Sumitomo SH300-5 Hydraulic Excavator Repair Manual

Sumitomo Excavator SH300-5
Manual Identification: WLST3305TS-01W, WLST3005-00T, WLSM3005-00W, WDL3005-1T, WCL3005-0T_003
English
Sumitomo SH300-5 Hydraulic Excavator Repair Service Manual – 1683 Pages
Operators Manual – 228 Pages
Parts Catalog – 682 Pages

Sumitomo SH300-5 Manual TABLE OF CONTENTS

About This Shop Manual
Safety …………………………………………………………………………………………………… 1
Introduction …………………………………………………………………………………………… 1
Using Technical Information …………………………………………………………………….. 1
Symbols……………………………………………………………………………………………………….1
Precautions for Use………………………………………………………………………………… 1
General Preparation for Disassembly ……………………………………………………………..12
General Cautions for Assembly ……………………………………………………………………..14
General Cautions When Performing Inspections………………………………………………18
Tightening Torque ………………………………………………………………………………….. 1
Tightening Bolts and Nuts ………………………………………………………………………………1
Retightening Torque Table………………………………………………………………………………1
Numerical Conversion Table ……………………………………………………………………. 1
This section describes unit notation for numerical values. …………………………………..1
Engine Section
Procedures for Replacing Consumable Parts …………………………………………….. 1
Engine Oil Replacement…………………………………………………………………………………1
Engine Oil Filter Element Replacement…………………………………………………………….5
Fuel Filter Replacement …………………………………………………………………………………6
Charge Fuel Pump Filter Replacement …………………………………………………………..12
Air Conditioner Belt Replacement ………………………………………………………………….14
Fan Belt Replacement ………………………………………………………………………………….16
Assembly and Disassembly …………………………………………………………………….. 1
Removal and Installation of Engine Hood………………………………………………………….1
Removal and Installation of Engine Assembly……………………………………………………4
Removal and Installation of Starter Motor ……………………………………………………….15
Removal and Installation of Alternator…………………………………………………………….17
Removal and Installation of Supply Pump ……………………………………………………….19
Removal and Installation of Common Rail……………………………………………………….28
Removal and Installation of Injector………………………………………………………………..30
Removal and Installation of Muffler ………………………………………………………………..42
Removal and Installation of Turbo Charger ……………………………………………………..44
Removal and Installation of EGR Cooler and EGR Valve…………………………………..48
Removal and Installation of Engine Sensors ……………………………………………………52
Removal and Installation of Fuel Cooler………………………………………………………….54
Removal and Installation of Engine Inter Cooler ………………………………………………55
Air Conditioner Section
Assembly and Disassembly …………………………………………………………………….. 1
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……………………………………………………………………………. 1
Work Precautions ………………………………………………………………………………………….1
Work Procedures…………………………………………………………………………………………..2
Filling Procedures………………………………………………………………………………………….4
Maintenance Section
Electrical Equipment Judgment Procedures ………………………………………………. 1
Electricity Measurement Procedures………………………………………………………………..1
Maintenance Standards ………………………………………………………………………….. 1
Check Sheet …………………………………………………………………………………………………1
Assembly and Disassembly Section
Track Shoe ……………………………………………………………………………………………. 1
Removal and Installation of Shoe Assembly ……………………………………………………..1
Removal and Installation of Shoe Plate…………………………………………………………….6
Travel Unit …………………………………………………………………………………………….. 1
Removal and Installation of Travel Motor…………………………………………………………..1
Assembly and Disassembly of Travel Motor ………………………………………………………9
Take-up Roller ……………………………………………………………………………………….. 1
Removal and Installation of Take-up Roller ……………………………………………………….1
Assembly and Disassembly of Take-up Roller……………………………………………………3
Upper Roller ………………………………………………………………………………………….. 1
Removal and Installation of Upper Roller ………………………………………………………….1
Assembly and Disassembly of Upper Roller………………………………………………………3
Lower Roller ………………………………………………………………………………………….. 1
Removal and Installation of Lower Roller ………………………………………………………….1
Assembly and Disassembly of Lower Roller………………………………………………………4
Grease Cylinder …………………………………………………………………………………….. 1
Removal and Installation of Grease Cylinder …………………………………………………….1
Assembly and Disassembly of Grease Cylinder…………………………………………………3
Swing Unit …………………………………………………………………………………………….. 1
Removal and Installation of Swing Unit …………………………………………………………….1
Assembly and Disassembly of Swing Unit…………………………………………………………6
Assembly and Disassembly of Swing Motor…………………………………………………….12
Assembly and Disassembly of Swing Reduction Gear………………………………………34
Center Joint…………………………………………………………………………………………… 1
Removal and Installation of Center Joint …………………………………………………………..1
Center Joint Assembly and Disassembly ………………………………………………………….5
Counterweight ……………………………………………………………………………………….. 1
Removal and Installation of Counterweight ……………………………………………………….1
Hydraulic Pump……………………………………………………………………………………… 1
Removal and Installation of Hydraulic Pump ……………………………………………………..1
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit……………..9
Pump Main Unit Maintenance Standards ………………………………………………………..17
Procedures for Assembly and Disassembly of Regulator…………………………………..30
Remote Control Valve …………………………………………………………………………….. 1
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 …………………………………………………………………………………………. 1
Removal and Installation of Control Valve …………………………………………………………1
Procedures for Assembly and Disassembly of Control Valve ……………………………….7
Other Valves………………………………………………………………………………………….. 1
Removal and Installation of 5 Stack Solenoid ……………………………………………………1
Removal and Installation of Cushion Valve………………………………………………………..5
Assembly and Disassembly of Cushion Valve……………………………………………………8
Radiator and Oil Cooler…………………………………………………………………………… 1
Removal and Installation of Radiator………………………………………………………………..1
Removal and Installation of Oil Cooler ……………………………………………………………..9
Tank……………………………………………………………………………………………………… 1
Removal and Installation of Hydraulic Oil Tank…………………………………………………..1
Removal and Installation of Fuel Tank………………………………………………………………8
Attachments ………………………………………………………………………………………….. 1
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
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ……….32
Structural Diagram……………………………………………………………………………………….61
Cylinder Handling Precautions ………………………………………………………………………64
Cautions for Safety ………………………………………………………………………………………65
Lights……………………………………………………………………………………………………. 1
Removal and Installation of Boom Light ……………………………………………………………1
Removal and Installation of Tool Box Light ………………………………………………………..2
Cab Inner and Outer Parts ………………………………………………………………………. 1
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……………………………………………………………. 1
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 ……………………………………………………………………………………………………. 1
Removal and Installation of Side Door ……………………………………………………………..1
Draining Oil from Hydraulic Oil Tank…………………………………………………………………2
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 SH300-5 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 SH300-5 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.