Description

Sumitomo SH460HD-5, SH480LHD-5, SH500LHD-5 Hydraulic Excavator Service Text & Troubleshooting Manual & Shop Manual

Sumitomo SH460HD-5, SH480LHD-5, SH500LHD-5 Hydraulic Excavator Index:

Engine Section
Procedures for Replacing Consumable Parts
Engine Oil …………………………………………………………………………………………………….1
Removal and Installation of Engine Oil Filter Element…………………………………………4
Fuel Filter……………………………………………………………………………………………………..6
Removal and Installation of Alternator Belt………………………………………………………..9
Removal and Installation of Air Conditioner Belt ………………………………………………11
Assembly and Disassembly
Removal and Installation of Engine Hood………………………………………………………..13
Removal and Installation of Engine Assembly………………………………………………….15
Removal and Installation of Starter Motor ……………………………………………………….23
Removal and Installation of Alternator…………………………………………………………….25
Removal and Installation of Supply Pump ……………………………………………………….27
Removal and Installation of Common Rail……………………………………………………….35
Removal and Installation of Injector………………………………………………………………..38
Removal and Installation of Muffler ………………………………………………………………..45
Removal and Installation of Turbo Charger ……………………………………………………..47
Removal and Installation of EGR Cooler and EGR Valve…………………………………..50
Removal and Installation of Engine Sensors ……………………………………………………53
Removal and Installation of Fuel Cooler………………………………………………………….55
Removal and Installation of Engine Inter Cooler ………………………………………………56
Air Conditioner Section
Assembly and Disassembly
Removal and Installation of Compressor…………………………………………………………..1
Removal and Installation of Condenser…………………………………………………………….3
Removal and Installation of Receiver Dryer ………………………………………………………6
Assembly and Disassembly of Unit ………………………………………………………………….8
Gas Filling Procedures
Work Precautions ………………………………………………………………………………………..13
Work Procedures…………………………………………………………………………………………14
Filling Procedures………………………………………………………………………………………..16
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Contents
Maintenance Section
Electrical Equipment Judgment Procedures
Electricity Measurement Procedures………………………………………………………………..1
Maintenance Standards
Check Sheet …………………………………………………………………………………………………3
Inspection Gauge ………………………………………………………………………………………..15
List of Attachment Gap Adjustment Shims ………………………………………………………17
List of Attachment Gap Adjustment Shims (for boom foot)…………………………………21
Assembly and Disassembly Section
Track Shoe
Removal and Installation of Shoe Assembly ……………………………………………………..1
Removal and Installation of Shoe Plate…………………………………………………………….5
Travel Unit (KTA10190)
Removal and Installation of Travel Motor…………………………………………………………..6
Assembly and Disassembly of Travel Motor …………………………………………………….13
Travel Unit (KTA11350)
Removal and Installation of Travel Motor…………………………………………………………65
Assembly and Disassembly of Travel Motor …………………………………………………….72
Take-up Roller
Removal and Installation of Take-up Roller ……………………………………………………125
Assembly and Disassembly of Take-up Roller………………………………………………..127
Upper Roller
Removal and Installation of Upper Roller ………………………………………………………137
Assembly and Disassembly of Upper Roller…………………………………………………..139
Lower Roller
Removal and Installation of Lower Roller ………………………………………………………150
Assembly and Disassembly of Lower Roller…………………………………………………..153
Swing Unit
Removal and Installation of Swing Unit …………………………………………………………163
Assembly and Disassembly of Swing Motor…………………………………………………..167
Assembly and Disassembly of Swing Reduction Gear…………………………………….192
Center Joint
Removal and Installation of Center Joint ……………………………………………………….208
Counterweight
Removal and Installation of Counterweight ……………………………………………………213

Hydraulic Pump
Removal and Installation of Hydraulic Pump ………………………………………………….215
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit………….221
Pump Main Unit Maintenance Standards ………………………………………………………229
PTO Subassembly Maintenance Procedure…………………………………………………..235
Gear Pump Handling ………………………………………………………………………………….240
Explanation of Regulator Operation………………………………………………………………242
Procedures for Assembly and Disassembly of Regulator…………………………………248
Remote Control Valve
Removal and Installation of Operation Remote Control Valve…………………………..259
Procedures for Assembly and Disassembly of Operation Remote Control Valve…268
Removal and Installation of Travel Remote Control Valve ………………………………..281
Procedures for Assembly and Disassembly of Travel Remote Control Valve ………284
Control Valve
Removal and Installation of Control Valve ……………………………………………………..304
Control Valve Assembly and Disassembly Procedures ……………………………………309
Other Valves
Removal and Installation of 5 Stack Solenoid ………………………………………………..342
Removal and Installation of Cushion Valve…………………………………………………….345
Assembly and Disassembly of Cushion Valve………………………………………………..349
Radiator and Oil Cooler
Removal and Installation of Radiator…………………………………………………………….356
Removal and Installation of Oil Cooler ………………………………………………………….365
Tank
Removal and Installation of Hydraulic Oil Tank……………………………………………….366
Removal and Installation of Fuel Tank…………………………………………………………..372
Attachments
Removal and Installation of Bucket……………………………………………………………….377
Removal and Installation of Bucket Link………………………………………………………..379
Removal and Installation of Bucket Cylinder ………………………………………………….382
Removal and Installation of Arm Cylinder………………………………………………………386
Removal and Installation of Arm…………………………………………………………………..391
Removal and Installation of Boom Cylinder……………………………………………………393
Removal and Installation of Boom ………………………………………………………………..398
Removal and Installation of Arm HBCV…………………………………………………………403
Removal and Installation of Boom HBCV………………………………………………………405
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ……..407
Structural Diagram……………………………………………………………………………………..432
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Contents
Light
Removal and Installation of Boom Light ………………………………………………………..436
Removal and Installation of Tool Box Light …………………………………………………….437
Procedures for Removal and Installation of Cab Inner and Outer Parts
Removal and Installation of Cab Assembly ……………………………………………………438
Removal and Installation of Operator’s Seat ………………………………………………….445
Removal and Installation of Wiper ………………………………………………………………..447
Removal and Installation of Wiper Controller …………………………………………………448
Removal and Installation of Wiper Motor……………………………………………………….451
Removal and Installation of Monitor ……………………………………………………………..454
Removal and Installation of Cab Front Glass …………………………………………………455
Window Lock Adjustment Procedure…………………………………………………………….457
Hydraulic Equipment-related Parts
Accumulator………………………………………………………………………………………………459
Suction Filter……………………………………………………………………………………………..460
Return Filter………………………………………………………………………………………………462
Pilot Filter………………………………………………………………………………………………….464
Other
Removal and Installation of Side Door ………………………………………………………….465
Draining Oil from Hydraulic Oil Tank……………………………………………………………..466