Sumitomo SH160-5 Excavator Service Manual – PDF DOWNLOAD
DESCRIPTION:
Sumitomo SH160-5 Excavator Service Manual – PDF DOWNLOAD
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.
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.
TABLE OF CONTENTS:
Sumitomo SH160-5 Excavator Service Manual – PDF DOWNLOAD
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
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Contents
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
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Contents
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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
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Contents
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
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