Hyundai Crawler Excavator R160LC-7A - Service Manual - Operators - Wiring Diagrams

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HYUNDAI R160LC-7A - WORKSHOP, SERVICE, REPAIR MANUAL - OPERATORS MANUAL - WIRING DIAGRAMS

- English Service Manual, Operators Manual and Wiring Diagrams, for Crawler Excavator Hyundai R160LC-7A.
 

CONTENTS:

SERVICE MANUAL

- FOREWORD
- CONTENTS
- SECTION 1
- GENERAL
- Group 1 Safety Hints
- Group 2 Specifications
- SECTION 2
- STRUCTURE
- Group 1 Pump Device
- Group 2 Main Control Valve
- Group 3 Swing Device
- Group 4 Travel Device
- Group 5 RCV Lever
- Group 6 RCV Pedal
- SECTION 3
- HYDRAULIC SYSTEM
- Group 1 Hydraulic Circuit
- Group 2 Main Circuit
- Group 3 Pilot Circuit
- Group 4 Single Operation
- Group 5 Combined Operation
- SECTION 4
- ELECTRICAL SYSTEM
- Group 1 Component Location
- Group 2 Electrical Circuit
- Group 3 Electrical Component Specification
- Group 4 Connectors
- SECTION 5
- MECHATROMICS SYSTEM
- Group 1 Outline
- Group 2 Mode selection System
- Group 3 Travel Speed Control System
- Group 4 Automatic Warming Up Function
- Group 5 Engine Overheat Prevention Function
- Group 6 Automatic Warming Up Function
- Group 7 Self-Diagnostic System
- Group 8 Engine Control System
- Group 9 Monitoring System
- SECTION 6
- TROUBLESHOOTING
- Group 1 Before troubleshooting
- Group 2 Hydraulic and Mechanical System
- Group 3 Electrical System
- Group 4 Mechatronics System
- SECTION 7
- MAINTENANCE STANDARD
- Group 1 Operational Performance Test
- Group 2 Major Components
- Group 3 Track and Work Equipment
- SECTION 8
- DISASSEMBLY AND ASSEMBLY
- Group 1 Precaution
- Group 2 Tightening Torque
- Group 3 Pump Device
- Group 4 Main Control Valve
- Group 5 Swing Device
- Group 6 Travel Device
- Group 7 RCV Lever
- Group 8 Turning Joint
- Group 9 Boom, Arm and Bucket Cylinder
- Group 10 Undercarriage
- Group 11 Work Equipment
- SECTION 9
- COMPONENT MOUNTING TORQUE
- Group 1 Introduction guide
- Group 2 Engine system
- Group 3 Electric system
- Group 4 Hydraulic system
- Group 5 Undercarriage
- Group 6 Structure
- Group 7 Work equipment


ENGINE SERVICE MANUAL

- BINDING
- INTRODUCTION
- How to use this manual
-  Methods of presentation
-  Terms used in this manual
-  Abbreviations
-  Units of measurement
- Safety Cautions
-  Fire and explosion
-  Keep flames away
-  Keep surrounding area tidy and clean
-  Avoid accessing crankcase until engine cools
-  Care about fuel, oil and exhaust gas leakage
-  Use explosion-proof lighting apparatus
-  Prevent electrical wires from short-circuiting
-  Keep fire extinguishers and first-aid kit handy
-  Stay clear of all rotating and moving parts
-  Install protective covers on rotating parts
-  Ensure safety of neighboring people before starting engine
-  Stay clear of moving parts during engine running
-  Lockout and tagout
-  Keep engine stopped during servicing
-  Always restore engine turning tools after use
-  Be careful of burns
-  Do not touch the engine during or immediately after operation
-  Slowly and carefully open radiator cap
-  Add coolant only after the coolant temperature dropped
-  Never remove heat shields
-  Be careful of exhaust fume poisoning
-  Operate engine in well-ventilated area
-  Protect ears from noises
-  Wear ear plugs
-  Be careful of falling down
-  Lift engine correctly
-  Do not climb onto the engine
-  Establish firm scaffold during work
-  Be careful of handling fuel, engine oil and LLC
-  Use only specified fuel, engine oil and long- life coolant (LLC)
-  Handle LLC (long life coolant) carefully
-  Proper disposal of waste oil and coolant (LLC)
-  Service battery
-  Handle the battery correctly
-  When abnormality occurs
-  Stop overheated engine after cooling run
-  Avoid immediate restart after abnormal stop
-  Avoid continuous engine operation with too low oil pressure
-  Stop the engine immediately if the fan belt breaks
-  Other cautions
-  Modification of engine prohibited
-  Never break the seals
-  Pre-operational check and periodic inspection/maintenance
-  Break-in operation
-  Warming-up operation
-  Avoid engine operations in a overload condition
-  Cooling operation before stopping engine
-  Protection of engine against water entry
-  Maintenance of air cleaner or pre-cleaner
-  Observe safety rules at work site
-  Work clothing and protective gear
-  Use of tools optimum for each work
-  Avoidance of prolonged time of starter operation
-  Do not turn off battery switch during operation
-  Cautionary instructions for transporting engine
-  Avoid continuous engine operation in a low load condition
-  Ventilation of engine room
-  Avoid contact with high-pressured fuel
-  About warning labels
-  Maintenance of warning labels
- GENERAL CONTENTS
- GENERAL
- 1. External view
- 2. System flow diagrams
-  2.1 Fuel system - flow diagram
-  2.2 Lubrication system - flow diagram
-  2.3 Cooling system - flow diagram
-  2.4 Inlet and exhaust system - flow diagram
- 3. Engine serial number location
- 4. Main specifications
- 5. Tips on disassembling and reassembling
-  5.1 Disassembling
-  5.2 Reassembling
- SERVICE DATA
- 1. Maintenance service data
-  1.1 General
-  1.2 Basic engine
-  1.3 Fuel system
-  1.4 Lubrication system
-  1.5 Cooling system
-  1.6 Inlet and exhaust system
-  1.7 Electrical system
- 2. Tightening torque table
-  2.1 Major bolt tightening torque
-  2.1.1 Basic engine
-  2.1.2 Fuel system
-  2.1.3 Lubrication system
-  2.1.4 Cooling system
-  2.1.5 Inlet and exhaust systems
-  2.1.6 Electrical system
-  2.2 Standard bolt and nut tightening torque
-  2.2.1 Metric automobile screw thread
-  2.2.2 Metric course screw thread
-  2.3 Standard stud tightening torque
- 3. Regarding submission of parts for EPA exhaust gas regulation
- SERVICE TOOLS
- 1. Special tool
- DETERMINATION OF OVERHAUL
- 1. Determining overhaul timing
- 2. Testing compression pressure
- DISASSEMBLY OF BASIC ENGINE
- 1. Disassembling and inspecting cylinder head and valve mechanism
-  1.1 Removing rocker shaft assembly
-  1.2 Disassembling rocker shaft assembly
-  1.3 Removing cylinder head bolt
-  1.4 Removing cylinder head assembly
-  1.5 Removing valve and valve spring
-  1.6 Removing valve stem seal
- 2. Disassembling and inspecting flywheel
-  2.1 Removing flywheel
-  2.2 Removing rear plate
- 3. Disassembling and inspecting damper, gear case, timing gear and camshaft
-  3.1 Removing crankshaft pulley and damper
-  3.2 Removing cover
-  3.3 Removing timing gear case
-  3.4 Measuring timing gear backlash
-  3.5 Measuring idler gear and camshaft gear end play
-  3.6 Removing fuel injection pump
-  3.7 Removing oil pan
-  3.8 Removing oil strainer
-  3.9 Removing oil pump gear
-  3.10 Removing idler gear
-  3.11 Removing PTO drive gear
-  3.12 Removing camshaft
-  3.13 Separating camshaft gear
-  3.14 Installing camshaft gear and thrust plate
-  3.15 Removing front plate
-  3.16 Removing oil pump
- 4. Disassembling and inspecting piston, connecting rod, crankshaft and crankcase
-  4.1 Removing connecting rod cap
-  4.2 Removing carbon deposits from the upper part of cylinder liner
-  4.3 Pulling out piston
-  4.4 Removing piston ring
-  4.5 Removing piston pin and piston
-  4.6 Removing main bearing cap
-  4.7 Removing crankshaft
-  4.8 Removing tappet
- INSPECTION AND REPAIR OF BASIC ENGINE
- 1. Inspecting and repairing cylinder head and valve mechanism
-  1.1 Measuring clearance between rocker bushing and rocker shaft
-  1.2 Measuring valve stem outside diameter and valve guide inside diameter
-  1.3 Replacing valve guide
-  1.4 Inspecting valve face
-  1.5 Refacing valve face
-  1.6 Refacing valve seat
-  1.7 Replacing valve seat
-  1.8 Lapping valve and valve seat
-  1.9 Measuring perpendicularity and free length of valve spring
-  1.10 Measuring distortion of the bottom surface of the cylinder head
-  1.11 Measuring push rod runout
-  1.12 Removing combustion jet
- 2. Inspecting and repairing flywheel
-  2.1 Measuring flatness of flywheel
-  2.2 Measuring flywheel face and radial runouts
-  2.3 Inspecting ring gear
-  2.4 Replacing ring gear
-  2.4.1 Removing ring gear
-  2.4.2 Installing ring gear
- 3. Inspecting and repairing timing gear and camshaft
-  3.1 Measuring timing gear backlash
-  3.2 Measuring idler gear and camshaft gear end play
-  3.3 Measuring cam lift
-  3.4 Measuring camshaft runout
-  3.5 Measuring camshaft journal outside diameter
-  3.6 Measuring camshaft bushing inside diameter
-  3.7 Replacing camshaft bushing
-  3.7.1 Removing camshaft bushing
-  3.7.2 Installing camshaft bushing
-  3.8 Measuring idler bushing inside diameter and idler shaft outside diameter
-  3.9 Replacing idler shaft
-  3.10 Measuring clearance between tappet and tappet guide hole
-  3.11 Inspecting tappet
-  3.11.1 Contact surface of camshaft
-  3.11.2 Contact surface of push rod
-  3.12 Inspecting V-belt groove wear
-  3.13 Inspecting damper
- 4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase
-  4.1 Measuring crankcase top surface distortion
-  4.2 Measuring cylinder inside diameter
-  4.3 Measuring piston outside diameter
-  4.4 Measuring piston ring end gap
-  4.5 Measuring clearance between piston ring groove and piston ring
-  4.6 Measuring piston pin bore diameter and piston pin outside diameter
-  4.7 Measuring piston protrusion
-  4.8 Measuring clearance between connecting rod bearing and crankpin
-  4.9 Measuring clearance between connecting rod bushing and piston pin
-  4.10 Replacing connecting rod bushing
-  4.11 Inspecting connecting rod bend and twist
-  4.12 Inspecting connecting rod bearing
-  4.13 Measuring connecting rod end play
-  4.14 Weight difference of connecting rod assembly in one engine
-  4.15 Measuring crankshaft journal outside diameter
-  4.16 Measuring crankshaft crankpin outside diameter
-  4.17 Grinding crankshaft
-  4.18 Measuring crankshaft end play
-  4.19 Measuring crankshaft runout
-  4.20 Replacing crankshaft gear
-  4.20.1 Removing crankshaft gear
-  4.20.2 Installing crankshaft gear
-  4.21 Inspecting oil seal contact surface
-  4.22 Installing oil seal sleeve
-  4.23 Removing oil seal sleeve
-  4.24 Inspecting main bearing surface
-  4.25 Measuring clearance between main bearing and crankshaft journal
- REASSEMBLY OF BASIC ENGINE
- 1. Reassembling piston, connecting rod, crankshaft and crankcase
-  1.1 Installing main bearing
-  1.2 Installing thrust plate
-  1.3 Installing tappet
-  1.4 Installing crankshaft
-  1.5 Installing main bearing caps
-  1.6 Inserting side seal
-  1.7 Installing main bearing cap bolt
-  1.8 Measuring crankshaft end play
-  1.9 Reassembling piston and connecting rod
-  1.10 Installing piston ring
-  1.11 Preparation for installing pistons
-  1.12 Installing connecting rod bolt and connecting rod bearing
-  1.13 Installing pistons
-  1.14 Installing connecting rod cap
- 2. Reassembling timing gear and camshaft
-  2.1 Installing oil pump
-  2.2 Installing front plate
-  2.3 Installing camshaft gear and thrust plate
-  2.4 Installing camshaft
-  2.5 Installing PTO drive gear
-  2.6 Installing idler gear
-  2.7 Installing oil pump gear
-  2.8 Installing fuel injection pump
-  2.9 Inspecting and adjusting timing gear after installation
-  2.9.1 Inspecting backlash and end play
-  2.10 Installing front oil seal
-  2.11 Installing timing gear case
-  2.12 Installing oil strainer
-  2.13 Installing oil pan
-  2.14 Installing cover
-  2.15 Installing crankshaft pulley and damper
- 3. Reassembling flywheel
-  3.1 Installing oil seal
-  3.2 Installing rear plate
-  3.3 Installing flywheel
- 4. Reassembling cylinder head and valve mechanism
-  4.1 Cleaning cylinder head bottom surface
-  4.2 Installing valve stem seal
-  4.3 Installing valve and valve spring
-  4.4 Installing cylinder head gasket
-  4.5 Installing cylinder head assembly
-  4.6 Tightening cylinder head bolts
-  4.7 Inserting push rod
-  4.8 Reassembling rocker shaft assembly
-  4.9 Installing rocker shaft assembly
-  4.10 Determining top dead center of No. 1 cylinder compression stroke
-  4.10.1 When reusing the damper
-  4.10.2 When replacing the damper with a new one
-  4.11 Adjusting valve clearance
-  4.12 Installing rocker cover
- FUEL SYSTEM
- 1. Removing fuel system
-  1.1 Removing fuel filter
-  1.2 Removing fuel injection pipe
-  1.3 Removing fuel injection pump
- 2. Disassembling, inspecting and reassembling fuel system
-  2.1 Disassembling and inspecting fuel filter
-  2.2 Changing fuel filter
-  2.3 Disassembling and inspecting fuel injection nozzle
-  2.4 Inspecting and adjusting fuel injection valve opening pressure
-  2.5 Inspecting fuel spray pattern of fuel injection nozzle
-  2.6 Cleaning and inspecting nozzle tip
-  2.7 Reassembling fuel injection nozzle
-  2.8 Inspecting and cleaning gauze filter of distribute type fuel injection pump
- 3. Installing fuel system
-  3.1 Installing fuel injection pump
-  3.2 Installing fuel injection pipe
-  3.3 Installing fuel filter
- LUBRICATION SYSTEM
- 1. Removing lubrication system
-  1.1 Removing oil filter and relief valve
-  1.2 Removing oil cooler
-  1.3 Removing oil pump, oil pan and oil strainer
- 2. Disassembling, inspecting and reassembling lubrication system
-  2.1 Disassembling and inspecting oil pump
-  2.2 Inspecting oil pump
-  2.2.1 Measuring clearance between outer rotor and inner rotor
-  2.2.2 Measuring end play of rotor and pump case
-  2.2.3 Measuring clearance between outer rotor and pump case
-  2.2.4 Measuring clearance between main shaft and pump case
-  2.2.5 Measuring clearance between main shaft and bushing
-  2.2.6 Installing oil pump bushing
-  2.3 Reassembling oil pump
-  2.4 Disassembling and inspecting oil cooler
-  2.5 Inspecting oil filter
-  2.6 Inspecting relief valve
-  2.7 Inspecting safety valve
- 3. Installing lubrication system
-  3.1 Installing oil pump, oil pan and oil strainer
-  3.2 Installing oil cooler
-  3.3 Installing oil filter and relief valve
- COOLING SYSTEM
- 1. Removing cooling system
-  1.1 Removing thermostat
-  1.2 Removing water pump, water pump pulley and V-belt
- 2. Disassembling, inspecting and reassembling cooling system
-  2.1 Disassembling and inspecting thermostat
-  2.2 Inspecting thermostat
-  2.3 Disassembling water pump
-  2.4 Inspecting water pump
- 3. Installing cooling system
-  3.1 Installing water pump, water pump pulley and V-belt
-  3.2 Installing thermostat
- INLET AND EXHAUST SYSTEMS
- 1. Removing turbocharger, inlet and exhaust systems
-  1.1 Removing turbocharger
-  1.2 Removing inlet manifold
-  1.3 Removing exhaust manifold
- 2. Disassembling, inspecting and reassembling inlet and exhaust systems
-  2.1 Measuring exhaust manifold distortion
-  2.2 Disassembling and inspecting turbocharger
-  2.2.1 Removing turbine housing
-  2.2.2 Removing compressor cover
-  2.2.3 Installing O-ring
-  2.2.4 Installing compressor cover
-  2.2.5 Installing snap ring
-  2.3 Cleaning
-  2.3.1 Measuring axial clearance of cartridge assembly
-  2.3.2 Reassembling turbocharger
-  2.3.3 Installing turbine housing
-  2.3.4 Installing coupling assembly
- 3. Installing turbocharger, inlet and exhaust systems
-  3.1 Installing exhaust manifold
-  3.2 Installing inlet manifold
-  3.3 Installing turbocharger
- ELECTRICAL SYSTEM
- 1. Removing electrical system
-  1.1 Removing starter
-  1.2 Inspection before removing alternator
-  1.2.1 Inspecting alternator operation
-  1.2.2 Handling precaution
-  1.3 Removing alternator
-  1.4 Removing glow plug
- 2. Disassembling, inspecting and reassembling electrical system
-  2.1 Inspection before disassembling starter
-  2.1.1 Inspecting magnetic switch
-  2.1.2 No load test
-  2.2 Disassembling and inspecting starter
-  2.2.1 Removing pinion set
-  2.2.2 Removing magnetic switch
-  2.2.3 Removing rear bracket
-  2.2.4 Removing brush holder and brush assembly
-  2.2.5 Removing armature and yoke
-  2.2.6 Removing overrunning clutch
-  2.3 Inspecting and repairing starter
-  2.3.1 Inspecting brushes for wear
-  2.3.2 Measuring brush spring load
-  2.3.3 Inspecting brush holder for insulation
-  2.3.4 Measuring commutator radial runout
-  2.3.5 Measuring commutator outside diameter
-  2.3.6 Measuring undercut depth
-  2.3.7 Checking armature coil
-  2.3.8 Inspecting field coil
-  2.3.9 Inspecting rear bracket
-  2.3.10 Inspecting overrunning clutch operation
-  2.3.11 Inspecting front bracket
-  2.3.12 Inspecting gears of starter
-  2.3.13 Inspecting magnetic switch
-  2.3.14 Inspecting starter relay
-  2.4 Reassembling starter
-  2.4.1 Installing gear shaft
-  2.5 Disassembling and inspecting alternator
-  2.5.1 Separating front bracket from stator
-  2.5.2 Removing field coil
-  2.5.3 Removing pulley
-  2.5.4 Removing rear bearing
-  2.5.5 Removing front bearing
-  2.5.6 Removing stator
-  2.5.7 Removing regulator assembly
-  2.5.8 Removing rectifier assembly
-  2.6 Inspecting and repairing alternator
-  2.6.1 Inspecting stator
-  2.6.2 Inspecting rectifier
-  2.6.3 Measuring field coil
-  2.7 Reassembling alternator
-  2.7.1 Installing rectifier assembly and regulator assembly
-  2.7.2 Installing stator
-  2.7.3 Installing front bearing
-  2.7.4 Installing rear bearing
-  2.7.5 Installing pulley
-  2.7.6 Assembling stator and front bracket
-  2.8 Inspecting glow plug
-  2.8.1 Continuity test of glow plug
-  2.8.2 Heating test of glow plug
-  2.9 Inspecting magnetic valve (stop solenoid)
-  2.9.1 Continuity test of magnetic valve (stop solenoid)
-  2.9.2 Inspecting magnetic valve (stop solenoid) operation
-  2.10 Installing magnetic valve (stop solenoid)
- 3. Installing electrical system
-  3.1 Installing glow plug
-  3.2 Installing alternator
-  3.3 Installing starter
- ADJUSTMENT AND OPERATION
- 1. Adjusting engine
-  1.1 Inspecting and adjusting valve clearance
-  1.1.1 Inspecting valve clearance
-  1.1.2 Adjusting valve clearance
-  1.2 Draining fuel system
-  1.2.1 Draining fuel filter
-  1.3 Bleeding fuel system
-  1.3.1 Bleeding fuel filter
-  1.4 Inspecting and adjusting fuel injection timing
-  1.4.1 Adjusting fuel injection timing
-  1.5 Inspecting V-belt and adjusting V-belt tension
-  1.6 Inspecting V-belt
-  1.7 Adjusting V-belt tension
- 2. Break-in operation
-  2.1 Starting up
-  2.2 Inspecting engine condition after starting up
-  2.3 Break-in operation time
-  2.4 Inspection and adjustment after break-in operation
- 3. Performance test (JIS standard)
-  3.1 Engine equipment condition
-  3.2 Test items and purposes
-  3.2.1 Operation load test
-  3.2.2 Continuous load test
-  3.2.3 Low idle test
-  3.3 Other inspections
-  3.4 Engine output adjustment
-  3.4.1 Standard atmospheric conditions:
-  3.4.2 Calculation of corrected power


OPERATORS MANUAL

- FOREWORD
- SECTION 1
- SAFETY HINT
- Group 1 Before operating the machine
- Group 2 During operating the machine
- Group 3 During maintenance
- Group 4 Parking
- SECTION 2
- SPECIFICATIONS
- Group 1 Major components
- Group 2 Specifications
- Group 3 Working range
- Group 4 Weight
- Group 5 Lifting capacities
- Group 6 Bucket selection guide
- Group 7 Undercarriage
- Group 8 Specification for major components
- Group 9 Recommended oils
- SECTION 3
- CONTROL DEVICE
- Group 1 Cab device
- Group 2 Cluster
- Group 3 Switches
- Group 4 Levers and pedals
- Group 5 Air conditioner and heater
- Group 6 Others
- SECTION 4
- OPERATION
- Group 1 Suggestion for new machine
- Group 2 Check before starting the engine
- Group 3 Starting and stop the engine
- Group 4 Mode selection system
- Group 5 Operation of the working device
- Group 6 Traveling of the machine
- Group 7 Efficient working method
- Group 8 Operation in the special work sites
- Group 9 Normal operation of excavator
- Group 10 Attachment lowering Pattern
- Group 11 Storage
- Group 12 RCV lever operating pattern
- Group 13 Switching Hydraulic attachment circuit
- SECTION 5
- TRANSPORTATION
- Group 1 Preparation for transportation
- Group 2 Dimension and weight
- Group 3 Loading the machine
- Group 4 Fixing the machine
- Group 5 Loading and unloading by crane
- SECTION 6
- MAINTENANCE
- Group 1 Instructions
- Group 2 Tightening torque
- Group 3 Specification of fuel, coolant and lubricants
- Group 4 Maintenance check list
- Group 5 Maintenance chart
- Group 6 Service instruction
- Group 7 Electrical system
- Group 8 Air conditioner and heater
- SECTION 7
- TROUBLESHOOTING GUIDE
- Group 1 Engine
- Group 2 Electrical system
- Group 3 Others
- SECTION 8
- HYDRAULIC BREAKER
- Group 1 Selecting hydraulic breaker
- Group 2 Circuit configuration
- Group 3 Maintenance
- Group 4 Precaution while operating the breaker
- Group 5 Quick clamp
- INDEX