Hyundai R160LC-3 Manual de usuario

SERVICE MANUAL

HYUNDAI

CRAWLER EXCAVATOR

R160LC-3

CONTENTS

0-1

FOREWORD

1. STRUCTURE

This service manual has been prepared as an aid to improve the quality of repairs by giving the

serviceman an accurate understanding of the product and by showing him the correct way to perform

repairs and make judgements. Make sure you understand the contents of this manual and use it to

full effect at every opportunity.

This service manual mainly contains the necessary technical information for operations performed in

a service workshop.

For ease of understanding, the manual is divided into the following sections.

SECTION 1 GENERAL

This section explains the safety hints and gives the specification of the machine and major

components.

SECTION 2 STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an

understanding of the structure, but also serves as reference material for troubleshooting.

SECTION 3 HYDRAULIC SYSTEM

This section explains the hydraulic circuit, single and combined operation.

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

This section explains the computer aided power optimization system and each component.

SECTION 6 TROUBLESHOOTING

This section explains the troubleshooting charts correlating problems to causes.

SECTION 7 MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

SECTION 8 DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling

each component, as well as precautions to be taken for these operations.

The specifications contained in this shop manual are subject to change at any time and without any

advance notice. Contact your HYUNDAI distributor for the latest information.

0-2

Revised edition mark(ڸڹںš)

When a manual is revised, an edition mark is

recorded on the bottom outside corner of the

pages.

Revisions

Revised pages are shown at the list of revised

pages on the between the contents page and

section 1 page.

Symbols

So that the shop manual can be of ample

practical use, important places for safety and

quality are marked with the following symbols.

2. HOW TO READ THE SERVICE MANUAL

Distribution and updating

Any additions, amendments or other changes

will be sent to HYUNDAI distributors.

Get the most up-to-date information before you

start any work.

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 as in the example.

Symbol Item Remarks

Special safety precautions are

necessary when performing the

work.

Extra special safety precautions

are necessary when performing

the work because it is under

internal pressure.

Special technical precautions or

other precautions for preserving

standards are necessary when

performing the work.

Safety

Caution

10 - 4

10 - 4 - 1

10 - 4 - 2

10 - 5

Added pages

1-18

GEAR PUMP

MAIN CONTROL VALVE

SWING MOTOR

TRAVEL MOTOR

Item

Type

Capacity

Maximum pressure

Rated oil flow

Specification

Fixed displacement gear pump single stage

10cc/rev

kgf/cm

(570

psi

)

22ֻ

/min

(5.8U.S.

gpm/

4.8U.K.

gpm

)

Item

Type

Operating method

Main relief valve pressure

Overload relief valve pressure

Specification

9 spools two-block

Hydraulic pilot system

320

kgf/cm

(4550

psi

)[350

kgf/cm

(4980

psi

)]

380

kgf/cm

(5405

psi

)

Item

Type

Capacity

Relief pressure

Braking system

Braking torque

Brake release pressure

Reduction gear type

Swing speed

Specification

Fixed displacement axial piston motor

99.2

cc/rev

260

kgf/cm

(3911

psi

)

Automatic, spring applied, hydraulic released

kgf

(304

lbf

)

4.5~20

kgf/cm

(64~284

psi

)

2 - stage planetary

12.1

rpm

Item

Type

Relief pressure

Capacity(max / min)

Reduction gear type

Braking system

Brake release pressure

Braking torque

Specification

Variable displacement axial piston motor

350

kgf/cm

(4980

psi

)

87.3/55.5

cc/rev

3-stage planetary

Automatic, spring applied, hydraulic released

kgf/cm

(156

psi

)

1060~1780

kgf

(7667~12874

lbf

)

[ ] : Power boost

1-19

REMOTE CONTROL VALVE

CYLINDER

SHOE

Item

Type

Specification

Pressure reducing type

5.5

kgf/cm

(78

psi

)

19.5

kgf/cm

(277

psi

)

82.7

(3.3

)

123

(4.8

)

Operating pressure Minimum

Maximum

Lever

Pedal

Single operation stroke

Item Specification

ٻ110źٻ80ź1180

Extend only

ٻ120źٻ85ź1320

Extend and retract

ٻ105źٻ75ź1005

Extend only

Bore diaźRod diaźStroke

Cushion

Bore diaźRod diaźStroke

Cushion

Bore diaźRod diaźStroke

Cushion

Boom cylinder

Arm cylinder

Bucket cylinder

Item Width

600

(24")

500

(20")

700

(28")

800

(32")

Ground pressure

0.40

kgf/cm

(5.69

psi

)

0.47

kgf/cm

(6.68

psi

)

0.35

kgf/cm

(4.98

psi

)

0.31

kgf/cm

(4.41

psi

)

Link quantity

Overall width

2590

( 8' 6")

2490

( 8' 2")

2690

( 8' 10")

2790

( 9' 2")

STD

OPT

BUCKET

Capacity

PCSA heaped CECE heaped

Without side cutter With side cutter

Width

Item

Tooth

quantity

STD

OPT

0.65

(

0.85

)

0.39

(

0.51

)

0.57

(

0.75

)

0.70

(

0.92

)

0.80

(

1.05

)

0.55

(

0.72

)

0.35

(

0.46

)

0.50

(

0.65

)

0.60

(

0.78

)

0.70

(

0.92

)

930

(37")

620

(24")

840

(33")

990

(39")

1080

(43")

1050

(41")

740

(29")

960

(38")

1110

(44")

1200

(47")

10)

2-17

Power shift control

The set horsepower valve is shifted by

varying the command current level of the

proportional pressure reducing valve

attached to the pump.

Only one proportional pressure reducing

valve is provided.

However, the secondary pressure Pf

(power shift pressure) is admitted to the

horsepower control section of each pump

regulator through the pump's internal path

to shift it to the same set horsepower level.

This function permits arbitrary setting of the pump output power, thereby providing the optimum

power level according to the operating condition.

The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown

in the figure.

As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the

pin(898) and compensating piston(621).

This decreases the pump tilting angle and then the set horsepower in the same way as explained

in the overload preventive function of the horsepower control. On the contrary, the set

horsepower rises as the power shift pressure Pf falls.

(3)

Delivery pressure, (P

)

Delivery flow, Q

=MAX

=MIN

621 651 652 623 612 625 626

B(E)

897

875

898

611

DSmall diameter

chamber

Servo piston

Large diameter

chamber

2-18

Adjustment of maximum flow

Adjust it by loosening the hexagon

nut(808) and by tightening(Or loosening)

the set screw(954).

The maximum flow only is adjusted without

changing other control characteristics.

Adjustment of maximum and minimum flows

Adjustment of minimum flow

Adjust it by loosening the hexagon nut

(808) and by tightening(Or loosening) the

hexagonal socket head set screw (953).

Similarly to the adjustment of the

maximum flow, other characteristics are

not changed.

However, remember that, if tightened too

much, the required horsepower during

the maximum delivery pressure(Or

during relieving) may increase.

Delivery pressure, P

Delivery flow, Q

Delivery pressure, P

Delivery flow, Q

808

954

808

953

(4)

Adjustment of min flow

Tightening amount

of adjusting screw

(953)

(Turn)

+1/4

Flow change

amount

(ֻ/

min

)

-3.5

Speed

(

min

-1

)

2200

Adjustment of max flow

Tightening amount

of adjusting screw

(954)

(Turn)

+1/4

Flow change

amount

(ֻ/

min

)

-3.5

Speed

(

min

-1

)

2200

2-19

78 64

15 25

14 68

676657656 65

65674

666757

65673

44 45 243

656

81212423

83 8298

1 Cap

2 O-ring

3 Socket bolt

4 Spring washer

5 Overload assy

6 O-ring

7 Orifice

8 Cap

9 O-ring

10 Cover

11 Socket bolt

12 Sleeve

13 Check

14 Cap

15 O-ring

16 Cap

17 Spring

18 Spring guide

19 Spring guide

20 Cap

21 Spring

22 Check

23 Cap

24 O-ring

25 O-ring

26 O-ring

27 O-ring

28 Housing

29 O-ring

30 Retainer

31 Socket bolt

32 Plunger assy(TS)

33 Plunger assy

(TL, TR)

34 Plunger assy

(SW)

35 Plunger assy

(BM

)

36 Plunger assy

(AM

)

37 Cover assy

1. STRUCTURE(1/2)

GROUP 2 MAIN CONTROL VALVE

4-16

WIPER AND WASHER CIRCUIT

CN-36

FUSE BOX

WIPER & WASHER SW

WASHER TANK

WIPER MOTOR

2731

CN-1

CN-6 CN-2

CN-22 M

CN-21 CN-13

CS-3

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