Sumitomo SH460HD-5, SH480LHD-5, SH500LHD-5 Hydraulic Excavator Repair Manual

Sumitomo Excavator SH460HD-5, SH480LHD-5, SH500LHD-5
Manual Identification: WLST4605TS-00W, WLST4605-00T, WLSM4605-01W, WDL4605-1T, WCL4605-0T_002
English
Sumitomo SH460HD-5, SH480LHD-5, SH500LHD-5 Hydraulic Excavator Repair Service Manual – 1706 Pages
Operators Manual – 236 Pages
Parts Catalog – 1014 Pages

Sumitomo SH460HD-5, SH480LHD-5, SH500LHD-5 Manual TABLE OF CONTENTS

About This Shop Manual
Safety ……………………………………………………………………………………………………………..1
Introduction……………………………………………………………………………………………………..3
Using Technical Information
Symbols……………………………………………………………………………………………………….5
Precautions for Use
General Preparation for Disassembly ……………………………………………………………..18
General Cautions for Assembly ……………………………………………………………………..20
General Cautions When Performing Inspections………………………………………………24
Tightening Torque ………………………………………………………………………………… 25
Tightening Bolts and Nuts …………………………………………………………………………….25
Retightening Torque Table…………………………………………………………………………….25
Numerical Conversion Table ………………………………………………………………………….27
Engine Section
Procedures for Replacing Consumable Parts
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
Removal and Installation of Engine Hood………………………………………………………..21
Removal and Installation of Engine Assembly………………………………………………….24
Removal and Installation of Starter Motor ……………………………………………………….36
Removal and Installation of Alternator…………………………………………………………….38
Removal and Installation of Supply Pump ……………………………………………………….40
Removal and Installation of Common Rail……………………………………………………….49
Removal and Installation of Injector………………………………………………………………..51
Removal and Installation of Muffler ………………………………………………………………..63
Removal and Installation of Turbo Charger ……………………………………………………..65
Removal and Installation of EGR Cooler and EGR Valve…………………………………..69
Removal and Installation of Engine Sensors ……………………………………………………73
Removal and Installation of Fuel Cooler………………………………………………………….75
Removal and Installation of Engine Inter Cooler ………………………………………………76
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
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…………………………………………………………….6
Travel Unit
Removal and Installation of Travel Motor…………………………………………………………..7
Assembly and Disassembly of Travel Motor (made by Nabtesco) ……………………….15
Assembly and Disassembly of Travel Motor (made by KYB)………………………………66
Take-up Roller
Removal and Installation of Take-up Roller ……………………………………………………133
Assembly and Disassembly of Take-up Roller………………………………………………..135
Upper Roller
Removal and Installation of Upper Roller ………………………………………………………145
Assembly and Disassembly of Upper Roller…………………………………………………..147
Lower Roller
Removal and Installation of Lower Roller ………………………………………………………159
Assembly and Disassembly of Lower Roller…………………………………………………..162
Grease Cylinder
Removal and Installation of Grease Cylinder …………………………………………………173
Assembly and Disassembly of Grease Cylinder……………………………………………..175
Swing Unit
Removal and Installation of Swing Unit …………………………………………………………181
Assembly and Disassembly of Swing Unit……………………………………………………..186
Assembly and Disassembly of Swing Motor…………………………………………………..192
Assembly and Disassembly of Swing Reduction Gear…………………………………….212
Center Joint
Removal and Installation of Center Joint ……………………………………………………….235
Center Joint Assembly and Disassembly ………………………………………………………239
Counterweight
Removal and Installation of Counterweight ……………………………………………………249
Hydraulic Pump
Removal and Installation of Hydraulic Pump ………………………………………………….251
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit………….259
Pump Main Unit Maintenance Standards ………………………………………………………267
Procedures for Assembly and Disassembly of Regulator…………………………………280
Remote Control Valve
Removal and Installation of Operation Remote Control Valve…………………………..295
Procedures for Assembly and Disassembly of Operation Remote Control Valve…304
Removal and Installation of Travel Remote Control Valve ………………………………..317
Procedures for Assembly and Disassembly of Travel Remote Control Valve ………320
Control Valve
Removal and Installation of Control Valve ……………………………………………………..341
Procedures for Assembly and Disassembly of Control Valve ……………………………347
Other Valves
Removal and Installation of 5 Stack Solenoid ………………………………………………..373
Removal and Installation of Cushion Valve…………………………………………………….377
Assembly and Disassembly of Cushion Valve………………………………………………..381
Radiator and Oil Cooler
Removal and Installation of Radiator…………………………………………………………….387
Removal and Installation of Oil Cooler ………………………………………………………….395
Tank
Removal and Installation of Hydraulic Oil Tank……………………………………………….401
Removal and Installation of Fuel Tank…………………………………………………………..407
Attachments
Removal and Installation of Bucket……………………………………………………………….413
Removal and Installation of Bucket Link………………………………………………………..415
Removal and Installation of Bucket Cylinder ………………………………………………….418
Removal and Installation of Arm Cylinder………………………………………………………422
Removal and Installation of Arm…………………………………………………………………..427
Removal and Installation of Boom Cylinder……………………………………………………430
Removal and Installation of Boom ………………………………………………………………..435
Removal and Installation of Arm HBCV…………………………………………………………441
Removal and Installation of Boom HBCV………………………………………………………443
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ……..446
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ……..479
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ……..513
Cylinder Handling Precautions …………………………………………………………………….540
Cautions for Safety …………………………………………………………………………………….541
Lights
Removal and Installation of Boom Light ………………………………………………………..545
Removal and Installation of Tool Box Light …………………………………………………….546
Cab Inner and Outer Parts
Removal and Installation of Cab Assembly ……………………………………………………547
Removal and Installation of Operator’s Seat ………………………………………………….554
Removal and Installation of Wiper ………………………………………………………………..556
Removal and Installation of Wiper Controller …………………………………………………557
Removal and Installation of Wiper Motor……………………………………………………….560
Removal and Installation of Monitor ……………………………………………………………..563
Removal and Installation of Cab Front Glass …………………………………………………564
Window Lock Adjustment Procedures …………………………………………………………..566
Tightening torque……………………………………………………………………………………….567
Hydraulic Equipment-related Parts
Removal and Installation of Accumulator ………………………………………………………569
Removal and Installation of Suction Filter ……………………………………………………..570
Removal and Installation of Return Filter……………………………………………………….572
Removal and Installation of Pilot Filter ………………………………………………………….574
Other
Removal and Installation of Side Door ………………………………………………………….575
Draining Oil from Hydraulic Oil Tank……………………………………………………………..576
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 SH460HD-5, SH480LHD-5, SH500LHD-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 SH460HD-5, SH480LHD-5, SH500LHD-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.