Hyundai HX160 L, Service Manual

Page 1: ...HX160 L HX180 L CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ...AULIC SYSTEM 152 Group 1 Hydraulic Circuit 153 Group 2 Main Circuit 154 Group 3 Pilot Circuit 157 Group 4 Single Operation 167 Group 5 Combined Operation 179 SECTION 4 ELECTRICAL SYSTEM 188 Group 1 Component Location 189 Group 2 Electrical Circuit 191 Memorandum 196 Group 3 Electrical Component Specification 213 Group 4 Connectors 224 SECTION 5 MECHATRONICS SYSTEM 249 Group 1 Outline 250 Group 2 M...

Page 3: ...Hydraulic And Mechanical System 371 Group 3 Electrical System 391 Group 4 Mechatronics Systegroup System 407 SECTION 7 MAINTENANCE STANDARD 437 Group 1 Operational Performance Test 438 Group 2 Major Component 458 Group 3 Track And Work Equipment 466 SECTION 8 DISASSEMBLY AND ASSEMBLY 473 Group 1 Precautions 474 Group 2 Tightening Torque 476 Group 3 Pump Device 480 Group 4 Main Control Valve 502 Gr...

Page 4: ...section explains the hydraulic circuit single and combined operation SECTION 4 ELECTRICAL SYSTEM SECTION 4 ELECTRICAL SYSTEM This section explains the electrical circuit monitoring system and each component It serves not only to give an understanding electrical system but also serves as reference material for trouble shooting SECTION 5 MECHATRONICS SYSTEM SECTION 5 MECHATRONICS SYSTEM This section...

Page 5: ...most up to date information before you start any work Filing method Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2 Structure and Function Consecutive page number for each item Additional pages Additional pages are indicated by a hyphen and number after the page number File ...

Page 6: ...10 Move the decimal point one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm was divided by 10 so multiply 2 165 inches by 10 Move the decimal point one place to the right to return to the original value This gives 550mm 21 65 inches 1 1 2 1 2 3 1 2 3 Millimeters to inches Millimeters to inches 1mm 0 03937 in ⓑ...

Page 7: ... 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 ...

Page 8: ... 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon Liter to U K Gallon 1ℓ 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 ...

Page 9: ...5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2 1070 5 1077...

Page 10: ...09 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2333 2347 2361...

Page 11: ...31 0 32 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 ...

Page 12: ...SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications HX160 L 1 10 Group 2 Specifications HX180 L 1 29 ...

Page 13: ...he excavator attach a Do Not Operate Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury When you get on and off the machine always maintain a three point contact with the steps and handrails and face the machine Do not use any controls as handholds Never jump on or off the machine Never mount or d...

Page 14: ...s Wear goggles or safety glasses PROTECT AGAINST NOISE PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises AVOID POWER LINES AVOID POWER LINES Serious injury or death can result from contact with electric lines Never move an...

Page 15: ...e excavator starts to move Use a signal person when moving swinging or operating the machine in congested areas Coordinate hand signals before starting the excavator OPERATE ONLY FORM OPERATOR S SEAT OPERATE ONLY FORM OPERATOR S SEAT Avoid possible injury machine damage Do not start engine by shorting across starter terminals NEVER start engine while standing on ground Start engine only from opera...

Page 16: ...SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands HANDLE FLUIDS SAFELY AVOID FIRES HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care It is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling ...

Page 17: ...side or in a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 mi...

Page 18: ... serious injury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hand...

Page 19: ...le materials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install fire resisting guards to protect hoses or other materials PREVENT BATTERY EXPLOSIONS PREVENT BATTERY EXPLOSIONS Keep sparks lighted matches and flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter ...

Page 20: ...or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediate ly If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately 13031GE22 USE TOOLS PROPERLY USE TOOLS PROPERLY Use tools appropriate to the work Makeshift tools parts and procedures can crea...

Page 21: ... DO NOT pour oil into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant brake fluid filters batteries and other harmful waste REPLACE SAFETY LABELS REPLACE SAFETY LABELS Replace missing or damaged safety labels See the machine operator s manual for correct safety label placement LIVE WITH SAFETY LIVE WITH ...

Page 22: ...ge air cooler Turning joint Radiator Main control valve Swing motor Bucket Tooth Cab Boom cylinder Boom Arm cylinder Arm Counterweight After treatment device Swing bearing Oil cooler Guardrail Track roller Carrier roller Dozer blade cylinder Dozer blade Track Idler Travel motor Air cleaner Sprocket DEF AdBlue tank R 160F2SP01 1 MAJOR COMPONENT ...

Page 23: ... height of cab E 2980 9 9 Ground clearance of counterweight F 1055 3 6 Engine cover height G 2525 8 3 Minimum ground clearance H 460 1 6 Rear end distance I 2480 8 2 Rear end swing radius I 2480 8 2 Distance between tumblers J 3170 10 5 Undercarriage length K 3926 12 11 Undercarriage width L 2590 8 6 Track gauge M 1990 6 6 Track shoe width standard N 600 24 Overall height of guardrail O 3220 10 6 ...

Page 24: ...ll height of cab E 2980 9 9 Ground clearance of counterweight F 1055 3 6 Engine cover height G 2525 8 3 Minimum ground clearance H 460 1 6 Rear end distance I 2480 10 5 Rear end swing radius I 2480 8 2 Distance between tumblers J 3170 10 5 Undercarriage length K 3926 12 11 Undercarriage width L 2590 8 6 Track gauge M 1990 6 6 Track shoe width standard N 600 24 Overall height of guardrail O 3220 10...

Page 25: ...80 9 9 Ground clearance of counterweight F 1055 3 6 Engine cover height G 2525 8 3 Minimum ground clearance H 460 1 6 Rear end distance I 2480 8 2 Rear end swing radius I 2480 8 2 Distance between tumblers J 3170 10 5 Undercarriage length K 3926 12 11 Undercarriage width L 2590 8 6 Track gauge M 1990 6 6 Track shoe width standard N 600 24 Height of blade O 645 2 1 Ground clearance of blade up P 61...

Page 26: ...8980 mm 29 6 Max dumping height E 6110 mm 20 1 6220 mm 20 5 6390 mm 21 0 Min swing radius F 3180 mm 10 5 3170 mm 10 5 3170 mm 10 5 Bucket digging force SAE 107 9 117 2 kN 107 9 117 2 kN 107 9 117 2 kN 11000 11940 kgf 11000 11940 kgf 11000 11940 kgf 24250 26330 lbf 24250 26330 lbf 24250 26330 lbf ISO 123 6 134 2 kN 123 6 134 2 kN 123 6 134 2 kN 12600 13680 kgf 12600 13680 kgf 12600 13680 kgf 27780 ...

Page 27: ... 15 2 4980 mm 16 4 Max digging height D 9420 mm 30 11 9610 mm 31 6 Max dumping height E 6710 mm 22 0 6910 mm 22 8 Min swing radius F 3100 mm 10 2 2970 mm 9 9 Bucket digging force SAE 107 9 117 2 kN 107 9 117 2 kN 11000 11940 kgf 11000 11940 kgf 24250 26330 lbf 24250 26330 lbf ISO 123 6 134 2 kN 123 6 134 2 kN 12600 13680 kgf 12600 13680 kgf 27780 30160 lbf 27780 30160 lbf Arm crowd force SAE 87 2 ...

Page 28: ...ack chain assembly 600 mm standard triple grouser shoe 1180 2600 Front attachment assembly 5 1 m boom assembly 1060 2340 2 6 m arm assembly 540 1190 0 7 m3 SAE heaped bucket 600 1320 Boom cylinder assembly 155 340 Arm cylinder assembly 180 400 Bucket cylinder assembly 125 280 Bucket control link assembly 120 265 Dozer blade assembly 655 1445 Dozer blade cylinder assembly 66 146 This information is...

Page 29: ...ft Capacity Reach m ft 7 5 m kg 3400 3400 4 85 24 6 ft lb 7500 7500 15 9 6 0 m kg 3830 3420 2960 2960 6 27 19 7 ft lb 8440 7540 6530 6530 20 6 4 5 m kg 4890 4890 4450 3370 2840 2550 7 10 14 8 ft lb 10780 10780 9810 7430 6260 5620 23 3 3 0 m kg 9410 9100 6140 4940 4960 3240 3100 2290 2870 2270 7 54 9 8 ft lb 20750 20060 13540 10890 10930 7140 6830 5050 6330 5000 24 7 1 5 m kg 7420 4610 5040 3090 36...

Page 30: ...g 7690 4550 5010 3060 3070 2280 7 36 4 9 ft lb 16950 10030 11050 6750 6770 5030 24 1 0 0 m kg 3900 3900 7570 4380 4900 2960 3410 2340 7 16 0 0 ft lb 8600 8600 16690 9660 10800 6530 7520 5160 23 5 1 5 m kg 9210 8060 7530 4350 4880 2940 4080 2600 6 62 4 9 ft lb 20300 17770 16600 9590 10760 6480 8990 5730 21 7 3 0 m kg 9400 8230 6720 4430 4890 3310 5 62 9 8 ft lb 20720 18140 14820 9770 10780 7300 18 ...

Page 31: ...840 15370 10270 11130 6810 7940 4870 5560 4340 26 5 0 0 m kg 6140 6140 7610 4400 4890 2950 3530 2150 2810 1990 7 91 0 0 ft lb 13540 13540 16780 9700 10780 6500 7780 4740 6190 4390 25 9 1 5 m kg 4780 4780 8740 7920 7480 4290 4810 2880 3360 2160 7 42 4 9 ft lb 10540 10540 19270 17460 16490 9460 10600 6350 7410 4760 24 3 3 0 m kg 8060 8060 11010 8010 7490 4310 4830 2900 4270 2580 6 56 9 8 ft lb 17770...

Page 32: ...ger HX160 L 2 PIECE BOOM Length mm Length mm weight kg width mm width mm Front Rear Front Rear 5100 2600 3250 600 A B 余 Rating over front Rating over side or 360 degree 余 Model Type Boom Arm Counterweight Shoe Wheel Dozer Outtriger HX160 L 2 PIECE BOOM Length mm Length mm weight kg width mm width mm Front Rear Front Rear 5100 2200 3250 600 A B 余 Rating over front Rating over side or 360 degree 余 L...

Page 33: ...50 m3 0 65 yd3 0 44 m3 0 58 yd3 760mm 29 9 880mm 34 6 470 kg 1040 lb 侐 侐 侐 侐 侐 0 64 m3 0 84 yd3 0 55 m3 0 72 yd3 920mm 36 2 1040mm 40 9 510 kg 1120 lb 侐 侐 俔 侐 俔 侍0 70 m3 0 92 yd3 0 60 m3 0 78 yd3 990mm 39 0 1110mm 43 7 600 kg 1320 lb 侐 俔 侑 俔 侑 0 76 m3 0 99 yd3 0 65 m3 0 35 yd3 1060mm 41 7 1180 mm 46 5 620 kg 1370 lb 俔 侑 俔 侑 0 89 m3 1 16 yd3 0 77 m3 1 01 yd3 1220mm 48 0 1340 mm 52 8 610 kg 1340 lb ...

Page 34: ... 6 m arm 8 6 ľ0 69 m3 0 90 yd3 0 62 m3 0 81 yd3 990mm 39 0 720 kg 1590 lb 侐 俔 侑 俔 侑 ľ0 72 m3 0 94 yd3 0 65 m3 0 85 yd3 940 mm 37 0 985 mm 38 8 640 kg 1410 lb 侐 俔 侑 俔 侑 Ľ0 75 m3 0 98 yd3 0 65 m3 0 85 yd3 1820 mm 71 7 540 kg 1190 lb 侐 俔 侑 侐 俔 ľ0 87 m3 1 18 yd3 0 78 m3 1 02 yd3 1090 mm 42 9 1140 mm 44 9 680 kg 1500 lb 俔 侑 侑 Applicable for materials with density of 2000 kg m3 3370 lb yd3 or less Appli...

Page 35: ...ON EACH SIDE 3 Model Shapes Triple grouser HX160 L Shoe width mm in 500 20 ö600 24 700 28 Operating weight kg lb 17855 39360 18100 39900 18345 40440 Ground pressure kgf cm2 psi 0 52 7 39 0 44 6 26 0 38 5 40 Overall width mm ft in 2490 8 2 2590 8 6 2690 8 10 HX160 L with dozer Shoe width mm in 500 20 ö600 24 700 28 Operating weight kg lb 18655 41130 18900 41670 19145 42210 Ground pressure kgf cm2 p...

Page 36: ... than recommendations will cause unexpected problem such as bending of shoes crack of link breakage of pin loosening of shoe bolts and the other various problems 4 1 24 ö Table 2 ö Table 1 Track shoe Specification Category 600 mm triple grouser Standard A 500 mm triple grouser Option A 700 mm triple grouser Option B Category Applications Applications A Rocky ground river beds normal soil  Travel ...

Page 37: ... Roted net horse power SAE J1349 128Hp 96 kW at 2050 rpm Rated gross horse power SAE J1995 137Hp 102 1 kW at 2050 rpm Maximum torque 57 1 kgfÂm 413 lbfÂft at 1400 rpm Engine oil quantity 10 5 2 8 U S gal Dry weight 589 kg 1300 lb High idling speed 2100Ü50 rpm Low idling speed 800Ü100 rpm Rated fuel consumption 164 g HpÂhr at 2050 rpm Starting motor 24 V 4 5 kW Alternator 24 V 100 A Battery 2Ý12 VÝ...

Page 38: ...sure 400 kgf cm2 5690 psi Item Specification Type Axial pistons motor Capacity 142 8 cc rev Relief pressure 285 kgf cm2 4053 psi Braking system Automatic spring applied hydraulic released Braking torque 66 5 kgfÂm 481 lbfÂft Brake release pressure 22 3 36 6 kgf cm2 317 521 psi Reduction gear type 2 stage planetary Item Specification Type Two speed axial pistons motor with brake valve and parking b...

Page 39: ...ke 110Ý 85Ý320 mm Item Width Ground pressure Link quantity Overall width HX160 L Option 500 mm 20 0 52 kgf cm2 7 39 psi 49 2490 mm 8 2 Standard 600 mm 24 0 44 kgf cm2 6 26 psi 49 2590 mm 8 6 Option 700 mm 28 0 38 kgf cm2 5 40 psi 49 2690 mm 8 10 BUCKET Item Capacity Tooth quantity Width SAE heaped CECE heaped Without side cutter With side cutter HX160 L 0 39 m3 0 51 yd3 0 34 m3 0 44 yd3 3 620 mm 2...

Page 40: ... the diesel particulate filter DPF Do not use any engine oil other than that specified above as it may clog the diesel particulate filter DPF For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures please For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures please contact HYUNDAI dealers contact HYUNDAI dealer...

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