Sumitomo SH80BS-6A Hydraulic Excavator Repair Service Manual

Sumitomo Excavator SH80BS-6A Format: PDF Manual Identification: WLSM0806-00T, WCL0806-0T, WDL0806-1T English Sumitomo SH80BS-6A Hydraulic Excavator Repair Service Manual – 1246 Pages Operators Manual – 272 Pages Parts Catalog –  510 Pages Description Sumitomo SH80BS-6A Hydraulic Excavator Repair Service Manual Sumitomo Excavator SH80BS-6A Format: PDF Manual Identification: WLSM0806-00T, WCL0806-0T, WDL0806-1T English Sumitomo SH80BS-6A Hydraulic Excavator Repair Service Manual – 1246 Pages Operators Manual – 272 Pages Parts Catalog –  510 Pages Sumitomo SH80BS-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……………………………………………………………………………………. 24 Overall View………………………………………………………………………………………………….. 34 WORK RANGE DIAGRAM……………………………………………………………………………… 36 Main Unit Weight…………………………………………………………………………………………… 40 FLUIDS AND LUBRICANTS……………………………………………………………………………. 53 Circuits and Operation explanation…………………………………………………………………… 57 Main Equipment Structure and Operation Explanation………………………………………… 60 Hydraulic Pump…………………………………………………………………………………………….. 61 Travel Motor………………………………………………………………………………………………….. 70 Swing Motor………………………………………………………………………………………………….. 85 3 Stack Solenoid Valve Operation Explanation………………………………………………….. 99 Upper Pilot Valve (remote control valve)…………………………………………………………. 101 Travel Pilot Valve (remote control valve)…………………………………………………………. 107 Blade Pilot Valve (remote control valve)………………………………………………………….. 112 Option Pilot Valve (remote control valve)………………………………………………………… 114 Cushion Valve …………………………………………………………………………………………….. 117 Swing Pilot Valve (remote control valve)…………………………………………………………. 121 Reverse Prevention Valve…………………………………………………………………………….. 124 2 Stack Solenoid Valve…………………………………………………………………………………. 133 Direction Valve (3-direction) (option)………………………………………………………………. 134 Shut-off Valve……………………………………………………………………………………………… 135 HBCV…………………………………………………………………………………………………………. 136 Engine Summary…………………………………………………………………………………………. 138 Hydraulic Equipment Layout………………………………………………………………………….. 183 Overall View………………………………………………………………………………………………… 184 Port Diagram……………………………………………………………………………………………….. 188 Hydraulic Device………………………………………………………………………………………….. 207 Electrical and Engine Functions and Service Support……………………………………….. 208 Basic Functions…………………………………………………………………………………………… 209 Service Support…………………………………………………………………………………………… 252 Maintenance precautions………………………………………………………………………………. 292 Electrical Equipment Layout Diagram……………………………………………………………… 306 Connection Connector Pin Layout………………………………………………………………….. 333 Sequence Circuit Diagram…………………………………………………………………………….. 336 Removal / Installation and Assembly / Disassembly………………………………………… 351 Pressure Bleeding Operations……………………………………………………………………….. 359 Removal and Installation of Track………………………………………………………………….. 360 Removal and Installation of Shoe Assembly……………………………………………………. 361 Removal and Installation of Shoe Plate…………………………………………………………… 364 Removal and Installation of Roller………………………………………………………………….. 365 Removal and Installation of Upper Roller………………………………………………………… 366 Assembly and Disassembly of Upper Roller…………………………………………………….. 368 Removal and Installation of Lower Roller………………………………………………………… 373 Assembly and Disassembly of Lower Roller…………………………………………………….. 375 Removal and Installation of Drive Sprocket……………………………………………………… 380 Removal and Installation of Take-up Roller……………………………………………………… 381 Assembly and Disassembly of Take-up Roller…………………………………………………. 383 Removal and Installation of Grease Cylinder…………………………………………………… 391 Assembly and Disassembly of Tension Shock Absorber…………………………………… 393 Removal and Installation of Center Joint…………………………………………………………. 396 Assembly and Disassembly of Center Joint…………………………………………………….. 398 Removal and Installation of Travel Motor………………………………………………………… 405 Assembly and Disassembly of Travel Motor…………………………………………………….. 407 Removal and Installation of Swing Unit…………………………………………………………… 453 Assembly and Disassembly of Swing Motor…………………………………………………….. 456 Assembly and Disassembly of Swing Unit……………………………………………………….. 474 Removal and Installation of Hydraulic Pump……………………………………………………. 483 Removal and Installation of Pump Coupling…………………………………………………….. 486 Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit……………. 487 Pump Main Unit Maintenance Standards………………………………………………………… 493 Removal and Installation of Control Valve……………………………………………………….. 503 Procedures for Assembly and Disassembly of Control Valve……………………………… 510 Removal and Installation of Engine Assembly………………………………………………….. 524 Removal and Installation of Fuel Cooler, Engine Intercooler, Radiator, and Oil Cooler………………………………………………………………………………………………………… 529 Removal and Installation of Turbocharger assembly…………………………………………. 539 Removal and Installation of EGR Valve…………………………………………………………… 543 Removal and Installation of Engine Hood………………………………………………………… 545 Removal and Installation of Muffler………………………………………………………………… 546 Removal and Installation of Cylinder Head Cover…………………………………………….. 547 Removal and Installation of Idle gear……………………………………………………………… 573 Removal and Installation of Cylinder Block……………………………………………………… 581 Lubrication System………………………………………………………………………………………. 613 Cooling System……………………………………………………………………………………………. 623 Disassembly, Removal and Installation of Crankshaft……………………………………….. 630 Disassembly, Removal and Installation of Piston……………………………………………… 661 Removal and Installation of Camshaft…………………………………………………………….. 684 Removal and Installation of Flywheel……………………………………………………………… 705 Removal and Installation of Crankshaft front oil seal…………………………………………. 708 Removal and Installation of Crankshaft rear oil seal…………………………………………. 712 Removal and Installation of Rocker arm shaft………………………………………………….. 718 Removal and Installation of Valve spring…………………………………………………………. 725 Removal and Installation of Valve stem oil seal……………………………………………….. 742 Removal and Installation of Intake chamber…………………………………………………….. 760 Removal and Installation of Integrated oxidation catalyst silencer………………………. 764 Removal and Installation of Generator……………………………………………………………. 766 Removal and Installation of Exhaust Manifold………………………………………………….. 772 Removal and Installation of Fuel Supply Pump………………………………………………… 778 Removal and Installation of Common Rail Assembly………………………………………… 783 Removal and Installation of Injector………………………………………………………………… 785 Removal and Installation of Starter Motor……………………………………………………….. 790 Removal and Installation of Alternator…………………………………………………………….. 791 Preheating System………………………………………………………………………………………. 793 Introduction to the trouble diagnosis……………………………………………………………….. 798 Removal and Installation of Fuel Tank……………………………………………………………. 822 Removal and Installation of Hydraulic Tank…………………………………………………….. 825 Removal and Installation of Pilot Blocs……………………………………………………………. 830 Removal and Installation of Travel Remote Control Valve…………………………………. 831 Procedures for Assembly and Disassembly of Travel Remote Control Valve……….. 834 Removal and Installation of Option Remote Control Valve…………………………………. 847 Assembly and Disassembly Procedures of Option Remote Control Valve……………. 850 Removal and Installation of Operation Remote Control Valve……………………………. 858 Procedures for Assembly and Disassembly of Operation Remote Control Valve….. 866 Removal and Installation of Blade Remote Control Valve………………………………….. 877 Assembly and Disassembly Procedures…………………………………………………………. 880 Removal and Installation of Swing Remote Control Valve…………………………………. 888 Procedures for Assembly and Disassembly of Swing Remote Control Valve……….. 890 Removal and Installation of 3 Stack Solenoid………………………………………………….. 898 Removal and Installation of Cushion Valve……………………………………………………… 900 Assembly and Disassembly of Cushion Valve………………………………………………….. 902 Removal and Installation of Operator's Seat……………………………………………………. 903 Removal/installation of the KAB Seat……………………………………………………………… 904 Removal and Installation of Cab Assembly……………………………………………………… 905 Removal and Installation of Wiper………………………………………………………………….. 909 Removal and Installation of Wiper Controller…………………………………………………… 910 Removal and Installation of Wiper Motor…………………………………………………………. 911 Removal and Installation of ECM…………………………………………………………………… 913 Removal and Installation of Computer A…………………………………………………………. 914 Removal and Installation of Computer B…………………………………………………………. 915 Removal and Installation of Monitor……………………………………………………………….. 916 Removal and Installation of Cab Front Glass…………………………………………………… 918 Window Lock Adjustment Procedures…………………………………………………………….. 920 Tightening torque…………………………………………………………………………………………. 922 Removal and Installation of Counterweight……………………………………………………… 923 Removal and Installation of Bucket………………………………………………………………… 927 Removal and Installation of Bucket Link………………………………………………………….. 929 Removal and Installation of Arm…………………………………………………………………….. 931 Removal and Installation of Boom………………………………………………………………….. 933 Removal and Installation of Blade………………………………………………………………….. 937 Removal and Installation of Bucket Cylinder……………………………………………………. 939 Removal and Installation of Arm Cylinder………………………………………………………… 942 Removal and Installation of Boom Cylinder……………………………………………………… 946 Removal and Installation of Boom Swing Cylinder……………………………………………. 950 Removal and Installation of Blade Cylinder……………………………………………………… 954 Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder (made by KYB)……………………………………………………………………………………………. 958 Removal and Installation of HBCV…………………………………………………………………. 991 List of special tools………………………………………………………………………………………. 993 Maintenance standards and Measurement procedures………………………………….. 1013 Pressure Measurement and Adjustment Procedures………………………………………. 1014 Hydraulic Pump Flow Measurement Procedures……………………………………………. 1027 Drain Volume Measurement Procedures……………………………………………………….. 1031 Air Bleed Procedure……………………………………………………………………………………. 1034 Maintenance Standards………………………………………………………………………………. 1037 Bolt Size and Torque Table…………………………………………………………………………. 1056 New Machine Performance Judgment Table………………………………………………….. 1061 Air Conditioning…………………………………………………………………………………………… 1071 Air Conditioner Overall Diagram…………………………………………………………………… 1072 Assembly and Disassembly of Unit………………………………………………………………. 1112 Removal and Installation of Compressor……………………………………………………….. 1117 Removal and Installation of Condenser…………………………………………………………. 1118 Removal and Installation of Receiver Dryer…………………………………………………… 1120 Work Precautions………………………………………………………………………………………. 1122 Troubleshooting…………………………………………………………………………………………… 1131 Engine-side Diagnostic Trouble Code List……………………………………………………… 1134 Main Unit-side Diagnostic Trouble Code List………………………………………………….. 1136 Diagnostic Trouble Code Display on the Front Screen…………………………………….. 1137 Engine-side Trouble……………………………………………………………………………………. 1138 Main Unit-side Trouble………………………………………………………………………………… 1185 Symptom…………………………………………………………………………………………………… 1224 Data Reference Values……………………………………………………………………………….. 1236 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 SH80BS-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 SH80BS-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.