Hyundai HX160 L Service Manual
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Hyundai HX160 L Service Manual

Crawler excavator
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HX160 L, HX180 L
CRAWLER EXCAVATOR
SERVICE MANUAL

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Summary of Contents for Hyundai HX160 L

  • Page 1 HX160 L, HX180 L CRAWLER EXCAVATOR SERVICE MANUAL...

  • Page 2: Table Of Contents

    2. How To Read The Service Manual 3. Conversion Table SECTION 1 GENERAL Group 1 Safety Group 2 Specifications (hx160 L) Group 3 Specifications (hx180 L) SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device Group 2 Main Control Valve...

  • Page 3: Table Of Content

    Group 8 Variable Power Control System Group 9 Attachment Flow Control System Group 10 Boom Floating Control System Group 11 Intelligent Power Control System Group 12 Anti-restart System Group 13 Self-diagnostic System Group 14 Engine Control System Group 15 Eppr Valve Group 16 Monitoring System Group 17 Fuel Warmer System SECTION 6 TROUBLESHOOTING...

  • Page 4: Foreword

    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. Find manuals at https://best-manuals.com...

  • Page 5: How To Read The Service Manual

    Revised edition mark(①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 6: Conversion Table

    3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Example 1.
  • Page 7 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
  • Page 8 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 9 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 10 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 11 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 12: Section 1 General

    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: Group 1 Safety

    SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
  • Page 14 PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
  • Page 15 KEEP RIDERS OFF EXCAVATOR KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
  • Page 16 SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under 13031GE10 continuous load.
  • Page 17 BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
  • Page 18 SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
  • Page 19 AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
  • Page 20 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
  • Page 21 DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 22: Group 2 Specifications (Hx160 L)

    GROUP 2 SPECIFICATIONS (HX160 L) 1. MAJOR COMPONENT Tool box DEF/AdBlue tank Fuel tank Hydraulic tank Main pump After treatment device Engine Oil cooler Charge air cooler Radiator Main control valve Tooth Bucket Turning joint Swing motor Air cleaner Arm cylinder...
  • Page 23 2. SPECIFICATIONS HX160 L 5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM I(I') B(L) 180F2SP02 Description Unit Specification Operating weight kg (lb) 18100 (39900) Bucket capacity (SAE heaped), standard 0.70 (0.92) Overall length 8650 (28' 5") Overall width, with 600 mm shoe 2590 ( 8' 6")
  • Page 24 HX160 L 5.1 m (16' 9") HYDRAULIC ADJUSTABLE BOOM AND 2.6 m (8' 6") ARM I(I') B(L) 180F2SP03 Description Unit Specification Operating weight kg (lb) 19000 (41890) Bucket capacity (SAE heaped), standard 0.70 (0.92) Overall length 8610 ( 28' 3") Overall width, with 600 mm shoe 2590 ( 8' 6")
  • Page 25 3) 3) HX160 L HX160 L ·5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM 5.1 m (16' 9") BOOM and 2.6 m (8' 6") ARM WITH WITH DOZER DOZER I(I') B(L) 180F2SP04A Description Unit Specification Operating weight...
  • Page 26 3. WORKING RANGE 5.1 m (16' 9") MONO BOOM 180F2SP06 Description 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm 3.1 m (10' 2") Arm Max digging reach 8690 mm (28' 6") 9020 mm (29' 7") 9450 mm (31' 0") Max digging reach on ground 8530 mm (27'12") 8860 mm (29' 1")
  • Page 27 5.1 m (16' 9") HYDRAULIC ADJUSTABLE BOOM 180F2SP08 Description 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm Max digging reach 8760 mm (28' 9") 9110 mm (29'11") Max digging reach on ground 8590 mm (28' 2") 8950 mm (29' 4") Max digging depth 5430 mm (17' 10") 5830 mm (19' 2")
  • Page 28 4. WEIGHT 4. WEIGHT HX160 L HX160 L (with dozer) Item Upper structure assembly ·Main frame weld assembly ← 1440 3170 ·Engine assembly ← 1300 ·Fan clutch assembly ← ·Main pump assembly ← ·Main control valve assembly ← ·Swing motor assembly ←...
  • Page 29 Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
  • Page 30 Boom Counterweight Shoe Wheel Dozer Outtriger Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear MONO HX160 L BOOM 5100 2200 2600 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach Lift-point 3.0 m (9.8 ft)
  • Page 31 Boom Counterweight Shoe Wheel Dozer Outtriger Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear MONO HX160 L BOOM 5100 3100 2600 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach Lift-point 1.5 m (4.9 ft)
  • Page 32 Boom Counterweight Shoe Wheel Dozer Outtriger Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear 2-PIECE HX160 L BOOM 5100 2200 3250 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach Lift-point 3.0 m (9.8 ft)
  • Page 33 6. BUCKET SELECTION GUIDE GENERAL AND HEAVY DUTY BUCKET 0.39 m 0.50 m 0.64, 0.70, 0.76 m 0.89, 1.05 m heaped bucket heaped bucket heaped bucket heaped bucket Recommendation Capacity Width 5.1 m (16' 9") 5.1 m (16' 9") Mono boom Hyd adjustable boom Weight CECE...
  • Page 34 HEAVY DUTY BUCKET 0.69, 0.72, 0.87 m SAE heaped bucket 0.75 m SAE heaped bucket Recommendation Capacity Width 5.1 m (16' 9") 5.1 m (16' 9") Mono boom Hyd adjustable boom Weight CECE Without With 2.2 m arm 2.6 m arm 3.1 m arm 2.2 m arm 2.6 m arm...
  • Page 35 Shoe width mm (in) 500 (20) 600 (24) 700 (28) Operating weight kg (lb) 17855 (39360) 18100 (39900) 18345 (40440) HX160 L Ground pressure 0.52 (7.39) 0.44 (6.26) 0.38 (5.40) kgf/cm (psi) Overall width mm (ft-in) 2490 (8' 2") 2590 (8' 6") 2690 (8' 10")
  • Page 36 SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Confirm the category from the list of applications in table 2, then use table 1 to select the shoe. Wide shoes (categories B) have limitations on applications. Before using wide shoes, check the precautions, then investigate and study the operating conditions to confirm if these shoes are suitable.
  • Page 37 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Perkins 1204F Type 4-cycle turbocharged charge air cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type Cylinder bore stroke 105 127 mm (4.1"...
  • Page 38 GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 40 kgf/cm (570 psi) Rated oil flow 31.5 /min (8.3 U.S. gpm / 6.9 U.K. gpm) MAIN CONTROL VALVE Item Specification Type 11 spools two-block Operating method Hydraulic pilot system Main relief valve pressure...
  • Page 39 Ground pressure Link quantity Overall width Option 500 mm (20") 2490 mm ( 8' 2") 0.52 kgf/cm (7.39 psi) HX160 L Standard 600 mm (24") 2590 mm ( 8' 6") 0.44 kgf/cm (6.26 psi) Option 700 mm (28") 2690 mm ( 8' 10") 0.38 kgf/cm...
  • Page 40 ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.

  • Page 41: Group 3 Specifications (Hx180 L)

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