Sumitomo SH135X-3B Hydraulic Excavator Shop Manual – PDF DOWNLOAD

Description

Sumitomo SH135X-3B Hydraulic Excavator Shop Manual – PDF DOWNLOAD

DESCRIPTION:

Sumitomo SH135X-3B Hydraulic Excavator Shop Manual – PDF DOWNLOAD

Introduction:

• Appropriate operations, maintenance, inspections, troubleshooting, and repair of the machine are vital to keep it performing at its best and for the longest possible period of time, and to prevent it from breaking down. This document includes a General Outline, Specifications (Performance), Troubleshooting and Disassembly/ maintenance instructions, which are necessary for inspection, troubleshooting and repair of the machine. (Note: This Shop Manual is to be filed with the additional information to be added later.)
• For details of the engine, refer to the maintenance manual published by the engine manufacturer. For daily inspections and maintenance, see the Operator’s Manual to take advantage of the machine’s full performance. Numerical values or others may be changed without notice due to design alterations or other reasons.

Safety :

[1] Before starting maintenance work, read carefully and fully understand materials (instruction manual
and maintenance manual).
[2] Before disassembling and assembling, take sufficient safety measures to prevent accidents such
as falling loads, being caught in or under the machine and burns.
When working under the machine, use safety blocks to support the machine to avoid workers
getting caught.
[3] Cranes and other hoist equipment must be operated by licensed operators.
1) Crane operators and slinging workers must be licensed.
2) Make sure to inspect rigging.
[4] Wear proper clothing and protective gear as necessary during inspection or maintenance
(safety shoes, helmets, protective goggles, gloves, earplugs, dust mask and other protective
devices).
[5] Always keep the work area clean to avoid accidents such as skidding during travel and falling
objects.
[6] Make sure to ventilate properly when inspecting or servicing a machine indoors.
[7] Be prepared for any emergencies and take necessary fire preventative measures.

TABLE OF CONTENTS:

Sumitomo SH135X-3B Hydraulic Excavator Shop Manual – PDF DOWNLOAD

About This Shop Manual
Safety 1
Introduction 2
Using Technical Information 3
Symbols 3
Precautions for Use 4
General Preparation for Disassembly 15
General Cautions for Assembly 17
General Cautions When Performing Inspections 21
Tightening Torque
Tightening Bolts and Nuts 22
Retightening Torque Table 22
Numerical Conversion Table 23
Specifications
Overall View 1
Equipment Layout 1
Overall 1
Operator’s Seat 2
Main Equipment Table 3
Lower Assembly Diagram (overall) 3
1 SH135X-3B (mono-boom with blade/offset-boom with blade) 3
Lower Component 4
1 Travel Unit 4
2 Take-up Roller 4
3 Upper Roller 4
4 Lower Roller 4
5 Recoil Spring 5
6 Shoe 5
Upper Component 6
1 Swing Unit 6
Engine-related 7
1 Engine 7
2 Muffler 8
3 Air Cleaner (double element) 8
4 Radiator 8
5 Fuel Tank 9
6 Hydraulic Oil Tank 11
1
MSM-17-00-001EN 2
Table of Contents
Hydraulic Device 13
1 Hydraulic Pump 13
Control-related 14
1 Control Valve 14
2 Solenoid Valve (3 stack) 15
3 Remote Control Valve 16
4 Remote Control Valve Characteristic Diagram 18
5 Cushion Valve (with heat circuit) 20
6 Center Joint 20
Backhoe Attachment 21
1 Cylinder 21
2 Attachments 23
Oil and Filters 24
Method of Use for Fuel and Lubricating Oil According to Air Temperature 24
Fuel and Oil 24
Anti-freeze 24
Sumitomo Genuine Parts 24
Engine Fuel and Filter Maintenance 25
1 Fuel Used 25
2 Filter and Maintenance 26
Consumable Parts 27
SH135X-3B Oil Feeding and Element Replacement 28
Replacement Times for Hydraulic Oil and Filters When Using the Breaker 31
Performances
Lifting Capacity 1
Precautions for Lifting Loads with the Hydraulic Excavator 1
Lifting Capacities SH135X-3B (Mono-boom with blade) 2
1 Standard Arm (2 39 m), 500 Grouser shoe (Blade down) 2
2 Standard Arm (2 39 m), 500 Grouser shoe (Blade up) 3
3 Long Arm (2 85 m), 500 Grouser shoe (Blade down) 4
4 Long Arm (2 85 m), 500 Grouser shoe (Blade up) 5
Lifting Capacities SH135X-3B (Offset-boom with blade) 6
1 Standard Arm (2 11 m), 500 Grouser shoe (Blade down) 6
2 Standard Arm (2 11 m), 500 Grouser shoe (Blade up) 7
3 Long Arm (2 41 m), 500 Grouser shoe (Blade down) 8
4 Long Arm (2 41 m), 500 Grouser shoe (Blade up) 9
Hydraulic Pump Control Diagram 10
P-Q Diagram 10
2
Table of Contents
3 MSM-17-00-001EN
Disassembling and Maintenance Instructions for Main Body
Maintenance Procedures
Lower Unit Path Block Diagram 1
Main Parts Tightening Torque 2
Bolt and Nut Tightening 2
Inspection and Maintenance 3
Retightening Torque Table 3
Lower Unit
Track Shoe 7
1 Removal Procedure 8
2 Installation Procedure 9
3 Track Link Replacement Procedure 10
Travel Unit 11
1 Cautions for Assembly 11
2 Removal Procedure 12
3 Installation procedure 13
Recoil Spring 14
1 Removal Procedure 15
2 Installation Procedure 16
Upper Roller 17
1 Removal Procedure 18
2 Installation Procedure 19
Lower Roller 20
1 Removal Procedure 21
2 Installation Procedure 22
Center Joint 23
1 Removal Procedure 24
2 Installation Procedure 25
Upper Unit
Swing Unit 26
Engine 30
Hydraulic Pump 33
Control Valve 35
Remote Control Valve 36
Operator Cab 39
3
MSM-17-00-001EN 4
Table of Contents
Disassembling and Maintenance Instructions for Major Parts
Attachment (mono boom)
Removal and Installation of Bucket Cylinder 1
1 Removal Procedure 1
2 Installation Procedure 3
Removal and Installation of Arm Cylinder 5
1 Removal Procedure 5
2 Installation Procedure 7
Removal and Installation of Boom Cylinder 9
1 Removal Procedure 9
2 Installation Procedure 11
Attachment (offset boom)
Removal Procedure 14
1 Boom Cylinder 14
2 Offset Cylinder 14
3 Arm Cylinder 15
Installation of Cylinder 16
Take-up Roller
Assembly and Disassembly Procedures 17
1 Configuration Diagram 17
2 Tools 17
3 Jig Dimension Diagram 17
4 Disassembly Procedures 18
5 Assembly Procedures 22
Assembly Diagram 26
Upper Roller
Assembly and Disassembly Procedures 27
1 Configuration Diagram 27
2 Tools 27
3 Jig Dimension Diagram 27
4 Disassembly Procedures 28
5 Assembly Procedures 31
Assembly Diagram 35
4
Table of Contents
5 MSM-17-00-001EN
Lower Roller
Assembly and Disassembly Procedures 36
1 Configuration Diagram 36
2 Tools 36
3 Jig Dimension Diagram 36
4 Disassembly Procedures 37
5 Assembly Procedures 40
Assembly Diagram 44
Grease Cylinder
Assembly and Disassembly Procedures 45
1 Configuration Diagram 45
2 Tools and Jigs 45
3 Disassembly Procedures 46
4 Assembly Procedures 47
Assembly Diagram 49
Rotating Joint
Disassembling and Assembling Instructions 50
1 Component Diagram 50
2 Tools and Jigs 51
3 Disassembling Instructions 52
4 Assembling Instructions 54
Assembly Drawings 57
Air Conditioner
Disassembling Instructions 58
1 Disassembling the Case 58
2 Replacing the Blower Motor 59
3 Replacing the Evaporator 59
4 Replacing the expansion valve 60
5 Replacing the heater core 60
6 Replacing the motor actuator 60
5
MSM-17-00-001EN 6
Table of Contents
Maintenance Standards
Check Sheet 61
1 Drive Sprocket 61
2 Take-up Roller 62
3 Upper Roller 63
4 Lower Roller 64
5 Track Shoe (grouser shoe) 65
6 Attachment (backhoe) 66
7 Attachment (offset boom) 75
8 Blade 84
Inspection Gauge 87
1 For Drive Sprocket 87
2 For Take-up Roller 87
3 For Upper Roller 88
4 For Lower Roller 88
List of Attachment Gap Adjustment Shims 89
List of Attachment Gap Adjustment Shims (for boom foot) 93
6
Table of Contents
7 MSM-17-00-001EN
Disassembling and Maintenance Instructions for Major Hydraulic Components
Hydraulic Pump
Disassembly and Maintenance Procedures 1
1 Procedures for Assembly and Disassembly of Pump Main Unit Section 1
2 Pump Main Unit Section Maintenance Standards 10
3 Causes of Trouble and Solutions 12
4 Pump Breakdown Diagram 14
5 Pump Structural Diagram 15
Regulator Handling 17
1 Summary 17
2 Operation Explanation 18
3 Regulator Adjustment 20
4 Causes and Solutions for Regulator Trouble 22
5 Table and Diagram 23
Regulator Assembly and Disassembly Procedures 27
1 Caution for Disassembly 27
2 Tool 27
3 Disassembly Procedures 28
4 Assembly Procedures 31
5 Regulator Assembly Structural Diagram (front side) 34
6 Regulator Assembly Structural Diagram (rear side) 36
Procedures for Assembly and Disassembly of PTO Unit 38
1 Tool 38
2 Disassembly Procedures 38
3 Assembly procedures 41
PTO Unit Maintenance Standards 44
1 Standards for replacing worn parts 44
2 Tightening torque 44
Travel Unit
Assembly and Disassembly of Travel Motor 47
1 Maintenance procedures 47
2 Disassembly 53
3 Maintenance standards 70
4 Assembly 72
5 Performance confirmation test 89
6 3-dimensional disassembly diagram of reduction gear section 90
7 3-dimensional disassembly diagram of hydraulic motor section 91
7
MSM-17-00-001EN 8
Table of Contents
Swing Unit 93
Hydraulic Motor 93
1 Cautions When Starting Operation 93
2 Causes of Trouble and Solutions 93
3 Assembly and Disassembly 96
4 Maintenance Procedures 102
5 Structural Diagram 103
Reduction Gear 105
1 Handling Precautions 105
2 Causes of Trouble and Solutions 106
3 Maintenance Procedures 107
4 External Shape Diagram 115
5 Assembly Cross-section Diagram 117
Control Valve
Disassembly 119
1 Cautions for Disassembly 119
2 Disassembly Procedure 119
Washing 123
Inspection 123
Assembly 123
1 Sub Assembly 123
2 Assembly of Control Valve 125
Relief Valve 129
1 Procedures for Assembly and Disassembly of
Main Unit Main Relief Valve 129
2 Procedures for Assembly and Disassembly of
Add-on Main Relief Valve 130
3 Procedures for Assembly and Disassembly of
Overload Relief Valve 131
4 Negative Control Relief Valve 132
5 Relief Valve Adjustment 134
Installation 135
Operation 135
Control Valve Specifications List 135
Troubles and Countermeasures 136
Control Valves Overall 136
Relief Valve 137
Hydraulic System Overall 137
8
Table of Contents
9 MSM-17-00-001EN
Part List 138
Reference Diagram 139
Service Parts 145
Cylinder
Structural Diagram 155
1 Boom Cylinder Left (Mono-boom with blade/Offset-boom with blade) 155
2 Boom Cylinder Right (Mono-boom with blade) 156
3 Arm Cylinder (Mono-boom with blade) 157
4 Bucket Cylinder (Mono-boom with blade) 158
5 Blade Cylinder (left/right) (Mono-boom with blade/Offset-boom with blade) 159
6 Arm Cylinder (Offset-boom with blade) 160
7 Bucket Cylinder (Offset-boom with blade) 161
8 Offset Cylinder (Offset-boom with blade) 162
Maintenance Procedures 163
1 Explanation of Functions 163
2 Maintenance Inspection and Service 166
3 Trouble Diagnostics 167
4 Storage Standards 172
5 Assembly and disassembly procedures 173
Specialty Tool and Jig for Repair 188
1 Tool Dimensions 188
2 Handling of Specialty Jigs for Cylinder Repair 189
Remote Control Valve
Safety Items 210
1 Cautions Concerning Operator’s Manual 210
2 Safety Cautions 210
3 Disclaimer 211
For Operation 212
1 Summary 212
2 Specifications 212
3 Structure 212
4 Function 212
5 Operation 213
6 Maintenance Procedures 215
7 Causes of Trouble and Countermeasures 227
8 Remote Control Valve Assembly Cross-section Diagram 228
9 Special Jig Assembly Cross-section Diagram and Detailed Diagram 229
9
MSM-17-00-001EN 10
Table of Contents
For Travel Use 230
1 Summary 230
2 Specifications 230
3 Operation 230
4 Maintenance Procedures 234
5 Causes of Trouble and Countermeasures 248
6 Remote Control Valve Assembly Cross-section Diagram 249
For Offset and Blade 250
1 Operation 250
2 Maintenance Procedures 251
3 Causes of Trouble and Countermeasures 263
4 Assembly Cross-section Diagram 264
Solenoid Valve (3 stack)
Assembly Diagram 265
Operation Principle 265
Maintenance 266
1 Assembly and Disassembly Precautions 266
2 Assembly and Disassembly of Electromagnetic Switchover Valve 266
3 Maintenance Standards 267
4 Troubleshooting 267
Cautions for Safety 268
Cushion Valve
Operation Explanation 270
1 Appearance Diagram 270
2 System Diagram 271
3 Operation Explanation 272

SUMITOMO SH135X-3B HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:

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