Hyundai R160LC-9 User manual

OPERATION MANUAL
HYUNDAI
Excavator
R160LC-9

http://marengine.com/r160lc-9-excavator

CONTENTS
CONTENTS
Foreword ----------------------------------------------------------- 0-1
Before servicing this machine --------------------------- 0-2
EC regulation approved ------------------------------------ 0-3
Table to enter S/No and distribution --------------------- 0-4
Safety labels ------------------------------------------------------ 0-5
Machine data plate -------------------------------------------- 0-17
Guide (direction, S/No, symbol) ------------------------ 0-18
SAFETY HINTS
SAFETY HINTS
1. Before operating the machine -------------------- 1-1
2. During operating the machine
-------------------- 1-6
3. During maintenance
----------------------------------- 1-13
4. Parking
-------------------------------------------------------- 1-16
SPECIFICATIONS
SPECIFICATIONS
1. Major components ------------------------------------- 2-1
2. Specifications
-------------------------------------------- 2-2
3. Working range
------------------------------------------- 2-5
4. Weight
------------------------------------------------------- 2-7
5. Lifting capacities
---------------------------------------- 2-8
6. Bucket selection guide
------------------------------- 2-12
7. Undercarriage
------------------------------------------- 2-13
8. Specification for major components
----------- 2-15
9. Recommended oils
------------------------------------ 2-18
CONTROL DEVICES
CONTROL DEVICES
1. Cab devices ----------------------------------------------- 3-1
2. Cluster
------------------------------------------------------- 3-2
3. Switches
---------------------------------------------------- 3-23
4. Levers and pedals
------------------------------------- 3-27
5. Air conditioner and heater
------------------------- 3-30
6. Others
-------------------------------------------------------- 3-37
OPERATION
OPERATION
1. Suggestion for new machine ---------------------- 4-1
2. Check before starting the engine
--------------- 4-2
3. Starting and stop the engine
---------------------- 4-3
4. Mode selection system
------------------------------ 4-6
5. Operation of the working device
----------------- 4-11
6. Traveling of the machine ---------------------------- 4-12
7. Efficient working method
--------------------------- 4-15
8. Operation in the special work sites
------------- 4-19
9. Normal operation of excavator
------------------- 4-21
10. Attachment lowering
---------------------------------- 4-22
11. Storage
----------------------------------------------------- 4-23
12. RCV lever operating pattern
----------------------- 4-25
13. Switching hydraulic attachment circuit
-------- 4-27
TRANSPORTATION
TRANSPORTATION
1. Preparation for transportation -------------------- 5-1
2. Dimension and weight
------------------------------- 5-2
3. Loading the machine
--------------------------------- 5-5
4. Fixing the machine
------------------------------------ 5-7
5. Loading and unloading by crane
---------------- 5-8
MAINTENANCE
MAINTENANCE
1. Instruction ------------------------------------------------- 6-1
2. Tightening torque
--------------------------------------- 6-6
3. Fuel, coolant and lubricants
----------------------- 6-9
4. Maintenance check list
------------------------------ 6-11
5. Maintenance chart
------------------------------------ 6-16
6. Service instruction
------------------------------------- 6-18
7. Electrical system
--------------------------------------- 6-39
8. Air conditioner and heater
-------------------------- 6-42
TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
1. Engine ------------------------------------------------------ 7-1
2. Electrical system
--------------------------------------- 7-2
3. Others
------------------------------------------------------- 7-3
HYDRAULIC BREAKER AND QUICK CLAMP
HYDRAULIC BREAKER AND QUICK CLAMP
1. Selecting hydraulic breaker ------------------------ 8-1
2. Circuit configuration
----------------------------------- 8-2
3. Maintenance
--------------------------------------------- 8-3
4. Precaution while operating the breaker
------ 8-4
5. Quick clamp
---------------------------------------------- 8-6
INDEX
INDEX ------------------------------------------------------------ 9-1

0-1
This manual contains a number of instructions and safety recommendations regarding driving, han-
dling, lubrication, maintenance, inspection and adjustment of the excavator.
The manual is to promote safety maintenance and enhance machine performance.
Keep this manual handy and have all personnel read it periodically.
If you sell the machine, be sure to give this manual to the new owners.
This machine complies with EC directive "2006/42/EC".
1.
Read
Read and
understand
understand this manual before operating the machine.
This operator's manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Hyundai distributor for those items you require.
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must be
sure that it is safe for you and others. In no event should you or others engage in prohibited uses
of actions as described in this manual.
2.
Inspect
Inspect the jobsite and
follow
follow the safety recommendations in the
safety hints
safety hints section before oper-
ating the machine.
3. Use
genuine Hyundai spare parts
genuine Hyundai spare parts for the replacement of parts.
We expressly point out that Hyundai will not accept any responsibility for defects resulting from non-
genuine parts or non workmanlike repair.
In such cases Hyundai cannot assume liability for any damage.
Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Hyundai or your Hyundai distributor for the latest available infor-
mation for your machine or for questions regarding information in this manual.
FOREWORD
FOREWORD

0-2
It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and
serious injury by keeping this machine properly maintained.
It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents
and serious injury while servicing the machine.
No one should service or attempt to repair this machine without proper training and supervision.
All service and maintenance personnel should be thoroughly familiar with the procedures and precau-
tions contained in this manual.
All personnel also must be aware of any federal, state, provincial or local laws or regulations covering
the use and service of construction equipment.
The procedures in this manual do not supersede any requirements imposed by federal, state, provin-
cial or local laws.
Hyundai can not anticipate every possible circumstance or environment in which this machine may be
used and serviced.
All personnel must remain alert to potential hazards.
Work within your level of training and skill.
Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast.
Use your common sense.
BEFORE SERVICING THIS MACHINE
BEFORE SERVICING THIS MACHINE

0-3
· Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings.
LWA : 100
dB (EU only)
LPA : 71
dB
· The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1
: 2006 and 2002/44/EC)
EC REGULATION APPROVED
EC REGULATION APPROVED

0-4
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine Serial No.
Engine Serial No.
Manufacturing year
Manufacturer
Address
Distributor for U.S.A
Address
Distributor for Europe
Address
Dealer
Address
Hyundai Heavy Industries co., Ltd.
1, Jeonha-Dong, Dong-Ku,
Ulsan 682-792, Korea
Hyundai Heavy Industries U.S.A, Inc
955 Estes Avenue EIK Grove village
IL, 60001
U.S.A
Hyundai Heavy Industries Europe N.V.
Vossendal 11
2240 Geel
Belgium

0-5
SAFETY LABELS
SAFETY LABELS
Bucket
1
2
3
4
7
6
PUMP SCREEN
LH CONSOLE BOX BATTERY COVER
CAB INSIDE-RH CAB INSIDE-LH
26
22
20
41
34
24
21
22
538
35
SCREEN PLATE
19 45
46
8
9
10
10
11 33
1212
13
14
15
16
17
48
1828
32
23
29
37
27
43
39
16
30
42 42
39 316
36
40
47
1. LOCATION
1. LOCATION
Always keep these labels clean. If they are lost or damage, attach them again or replace them with
a new label.
16090SL01
1 Air cleaner filter
2 Turbocharger cover
3 Radiator cap
4 Fueling
5 Battery accident
6 High pressure hose
7 Hydraulic oil level
8 Hydraulic oil lub
9 Keep clear-rear
10 Lifting eye
11 Name plate
12 Slinging ideogram
13 Keep clear-side
14 Stay fix
15 Shearing-engine hood
16
No step-engine hood and CWT
17 Transporting
18 Low emission engine
19 Control ideogram
20
Ref operator manual-cab RH pillar
21 Hammer
22 Safety front window
23 Alternate exit
24 Air conditioner filter
26 Safety lever
27 Model name
28 Logo (ROBEX)
29 Trade mark (boom)
30 Trade mark (CWT)
31 Reduction gear grease
32 Clamp-locking
33 Noise level (LWA)
34 Service instruction
35 Lifting chart
36 Tie
37 Keep clear-Boom/arm
38 ECM connector
39 Falling
40 FOPS FOG plate
41 Turbocharger
42 Reflecting
43 Accumulator
44 Machine control pattern
45 Control ideogram-dozer
46 RCV lever pattern
47 Swing bearing
48 Battery position

0-6
2. DESCRIPTION
2. DESCRIPTION
AIR CLEANER FILTER
AIR CLEANER FILTER (item 1)
This warning label is positioned on the air
cleaner cover.
Periodic and proper inspection, cleaning
Periodic and proper inspection, cleaning
and change of elements prolong engine
and change of elements prolong engine
life time and maintain the good perfor-
life time and maintain the good perfor-
mance of engine.
mance of engine.
There are several specific warning labels on this machine please become familiarized with all warn-
ing labels.
Replace any safety label that is damaged, or missing.
1)
1)
ö
21070FW01
TURBOCHARGER COVER
TURBOCHARGER COVER (item 2)
This warning label is positioned on the tur-
bocharger cover.
Do not touch turbocharger or it may
Do not touch turbocharger or it may
cause severe burn.
cause severe burn.
2)
2)
21070FW02
14070FW03
21070FW04
RADIATOR CAP
RADIATOR CAP (item 3)
This warning label is positioned on the radi-
ator.
Never open the filler cap while engine
Never open the filler cap while engine
running or at high coolant temperature.
running or at high coolant temperature.
3)
3)
FUELING
FUELING (item 4)
This warning label is positioned on the fuel
filler neck.
Stop the engine when refueling. All
Stop the engine when refueling. All
lights or flames shall be kept at a safe
lights or flames shall be kept at a safe
distance while refueling.
distance while refueling.
4)
4)

0-7
BATTERY ACCIDENT
BATTERY ACCIDENT (item 5)
This warning label is positioned on the bat-
tery cover.
Electrolyte containing sulfuric acid cause
Electrolyte containing sulfuric acid cause
severe burns. Avoid being in contact with
severe burns. Avoid being in contact with
skin, eyes or clothes. In the event of
skin, eyes or clothes. In the event of
accident flush with sufficient water, call a
accident flush with sufficient water, call a
physician immediately.
physician immediately.
Maintain the electrolyte at the recom-
Maintain the electrolyte at the recom-
mended level.
mended level.
With electrolyte at proper level, less
With electrolyte at proper level, less
space may cause the gases to be accu-
space may cause the gases to be accu-
mulated in the battery.
mulated in the battery.
Extinguish all smoking materials and
Extinguish all smoking materials and
open flames before checking the battery.
open flames before checking the battery.
Do not use matches, lighters or torches
Do not use matches, lighters or torches
as a light source near the battery for the
as a light source near the battery for the
probable presence of explosive gas.
probable presence of explosive gas.
Do not allow unauthorized personnel to
Do not allow unauthorized personnel to
change the battery or to use booster
change the battery or to use booster
cables.
cables.
For safety from electric shock, do not bat-
For safety from electric shock, do not bat-
tery terminal with a wet hand.
tery terminal with a wet hand.
5)
5)
ö
36070FW05
14070FW29
HIGH PRESSURE HOSE
HIGH PRESSURE HOSE (item 6)
These warning labels are positioned in the
front of upper frame and on the screen
plate.
Escaping fluid under pressure can pene-
Escaping fluid under pressure can pene-
trate the skin causing serious injury.
trate the skin causing serious injury.
Study the service manual before service
Study the service manual before service
job.
job.
6)
6)
ö