Sumitomo SH160-5 Hydraulic Excavator Repair Manual

Sumitomo Excavator SH160-5
Manual Identification: WLST1605-00T, WLST1305TS-01W, WLSM1605-00W, WDL1605-1T, WCL1605-0T
English
Jan. 2015
Sumitomo SH160-5 Hydraulic Excavator Repair Service Manual – 1816 Pages
Operators Manual – 228 Pages
Parts Catalog – 788 Pages

Sumitomo SH160-5 Manual TABLE OF CONTENTS

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
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

Troubleshooting Manual explains troubleshooting of the engine electronic control fuel injection system (common rail type) and main unit of the hydraulic excavator equipped with 4JJ1 type engine.

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 SH160-5 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 SH160-5 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.