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Hyundai R80-7 Service Manual
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Hyundai R80-7 Service Manual

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SERVICE MANUAL
EXCAVATOR
R80-7

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Summary of Contents for Hyundai R80-7

  • Page 1 SERVICE MANUAL EXCAVATOR R80-7...
  • Page 2 http://marengine.com/r80-7-excavator...
  • Page 3 CONTENTS SECTION 1 GENERAL Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1...
  • Page 4 Group 9 Monitoring system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 SECTION 6 TROUBLESHOOTING Group 1 Before Trobleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4...
  • Page 5 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.
  • Page 6 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 7 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 Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
  • Page 8 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 1.378 1.417 1.457...
  • Page 9 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 8.454 8.718 8.982 9.246...
  • Page 10 kgf·m to lbf·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 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
  • Page 11 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 12 SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4 Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-25...
  • Page 13 SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil.
  • Page 14 2. INSTALL WORK Tighten all bolts and nuts(Sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
  • Page 15 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
  • Page 16 G G ROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 17 NECESSARY TOOLS AND JIGS The following tools and jigs are necessary to disassemble and assemble the pump. Tools Name Size(nominal) Hexagon socket screw keys 6, 8, 10, 12mm Spanner 14, 17, 24, 27 Screwdrivers for slotted-head screws Middle Pliers for retaining rings Bore use 80 Grease Adhesive...
  • Page 18 GROUP 9 BOOM, ARM AND BUCKET CYLINDER 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal ※ Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. ※ Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 19 ④ Sling bucket cylinder assembly(8) and remove bolt(6) then pull out pin (5). ⑤ Remove bucket cylinder assembly(8). ·Weight : 50kg(110lb) R5577CY05 Install ① Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
  • Page 20 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 21078DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-125...
  • Page 21 isassembly Press ① Remove plug and drain oil. ② Draw out the spring pin(7), using a press. R140LC-기타 7 8-166(1) ③ Pull out the shaft(2) with a press. Press ④ Remove seal(3) from idler(1) and bracket (5). ⑤ Remove O-ring(6) from shaft. R140LC-기타...
  • Page 22 Assembly ※ Before assembly, clean the parts. Press ※ Coat the sliding surfaces of all parts with oil. ① Cool up bushing(4) fully by some dry ice and press it into shell(1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
  • Page 23 ⑥ Install bracket(5) attached with seal(3). R140LC-기타 7 8-168(1) ⑦ Knock in the spring pin(7) with a hammer. R140LC-기타 7 8-168(2) ⑧ Lay bracket(5) on its side. Supply engine oil to the specified level, and tighten plug. R140LC-기타 7 8-168(3) 8-128...
  • Page 24 . ELECTRIC COMPONENTS MOUNTING 2 Beacon lamp Wiper motor Cluster Wiper motor cover 7079CM04 ·Tightening torque kgf·m lbf·ft kgf·m lbf·ft Item Size Item Size M 6×1.0 1.05±0.2 7.6±1.45 M10×1.5 6.9±1.4 49.9±10.1 M 8×1.25 2.5±0.5 18.1±3.6...
  • Page 25 Doosan-Daewoo Fiat Halla Hamm Ford Hangcha Hanix Grenaa Guascor Hanomag Hartl Hanshin Hatz Haulpack Hiab Hino Honda Hidromek Hino truck Hyundai Isotta Hitachi Hyster Isuzu Iveco Hyundai John-Deere Kelvin Ingersoll-rand Kioti Komatsu John-Deere Kubota Liebherr Jungheinrich Kalmar Lister Lombardini Kato Kioti MAN B&W...