………………………………. 142 Direction Valve (3-direction) (option)………………………………………………………………. 143 Shut-off Valve……………………………………………………………………………………………… 144 HBCV…………………………………………………………………………………………………………. 145 Engine Summary…………………………………………………………………………………………. 147 Hydraulic Equipment Layout………………………………………………………………………….. 192 Overall View………………………………………………………………………………………………… 193 Port Diagram……………………………………………………………………………………………….. 197 Hydraulic Device………………………………………………………………………………………….. 216 Electrical and Engine Functions and Service Support……………………………………….. 217 Basic Functions…………………………………………………………………………………………… 218 Service Support…………………………………………………………………………………………… 261 Maintenance precautions………………………………………………………………………………. 301 Electrical Equipment Layout Diagram……………………………………………………………… 315 Connection Connector Pin Layout………………………………………………………………….. 342 Sequence Circuit Diagram…………………………………………………………………………….. 345 Removal / Installation and Assembly / Disassembly………………………………………… 361 Pressure Bleeding Operations……………………………………………………………………….. 369 Removal and Installation of Track………………………………………………………………….. 370 Removal and Installation of Shoe Assembly……………………………………………………. 371 Removal and Installation of Shoe Plate…………………………………………………………… 374 Removal and Installation of Roller………………………………………………………………….. 375 Removal and Installation of Upper Roller………………………………………………………… 376 Assembly and Disassembly of Upper Roller…………………………………………………….. 378 Removal and Installation of Lower Roller………………………………………………………… 383 Assembly and Disassembly of Lower Roller…………………………………………………….. 385 Removal and Installation of Drive Sprocket……………………………………………………… 390 Removal and Installation of Take-up Roller……………………………………………………… 391 Assembly and Disassembly of Take-up Roller…………………………………………………. 393 Removal and Installation of Grease Cylinder…………………………………………………… 401 Assembly and Disassembly of Tension Shock Absorber…………………………………… 403 Removal and Installation of Center Joint…………………………………………………………. 406 Assembly and Disassembly of Center Joint…………………………………………………….. 408 Removal and Installation of Travel Motor………………………………………………………… 416 Assembly and Disassembly of Travel Motor…………………………………………………….. 418 Removal and Installation of Swing Unit…………………………………………………………… 464 Assembly and Disassembly of Swing Motor…………………………………………………….. 467 Assembly and Disassembly of Swing Unit……………………………………………………….. 485 Removal and Installation of Hydraulic Pump……………………………………………………. 494 Removal and Installation of Pump Coupling…………………………………………………….. 497 Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit……………. 498 Pump Main Unit Maintenance Standards………………………………………………………… 504 Removal and Installation of Control Valve……………………………………………………….. 514 Procedures for Assembly and Disassembly of Control Valve……………………………… 521 Removal and Installation of Engine Assembly………………………………………………….. 551 Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler………………………………………………………………………………………………………… 556 Removal and Installation of Turbocharger assembly…………………………………………. 566 Removal and Installation of EGR Valve…………………………………………………………… 570 Removal and Installation of Engine Hood………………………………………………………… 572 Removal and Installation of Muffler………………………………………………………………… 573 Removal and Installation of Cylinder Head Cover…………………………………………….. 574 Removal and Installation of Idle gear……………………………………………………………… 600 Removal and Installation of Cylinder Block……………………………………………………… 608 Lubrication System………………………………………………………………………………………. 640 Cooling System……………………………………………………………………………………………. 650 Disassembly, Removal and Installation of Crankshaft……………………………………….. 657 Disassembly, Removal and Installation of Piston……………………………………………… 688 Removal and Installation of Camshaft…………………………………………………………….. 711 Removal and Installation of Flywheel……………………………………………………………… 732 Removal and Installation of Crankshaft front oil seal…………………………………………. 735 Removal and Installation of Crankshaft rear oil seal…………………………………………. 739 Removal and Installation of Rocker arm shaft………………………………………………….. 745 Removal and Installation of Valve spring…………………………………………………………. 752 Removal and Installation of Valve stem oil seal……………………………………………….. 769 Removal and Installation of Intake chamber…………………………………………………….. 787 Removal and Installation of Integrated oxidation catalyst silencer………………………. 791 Removal and Installation of Generator……………………………………………………………. 793 Removal and Installation of Exhaust Manifold………………………………………………….. 799 Removal and Installation of Fuel Supply Pump………………………………………………… 805 Removal and Installation of Common Rail Assembly………………………………………… 810 Removal and Installation of Injector………………………………………………………………… 812 Removal and Installation of Starter Motor……………………………………………………….. 817 Removal and Installation of Alternator…………………………………………………………….. 818 Preheating System………………………………………………………………………………………. 820 Introduction to the trouble diagnosis……………………………………………………………….. 825 Removal and Installation of Fuel Tank……………………………………………………………. 849 Removal and Installation of Hydraulic Tank…………………………………………………….. 852 Removal and Installation of Pilot Blocs……………………………………………………………. 857 Removal and Installation of Travel Remote Control Valve…………………………………. 858 Procedures for Assembly and Disassembly of Travel Remote Control Valve……….. 861 Removal and Installation of Option Remote Control Valve…………………………………. 874 Assembly and Disassembly Procedures of Option Remote Control Valve……………. 877 Removal and Installation of Operation Remote Control Valve……………………………. 885 Procedures for Assembly and Disassembly of Operation Remote Control Valve….. 893 Removal and Installation of Blade Remote Control Valve………………………………….. 904 Assembly and Disassembly Procedures…………………………………………………………. 907 Removal and Installation of 3 Stack Solenoid………………………………………………….. 915 Removal and Installation of Cushion Valve……………………………………………………… 917 Assembly and Disassembly of Cushion Valve………………………………………………….. 919 Removal and Installation of Operator's Seat……………………………………………………. 920 Removal/installation of the KAB Seat……………………………………………………………… 921 Removal and Installation of Cab Assembly……………………………………………………… 922 Removal and Installation of Wiper………………………………………………………………….. 926 Removal and Installation of Wiper Controller…………………………………………………… 927 Removal and Installation of Wiper Motor…………………………………………………………. 928 Removal and Installation of ECM…………………………………………………………………… 930 Removal and Installation of Computer A…………………………………………………………. 931 Removal and Installation of Computer B…………………………………………………………. 932 Removal and Installation of Monitor……………………………………………………………….. 933 Removal and Installation of Cab Front Glass…………………………………………………… 935 Window Lock Adjustment Procedures…………………………………………………………….. 937 Tightening torque…………………………………………………………………………………………. 939 Removal and Installation of Counterweight……………………………………………………… 940 Removal and Installation of Bucket………………………………………………………………… 944 Removal and Installation of Bucket Link………………………………………………………….. 946 Removal and Installation of Arm…………………………………………………………………….. 948 Removal and Installation of Boom………………………………………………………………….. 950 Removal and Installation of Blade………………………………………………………………….. 954 Removal and Installation of Bucket Cylinder……………………………………………………. 956 Removal and Installation of Arm Cylinder………………………………………………………… 959 Removal and Installation of Boom Cylinder……………………………………………………… 963 Removal and Installation of Blade Cylinder……………………………………………………… 967 Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder (made by KYB)……………………………………………………………………………………………. 971 Removal and Installation of HBCV……………………………………………………………….. 1002 List of special tools…………………………………………………………………………………….. 1004 Maintenance standards and Measurement procedures………………………………….. 1023 Pressure Measurement and Adjustment Procedures………………………………………. 1024 Hydraulic Pump Flow Measurement Procedures……………………………………………. 1037 Drain Volume Measurement Procedures……………………………………………………….. 1041 Air Bleed Procedure……………………………………………………………………………………. 1044 Maintenance Standards………………………………………………………………………………. 1047 Bolt Size and Torque Table…………………………………………………………………………. 1067 New Machine Performance Judgment Table………………………………………………….. 1072 Air Conditioning…………………………………………………………………………………………… 1083 Air Conditioner Overall Diagram…………………………………………………………………… 1084 Assembly and Disassembly of Unit………………………………………………………………. 1124 Removal and Installation of Compressor……………………………………………………….. 1129 Removal and Installation of Condenser…………………………………………………………. 1130 Removal and Installation of Receiver Dryer…………………………………………………… 1132 Work Precautions………………………………………………………………………………………. 1134 Troubleshooting…………………………………………………………………………………………… 1143 Engine-side Diagnostic Trouble Code List……………………………………………………… 1146 Main Unit-side Diagnostic Trouble Code List………………………………………………….. 1148 Diagnostic Trouble Code Display on the Front Screen…………………………………….. 1149 Engine-side Trouble……………………………………………………………………………………. 1150 Main Unit-side Trouble………………………………………………………………………………… 1197 Symptom…………………………………………………………………………………………………… 1229 Data Reference Values……………………………………………………………………………….. 1241 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 SH75X-6A 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 SH75X-6A 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.