Description
Sumitomo SH160-5 Hydraulic Excavator Service Text & Troubleshooting Manual & Shop Manual
Sumitomo SH160-5 Hydraulic Excavator Index:
About This Shop Manual
Safety ……………………………………………………………………………………………………………..1
Introduction……………………………………………………………………………………………………..1
Using Technical Information
Symbols……………………………………………………………………………………………………….1
Precautions for Use
General Preparation for Disassembly ……………………………………………………………..12
General Cautions for Assembly ……………………………………………………………………..14
General Cautions When Performing Inspections………………………………………………18
Tightening Torque
Tightening Bolts and Nuts ………………………………………………………………………………1
Retightening Torque Table………………………………………………………………………………1
Numerical Conversion Table
Engine Section
Procedures for Replacing Consumable Parts
Engine Oil Replacement…………………………………………………………………………………1
Engine Oil Filter Element Replacement…………………………………………………………….4
Fuel Filter Replacement …………………………………………………………………………………5
Charge Fuel Pump Filter Replacement …………………………………………………………..11
Air Conditioner Belt Replacement ………………………………………………………………….13
Fan Belt Replacement ………………………………………………………………………………….16
Assembly and Disassembly
Removal and Installation of Engine Hood………………………………………………………….1
Removal and Installation of Engine Assembly……………………………………………………3
Removal and Installation of Starter Motor ……………………………………………………….14
Removal and Installation of Alternator…………………………………………………………….16
Removal and Installation of Supply Pump ……………………………………………………….18
Removal and Installation of Common Rail……………………………………………………….28
Removal and Installation of Injector………………………………………………………………..31
Removal and Installation of Muffler ………………………………………………………………..41
Removal and Installation of Turbo Charger ……………………………………………………..43
Removal and Installation of EGR Cooler and EGR Valve…………………………………..47
Removal and Installation of Engine Sensors ……………………………………………………49
Removal and Installation of Fuel Cooler………………………………………………………….50
Removal and Installation of Engine Inter Cooler ………………………………………………51
Air Conditioner Section
Assembly and Disassembly
Removal and Installation of Compressor…………………………………………………………..1
Removal and Installation of Condenser…………………………………………………………….3
Removal and Installation of Receiver Dryer ………………………………………………………5
Assembly and Disassembly of Unit ………………………………………………………………….7
Procedures for Gas Filling
Work Precautions ………………………………………………………………………………………….1
Work Procedures…………………………………………………………………………………………..2
Procedures for Filling……………………………………………………………………………………..4
Maintenance Section
Procedure for Electrical Equipment Judgment
Procedure for Electricity Measurement……………………………………………………………..1
Maintenance Standards
Check Sheet …………………………………………………………………………………………………1
Inspection Gauge ………………………………………………………………………………………..17
List of Attachment Gap Adjustment Shims ………………………………………………………19
List of Attachment Gap Adjustment Shims (for boom foot)………………………………..23
Assembly and Disassembly Section
Track Shoe
Removal and Installation of Shoe Assembly ……………………………………………………..1
Removal and Installation of Shoe Plate…………………………………………………………….6
Travel Unit
Removal and Installation of Travel Motor…………………………………………………………..1
Assembly and Disassembly of Travel Motor ………………………………………………………9
Travel Motor Internal Structure Diagram………………………………………………………….76
Travel Motor Part Table…………………………………………………………………………………78
Take-up Roller
Removal and Installation of Take-up Roller ……………………………………………………….1
Assembly and Disassembly of Take-up Roller……………………………………………………3
Upper Roller
Removal and Installation of Upper Roller ………………………………………………………….1
Assembly and Disassembly of Upper Roller………………………………………………………4
Lower Roller
Removal and Installation of Lower Roller ………………………………………………………….1
Assembly and Disassembly of Lower Roller………………………………………………………4
Grease Cylinder
Removal and Installation of Grease Cylinder …………………………………………………….1
Assembly and Disassembly of Grease Cylinder…………………………………………………3
2
Contents
3 LSM-00-00-009EN
Swing Unit
Removal and Installation of Swing Unit …………………………………………………………….1
Assembly and Disassembly of Swing Unit…………………………………………………………6
Assembly and Disassembly of Swing Motor…………………………………………………….11
Assembly and Disassembly of Swing Reduction Gear………………………………………35
Center Joint
Removal and Installation of Center Joint …………………………………………………………..1
Center Joint Assembly and Disassembly ………………………………………………………….6
Disassembling and Assembling Instructions ……………………………………………………..7
Counterweight
Removal and Installation of Counterweight ……………………………………………………….1
Hydraulic Pump
Removal and Installation of Hydraulic Pump ……………………………………………………..1
Procedures for Assembly and Disassembly of Pump Main Unit Section………………..7
Pump Main Unit Section Maintenance Standards …………………………………………….17
Explanation of Regulator Operation………………………………………………………………..23
Procedures for Assembly and Disassembly of Regulator…………………………………..29
Procedures for Assembly and Disassembly of PTO Unit……………………………………40
PTO Unit Maintenance Standards ………………………………………………………………….46
Remote Control Valve
Removal and Installation of Operation Remote Control Valve………………………………1
Procedures for Assembly and Disassembly of Operation Remote Control Valve…..10
Removal and Installation of Travel Remote Control Valve ………………………………….23
Procedures for Assembly and Disassembly of Travel Remote Control Valve ………..26
Control Valve
Removal and Installation of Control Valve …………………………………………………………1
Assembly and Disassembly Precautions…………………………………………………………..9
Inspection and Handling ……………………………………………………………………………….10
Replacing the Main Plunger ………………………………………………………………………….12
Accessories ………………………………………………………………………………………………..13
External shape diagram………………………………………………………………………………..14
Cross-section Structure Diagram……………………………………………………………………15
Assembly and Disassembly…………………………………………………………………………..27
Other Valves
Removal and Installation of Solenoid Valve……………………………………………………….1
Removal and Installation of Cushion Valve………………………………………………………..5
Assembly and Disassembly of Cushion Valve……………………………………………………9
Radiator and Oil Cooler
Removal and Installation of Radiator………………………………………………………………..1
Removal and Installation of Oil Cooler ……………………………………………………………..9
Tank
Removal and Installation of Hydraulic Oil Tank…………………………………………………..1
Removal and Installation of Fuel Tank………………………………………………………………7
Attachments
Removal and Installation of Bucket…………………………………………………………………..1
Removal and Installation of Bucket Link……………………………………………………………3
Removal and Installation of Bucket Cylinder ……………………………………………………..6
Removal and Installation of Arm Cylinder………………………………………………………..10
Removal and Installation of Arm…………………………………………………………………….15
Removal and Installation of Boom Cylinder……………………………………………………..17
Removal and Installation of Boom ………………………………………………………………….22
Removal and Installation of Arm HBCV…………………………………………………………..27
Removal and Installation of Boom HBCV………………………………………………………..29
Operation and Assembly/Disassembly of Hydraulic Cylinder ……………………………..32
Structural Diagram……………………………………………………………………………………….61
Lights
Removal and Installation of Boom Light ……………………………………………………………1
Removal and Installation of Tool Box Light ………………………………………………………..2
Cab Inner and Outer Parts
Removal and Installation of Cab Assembly ……………………………………………………….1
Removal and Installation of Operator’s Seat ……………………………………………………..8
Removal and Installation of Wiper ………………………………………………………………….10
Removal and Installation of Wiper Controller …………………………………………………..11
Removal and Installation of Wiper Motor…………………………………………………………14
Removal and Installation of Monitor ……………………………………………………………….17
Removal and Installation of Cab Front Glass …………………………………………………..18
Window Lock Adjustment Procedures …………………………………………………………….20
Tightening torque…………………………………………………………………………………………21
Hydraulic Equipment-related Parts
Removal and Installation of Accumulator ………………………………………………………….1
Removal and Installation of Suction Filter …………………………………………………………2
Removal and Installation of Return Filter…………………………………………………………..4
Removal and Installation of Pilot Filter ……………………………………………………………..6
Other
Removal and Installation of Side Door ……………………………………………………………..1
Draining Oil from Hydraulic Oil Tank…………………………………………………………………2
