Hyundai Robex 160LC-9A Service Manual
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Hyundai Robex 160LC-9A Service Manual

Hyundai Robex 160LC-9A Service Manual

Crawler excavator
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Robex 160LC-9A, 180LC-9A
CRAWLER EXCAVATOR
SERVICE MANUAL

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Summary of Contents for Hyundai Robex 160LC-9A

  • Page 1 Robex 160LC-9A, 180LC-9A CRAWLER EXCAVATOR SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENT FOREWORD 1. Structure 2. How To Read The Service Manual 3. Conversion Table SECTION 1 GENERAL Group 1 Safety Group 2 Specifications (r160lc-9a) 1. Major Component 2. Specifications 3. Working Range 4. Weight 5. Lifting Capacities 6. Bucket Selection Guide 7.
  • Page 3 Group 5 Rcv Lever 1. Structure 2. Functions Group 6 Rcv Pedal 1. Structure 2. Function SECTION 3 HYDRAULIC SYSTEM Group 2 Main Circuit 1. Suction And Delivery Circuit 2. Return Circuit 3. Drain Circuit Group 3 Pilot Circuit 1. Suction, Delivery And Return Circuit 2.
  • Page 4 Memorandum 1. Power Circuit 2. Starting Circuit 3. Charging Circuit 4. Head And Work Light Circuit 5. Beacon Lamp And Cab Light Circuit 6. Wiper And Washer Circuit Group 3 Electrical Component Specification Group 4 Connectors 1. Connector Destination 2. Connection Table For Connectors SECTION 5 MECHATRONICS SYSTEM Group 1 Outline Group 2 Mode Selection System...
  • Page 5 2. Operation 3. Electric Circuit SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting 1. Introduction 2. Diagnosing Procedure Group 2 Hydraulic And Mechanical System 1. Introduction 2. Drive System 3. Hydraulic System 4. Swing System 5. Travel System 6. Attachment System Group 3 Electrical System 1.
  • Page 6 11. Malfunction Of Swing Pressure Sensor 12. Malfunction Of Arm In/out & Bucket In Pressure Sensor 13. Malfunction Of Boom Up Pressure Sensor 14. Malfunction Of Power Max 15. Malfunction Of Boom Priority Eppr Valve 16. Malfunction Of Arm Regeneration Solenoid SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test 1.
  • Page 7 4. Disassembly And Assembly Of Reduction Gear Group 6 Travel Device 1. Removal And Install 2. Travel Motor 3. Outline Of Disassembling 4. Outline For Assembling Group 7 Rcv Lever 1. Removal And Install 2. Disassembly And Assembly Group 8 Turning Joint 1.

  • Page 8: Foreword

    This section shows bolt specifications and standard torque values needed when mounting components to the machine. 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 9: 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 10: 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 11 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 12 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 13 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 14 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 15 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 16: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...

  • Page 17: Group 1 Safety

    SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k 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 18 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 ser vice, 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 19 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 20 SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k 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 21 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 22 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 23 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 24 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 25 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 26: Group 2 Specifications (R160Lc-9A)

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS (R160LC-9A) 1. MAJOR COMPONENT 1. MAJOR COMPONENT Tool box Fuel tank Hydraulic tank Main pump After treatment device Engine Radiator Oil cooler Tooth Turning joint Swing motor Bucket Main control valve Arm cylinder Boom Boom cylinder Counterweight Muffler...

  • Page 27: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) R160LC-9A R160LC-9A ·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 I(I') B(L) 16092SP02 Description Unit Specification Operating weight kg (lb) 17800 (39240) Bucket capacity (SAE heaped), standard 0.70 (0.92)
  • Page 28 2) 2) R160LC-9A R160LC-9A · 5.1 m (16' 9") 5.1 m (16' 9") H HYDRAULIC ADJUSTABLE BOOM AND YDRAULIC ADJUSTABLE BOOM AND 2.6 m (8' 6") ARM 2.6 m (8' 6") ARM I(I') B(L) 16092SP03 Description Unit Specification Operating weight kg (lb) 18290 (40320) Bucket capacity (SAE heaped), standard...
  • Page 29 3) 3) R160LCD-9A R160LCD-9A ·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 I(I') B(L) 16092SP04 Description Unit Specification Operating weight kg (lb) 18800 (41450) Bucket capacity (SAE heaped), standard 0.70 (0.92) Overall length 9100 (29' 10")

  • Page 30: Working Range

    3. 3. WORKING RANGE WORKING RANGE 1) 1) 5.1 m (16' 9") MONO (16' 9") MONO BOOM BOOM 16092SP05 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...
  • Page 31 2) 2) 5.1 m (16' 9") 5.1 m (16' 9") H HYDRAULIC ADJUSTABLE BOOM YDRAULIC ADJUSTABLE BOOM 16092SP06 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...

  • Page 32: Weight

    4. WEIGHT 4. WEIGHT R160LC-9A R160LCD-9A Item ← Upper structure assembly 7880 17370 ← Main frame weld assembly 1470 3240 ← Engine assembly 1190 ← Fan clutch assembly ← Main pump assembly ← Main control valve assembly ← Swing motor assembly ←...

  • Page 33: Lifting Capacities

    5. LIFTING CAPACITIES 5. LIFTING CAPACITIES 1) 1) R160LC-9A R160LC-9A 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.70 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe and 2900 kg (6390 Ib) counterweight. ·...
  • Page 34 5.1 m (16' 9") hydraulic adjustable boom, 2.6 m (8' 6") arm equipped with 0.70 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe and 2900 kg (6390 Ib) counterweight. Load radius At max. reach Load 1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach...
  • Page 35 2) 2) R160LCD-9A R160LCD-9A 5.1 m (16' 9") boom, 2.6 m (8' 6") arm equipped with 0.7 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe and 2900 kg (6390 Ib) counterweight. · · : Rating over-front : Rating over-side or 360 degree Load radius At max.
  • Page 36 5.1 m (16' 9") hydraulic adjustable boom, 2.6 m (8' 6") arm equipped with 0.7 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe and 2900 kg (6390 Ib) counterweight. Load radius At max. reach Load 1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach...

  • Page 37: Bucket Selection Guide

    6. BUCKET SELECTION GUIDE 6. BUCKET SELECTION GUIDE 1) 1) GENERAL AND HEAVY DUTY BUCKET GENERAL AND HEAVY DUTY BUCKET 0.64, ※0.70 m 0.39 m 0.50 m 0.89 m heaped bucket heaped bucket heaped bucket heaped bucket Recommendation Capacity Width 5.1 m (16' 9") 5.1 m (16' 9") Mono boom...

  • Page 38: Weight

    2) 2) HEAVY DUTY BUCKET HEAVY DUTY BUCKET ◈ 0.69, 0.72, 0.87 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 39: Undercarriage

    7. UNDERCARRIAGE 7. UNDERCARRIAGE 1) 1) TRACKS TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. 2) 2) TYPES OF SHOES TYPES OF SHOES...
  • Page 40 4) 4) SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Method of selecting shoes Confirm the category from the list of applications in table table 2 2, then use table table 1 1 to select the shoe.

  • Page 41: Specifications For Major Components

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