Hyundai R160LC3 Repair Manual

0-1

FOREWORD

1. STRUCTURE

This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.

SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.

SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.

SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.

SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.

SECTION 5 MECHA TRONICS SYSTEM
This section explains the computer aided power optimization system and each component.

SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.

SECTION 7 MAINTENANCE ST ANDARD
This section gives the judgement standards when inspecting disassembled parts.

SECTION 8 DISASSEMBL Y AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.

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.

0-2

Revised edition mark(ڸڹںš)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.

Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and

section 1 page.

Symbols

So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.

2. HOW TO READ THE SERVICE MANUAL

Distribution and updating

Any additions, amendments or other changes
will be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.

Filing method

See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
2 - 3

Item number(2. Structure and
Function)
Consecutive page number for

each item.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.

1.

2.

3.

Symbol Item Remarks

Special safety precautions are
necessary when performing the
work.

Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.

Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.

Safety

Caution

Ɠ

10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5

Added pages

0-3

3. CONVERSION T ABLE

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 55

mm

into inches.

Locate the number 50

in

the vertical column at the left side, take this as ڞ, then draw a

horizontal line from ڞ.
Locate the number 5

in

the row across the top, take this as ڟ, then draw a perpendicular line

down from ڟ.
Take the point where the two lines cross as ڠ. This point ڠ gives the value when converting

from millimeters to inches. Therefore, 55

mm

= 2.165 inches.

Convert 550

mm

into inches.

The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55

mm

.
Carry out the same procedure as above to convert 55mm to 2.165 inches.
The original value(550

mm

) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550

mm

= 21.65 inches.

1.

2.

(1)

(2)

(3)

(1)

(2)
(3)

Millimeters to inches

1mm= 0.03937 in

ڟ

ڞ

01 2 345 678 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.1 10
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

ڠ

0-4

Millimeters to inches

1mm= 0.03937

in

01 2 345 678 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.1 10
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound

1kg= 2.2046

lb

01 2 345 678 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 1 10.23 112.44 114.64 1 16.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-5

Liter to U.S. Gallon

1ֻ = 0.2642 U.S.Gal

3

01 2 345 678 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 1 1.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153

Liter to U.K. Gallon

1ֻ = 0.21997 U.K.Gal

01 2 345 678 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 1 1.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.1 17 21.337 21.557 21.777

0-6

kgşm

to

lbşft

1

kgşm

= 7.233

lbşft

01 2 345 678 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
1 10 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 91 1.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1 106.6 1113.9 1121.1 1128.3 1 135.6 1142.8 1150.0
160 1 157.3 1 164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1 129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

0-7

kg/cm2to

lb/in

2

1kg/

cm2= 14.2233 lb /

in

2

01 2 345 678 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1 109 1124
80 1 138 1152 1166 1 181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
1 10 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

TEMPERA TURE

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.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.

0-8

ŞC ŞF ŞC ŞF ŞC ŞF ŞC ŞF

-40.4 -40 -40.0 -1 1.7 11 51.8 7.8 46 114.8 27.2 81
1 17.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6

-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4

-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2

-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6

-27.2 -17 1.4 -7.8 18 64.4 1 1.7 53 127.4 31.1 88 190.4

-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6

-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4

-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2

-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6

-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4

-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2

-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0

-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0

-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0

-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0

-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0

-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0

-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0

-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0

FOLLOW SAFE PROCEDURE

Unsafe work practices are dangerous. Understand
service procedure before doing work; Do not attempt
shortcuts.

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious
injury.
Before performing any work on the excavator, attach a

ųDo Not OperateŴtag on the right side control lever.

USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.
When you get on and off the machine, always maintain
a three point contact with the steps and handrails and
face the machine. Do not use any controls as
handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine.

SECTION 1 GENERAL

GROUP 1 SAFETY

1-1

WARN

DO
NOT
OPERATE

PREP ARE 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.

PROTECT AGAINST FL YING DEBRIS

Guard against injury from flying pieces of metal or
debris; Wear goggles or safety glasses.

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.

Wear a suitable hearing protective device such as ear­muffs or earplugs to protect against objectionable or
uncomfortable loud noises.

A VOID POWER LINES

Serious injury or death can result from contact with
electric lines.

Never move any part of the machine or load closer to
electric line than 3m(10ft) plus twice the line insulator
length.

1-2

KEEP RIDERS OFF EXCA VATOR

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.

MOVE AND OPERA TE MACHINE SAFELY

Bystanders can be run over. Know the location of
bystanders before moving, swinging, or operating the
machine.

Always keep the travel alarm in working condition. It
warns people when the excavator starts to move.

Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate
hand signals before starting the excavator.

OPERA TE ONLY FORM OPERATOR'S SEAT

Avoid possible injury machine damage. Do not start
engine by shorting across starter terminals.

NEVER start engine while standing on ground. Start
engine only from operator's seat.

P ARK MACHINE SAFELY

Before working on the machine:

şPark machine on a level surface.
şLower bucket to the ground.
şTurn auto idle switch off.
şRun engine at 1/2 speed without load for 2 minutes.
şTurn key switch to OFF to stop engine. Remove key

from switch.

şMove pilot control shutoff lever to locked position.
şAllow engine to cool.

1-3

SUPPORT MACHINE PROPERL Y

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 continuous load.
Do not work under a machine that is supported solely by
a jack. Follow recommended procedures in this manual.

SERVICE COOLING SYSTEM SAFEL Y

Explosive release of fluids from pressurized cooling
system can cause serious burns.

Shut off engine. Only remove filler cap when cool
enough to touch with bare hands.

HANDLE FLUIDS SAFEL Y-AVOID FIRES

Handle fuel with care; It is highly flammable. Do not
refuel the machine while smoking or when near open
flame or sparks. Always stop engine before refueling
machine.
Fill fuel tank outdoors.

Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and
debris.

Do not store oily rags; They can ignite and burn
spontaneously.

1-4

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.

REMOVE P AINT BEFORE WELDING OR HEA TING

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.

Dispose of paint and solvent properly.
Remove paint before welding or heating:
ş If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

ş If you use solvent or paint stripper, remove stripper

with soap and water before welding. Remove
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or
heating.

ILLUMINA TE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.

1-5

SERVICE MACHINE SAFEL Y

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.

Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

ST AY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious
injury.

To prevent accidents, use care when working around
rotating parts.

A VOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin
causing serious injury.

Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.

Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result.

1-6

AVOID HEATING NEAR PRESSURIZED 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.

Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install fire
resisting guards to protect hoses or other materials.

PREVENT BA TTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away from the
top of battery. Battery gas can explode.

Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; It may explode. Warm
battery to 16ŞC(60ŞF).

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. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling of dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the
acid.

3. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.

If acid is swallowed:

1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or

vegetable oil.

3. Get medical attention immediately.

1-7

USE TOOLS PROPERL Y

Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.

Use power tools only to loosen threaded tools and
fasteners.

For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.

Use only recommended replacement parts.(See Parts
catalogue.)

DISPOSE OF FLUIDS PROPERL Y

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.

DO NOT pour oil into the ground, down a drain, or into a
stream, pond, or lake. Observe relevant environmental
protection regulations when disposing of oil, fuel,
coolant, brake fluid, filters, batteries, and other harmful
waste.

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the
machine operator's manual for correct safety sign
placement.

LIVE WITH SAFETY

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.

1-8

1-9

1. MAJOR COMPONENT

GROUP 2 SPECIFICA TIONS

Arm Arm cylinder Boom Boom cylinder

Cab

Muffler Counterweight

Side cutter

Bucket cylinder Connecting link

Connecting rod

Idler

Track roller

Carrier roller

Track

Sprocket

Travel motor

Tooth Turning jointBucket Swing motor Main control valve Oil cooler

Fuel tankTool box Hydraulic oil tank Main pump

Engine

Radiator

1-10

2. SPECIFICA TION

ROBEX 160LC-3

1)

Operating weight
Bucket capacity(PCSA heaped), standard
Overall length
Overall width, with 600

mm

shoe
Overall height
Superstructure width
Overall height of cab
Ground clearance of counterweight
Engine cover height
Minimum ground clearance
Rear-end distance
Rear-end swing radius
Distance between tumblers
Undercarriage length
Undercarriage width
Track gauge
Track shoe width, standard
Travel speed(Low/high)
Swing speed
Gradeability
Ground pressure(600

mm

shoe)

kg(lb)

m

3

(yd3)

mm(ft-in)

km/hr(mph)

rpm

Degree(

%

)

kg/cm2(psi)

Specification

16600(36600)

0.65(0.85)
8530(28' 0")
2590( 8' 6")
2870( 9' 5")
2470( 8' 1")
2850( 9' 4")
1035( 3' 5")
2135( 7' 0")

460( 1' 6")
2400( 7'10")
2490( 8' 2")
3190(10' 6")
3980(13' 1")
2590( 8' 6")
1990( 6' 6")

600(24")

3.5/5.5(2.2/3.4)

12.1
35(70)

0.40(5.69)

Unit

Description

A
B
C
D
E
F
G
H

I
I'
J

K

L
M
N

C

A

K

J

I(I')

F

G

E

H

D

M

B(L)

N

1-11

3. WORKING RANGE

5.10m(16' 9") BOOM

1)

A

D

A'

F

E

B

B'

C

8ft

[ ] : Power boost

Max digging reach
Max digging reach on ground
Max digging depth
Max digging depth (8

ft

level)
Max vertical wall digging depth
Max digging height
Max dumping height
Min swing radius

Bucket digging force

Arm crowd force

Description

2.25

m

(7' 5") Arm

A
A'
B
B'
C
D
E
F

8630

mm

8470

mm

5740

mm

5480

mm

4930

mm

8750

mm

6120

mm

2960

mm

(28' 4")
(27' 9")
(18'10")
(18' 0")
(16' 2")
(28' 8")
(20' 1")
( 9' 9")

90 [99]

9200 [10060]

20280 [22180]

104 [1 13]

10570 [1 1560]

23300 [25480]

78 [85]

7920 [8660]

17460 [19100]

81 [89]

8260 [9030]

18210 [19920]

2.60

m

(8' 6") Arm

8950

mm

8800

mm

6090

mm

5860

mm

5370

mm

8940

mm

6310

mm

2920

mm

(29' 4")
(28'10")
(20' 0")
(19' 3")
(17' 7")
(29' 4")
(20' 8")
( 9' 7")

3.10

m

(10' 2") Arm

9340

mm

9200

mm

6590

mm

6360

mm

5580

mm

9000

mm

6400

mm

2940

mm

(30' 8")
(30' 2")
(21' 7")
(20'10")
(18' 4")
(29' 6")
(21' 0")
( 9' 8")

90 [99]

9200 [10060]

20280 [22180]

104 [1 13]

10570 [1 1560]

23300 [25480]

70 [76]

71 10 [7780]

15670 [17140]

73 [79]

7390 [8080]

16290 [17820]

90 [99]

9200 [10060]

20280 [22180]

104 [1 13]
10570 [1 1560]
23300 [25480]

63 [69]

6440 [7040]

14200 [15530]

65 [71]

6650 [7270]

14660 [16030]

SAE

ISO

SAE

ISO

kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf

kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf

kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf

1-12

4. WEIGHT

R160LC-3

1)

Upperstructure assembly
Main frame weld assembly
Engine assembly
Main pump assembly
Main control valve assembly
Swing motor assembly
Hydraulic oil tank assembly
Fuel tank assembly
Counterweight
Cab assembly
Lower chassis assembly
Track frame weld assembly
Swing bearing
Travel motor assembly
Turning joint
Track recoil spring and idler
Idler
Carrier roller
Track roller
Track-chain assembly(600

mm

standard triple grouser shoe)

Front attachment assembly(5.10

m

boom, 2.60marm,

0.65

m3PCSA heaped bucket)

5.10

m

boom assembly

2.60

m

arm assembly

0.65

m3PCSA heaped bucket
Boom cylinder assembly
Arm cylinder assembly
Bucket cylinder assembly
Bucket control link assembly

Item

7220
1210

410
125
135
218
145

110

2900

275
6450
2005

230

210

36
137
160

21

38

1183

2930

1035

525
510
135
183
125

112

kg lb

15920

2670

904
276
298
481
320
243

6390

610

14220

4420

507
463

79
302
353

46

84

2610

6460

2280

1157
1124

298
403
276
247

R160LC-3

1-13

5. LIFTING CAP ACITIES
ROBEX 160LC-3

5.10m(16' 9") boom, 2.60m(8' 6") arm equipped with 0.65

m3(PCSA heaped) bucket and 600

mm

(24") triple grouser shoe.

1)

(1)

ş

: Rating over-front : Rating over-side or 360 degree

ş

Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.

2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity .

3. The load point is a hook located on the back of the bucket.

4.

*

indicates load limited by hydraulic capacity .

Load point

height

Load radius At max. reach

1.5

m(5ft

) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach

7.5

mkg

*2800 *2800 6.20

(

25ft)

lb

*6170 *6170 (20.3)

6.0

mkg

*2620 *2620 *2800 2040 7.46

(

20ft)

lb

*5780 *5780 *6170 4500 (24.5)

4.5

mkg

*3220 2910 2810 1660 8.20

(

15ft)

lb

*7100 6420 6190 3660 (26.9)

3.0

mkg

*6720 *6720 *4530 4420 *3670 2760 *2400 1840 2550 1470 8.56

(

10ft)

lb

*14820 *14820 *9990 9740 *8090 6080 *5290 4060 5620 3240 (28.1)

1.5

mkg

*7670 7470 *5690 4050 *4210 2590 3060 1770 2480 1410 8.61

(

5ft)

lb

*16910 16470 *12540 8930 *9280 5710 6750 3900 5470 3110 (28.2)

-1.5

mkg

*6100 *6100 *9750 7060 *6600 3690 4190 2390 2900 1660 7.73

(

-5ft)

lb

*13450 *13450 *21500 15560 *14550 8140 9240 5270 6390 3660 (25.4)

-3.0

mkg

*9050 *9050 *9000 7170 *6070 3720 4220 2410 *3280 2160 6.66

(

-10ft)

lb

*19950 *19950 *19840 15810 *13380 8200 9300 5310 *7230 4760 (21.9)

-4.5

mkg

*6610 *6610 *4370 3890

(

-15ft)

lb

*14570 *14570 *9630 8580

m(ft)

Ground

kg

*7280 7100 *6450 3800 4270 2450 *2970 1710 2570 1460 8.34

Line

lb

*16050 15650 *14220 8380 9410 5400 *6550 3770 5670 3220 (27.4)

1-14

Load point

height

Load radius At max. reach

1.5

m(5ft

) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach

m(ft)

7.5

mkg

*3040 *3040 5.71

(

25ft)

lb

*6700 *6700 (18.7)

6.0

mkg

*3020 2260 7.08

(

20ft)

lb

*6660 4980 (23.2)

4.5

mkg

*3870 *3870 *3490 2900 3030 1810 7.86

(

15

ft) lb

*8530 *8530 *7690 6390 6680 3990 (25.8)

3.0

mkg

*7610 *7610 *4900 4390 *3910 2760 2740 1610 8.24

(

10

ft)lb

*16780 *16780 *10800 9680 *8620 6080 6040 3550 (27.0)

1.5

mkg

*5740 *5740 *5990 4030 *4410 2610 2660 1540 8.28

(

5ft)

lb

*12650 *12650 *13210 8880 *9720 5750 5860 3400 (27.2)

-1.5

mkg

*6620 *6620 *9920 7150 *6600 3750 4250 2440 3170 1850 7.37

(

-5ft)

lb

*14590 *14590 *21870 15760 *14550 8270 9370 5380 6990 4080 (24.2)

-3.0

mkg

*10180 *10180 *8540 7300 *5870 3800 *3370 2470 6.22

(

-10ft)

lb

*22440 *22440 *18830 16090 *12940 8380 *7430 5450 (20.4)

-4.5

mkg

*5730 *5730

(

-15ft)

lb

*12630 *12630

5.10m(16' 9") boom, 2.25m(7' 5") arm equipped with 0.65

m3(PCSA heaped) bucket and 600

mm

(24") triple grouser shoe.

(2)

5.10

m

(16' 9") boom, 3.10m(10' 2") arm equipped with 0.65

m3(PCSA heaped) bucket and 600

mm

(24") triple grouser shoe.

(3)

Ground

kg

*6990 *6990 *6610 3820 4300 2490 2780 1610 8.01

Line

lb

*15410 *15410 *14570 8420 9480 5490 6130 3550 (26.3)

Load point

height

Load radius At max. reach

1.5

m(5ft

) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach

7.5

mkg

*2480 *2480 6.76

(

25ft)

lb

*5470 *5470 (22.2)

6.0

mkg

*2580 *2580 *2530 1850 7.92

(

20ft)

lb

*5690 *5690 *5580 4080 (26.0)

4.5

mkg

*2880 *2880 *1840 *1840 2590 1520 8.61

(

15ft)

lb

*6350 *6350 *4060 *4060 5710 3350 (28.2)

3.0

mkg

*4030 *4030 *3370 2800 *2750 1870 2360 1350 8.95

(

10ft)

lb

*8880 *8880 *7430 6170 *6060 4120 5200 2980 (29.4)

1.5

mkg

*8730 7710 *5280 4120 *3960 2610 3070 1780 2290 1290 9.00

(

5ft)

lb

*19250 17000 *11640 9080 *8730 5750 6770 3920 5050 2840 (29.5)

-1.5

mkg

*5830 *5830 *9570 6970 *6550 3660 4160 2360 2620 1480 8.17

(

-5ft)

lb

*12850 *12850 *21100 15370 *14440 8070 9170 5200 5780 3260 (26.8)

-3.0

mkg

*8220 *8220 *9510 7020 *6270 3640 4150 2350 *3230 1870 7.18

(

-10ft)

lb

*18120 *18120 *20970 15480 *13820 8020 9150 5180 *7120 4120 (23.6)

-4.5

mkg

*11360 *11360 *7600 7240 *5090 3750

(

-15ft)

lb

*25040 *25040 *16760 15960 *11220 8270

m(ft)

Ground

kg

*8130 7110 *6200 3810 4270 2450 2990 1700 2370 1330 8.75

Line

lb

*17920 15670 *13670 8400 9410 5400 6590 3750 5220 2930 (28.7)

1-15

6. BUCKET SELECTION GUIDE

GENERAL BUCKET

1)

PCSA

heaped

0.39

m

3

(0.51

yd3)

0.57

m

3

(0.75

yd3)

Ɠ0.65

m

3

(0.85

yd3)

0.70

m

3

(0.92

yd3)

0.80

m

3

(1.05

yd3)

CECE

heaped

0.35

m

3

(0.46

yd3)

0.50

m

3

(0.65

yd3)

0.55

m

3

(0.72

yd3)

0.60

m

3

(0.78

yd3)

0.70

m

3

(0.92

yd3)

Without

side cutter

620

mm

(24")

840

mm

(33")

930

mm

(37")

990

mm

(39")

1080

mm

(43")

With

side cutter

740

mm

(29")

960

mm

(38")

1050

mm

(41")

1110

mm

(44")

1200

mm

(47")

410

kg

(900lb)

490

kg

(1080lb)

510

kg

(1 120lb)

540

kg

(1 190lb)

570

kg

(1260lb)

2.25marm
(7' 5")

2.60marm
(8' 6")

3.10marm
(10' 2")

Recommendation

5.10

m

(16' 9") boom

Capacity Width

Weight

0.39

m3PCSA

heaped bucket

0.57

m3PCSA

heaped bucket

Ɠ

0.65

m3PCSA

heaped bucket

0.70

m3PCSA

heaped bucket

0.80

m3PCSA

heaped bucket

Applicable for materials with density of 2000

kg/m

3

(3370

lb/yd

3

) or less

Applicable for materials with density of 1600

kg/m

3

(2700

lb/yd

3

) or less

Applicable for materials with density of 1100

kg/m

3

(1850

lb/yd

3

) or less

Ɠ

Standard bucket

1-16

7. UNDERCARRIAGE

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.

TYPES OF SHOES

NUMBER OF ROLLERS AND SHOES ON EACH SIDE

3)

1)

2)

mm(in)

kg(lb)

kg/cm

2

(psi)

mm(ft-in)

600(24)

16600(36600)

0.40(5.69)

2590(8' 6")

700(28)

16970(37410)

0.35(4.98)

2690(8' 10")

800(32)

17240(38010)

0.31(4.41)

2790(9' 2")

500(20)

16360(36070)

0.47(6.68)

2490(8' 2")

Triple grouser

Shapes

Shoe width
Operating weight
Ground pressure
Overall width

R160LC-3

Model

Carrier rollers
Track rollers
Track shoes

2EA
7EA

49EA

Item Quantity

1-17

8. SPECIFICA TIONS FOR MAJOR COMPONENTS

ENGINE

1)

MAIN PUMP

Item

Model
Type
Cooling method

Number of cylinders and arrangement
Firing order
Combustion chamber type
Cylinder boreźstroke
Piston displacement
Compression ratio
Rated gross horse power(SAE J1349)
Maximum torque at 1500

rpm
Engine oil quantity
Dry weight
High idling speed
Low idling speed
Rated fuel consumption
Starting motor
Alternator
Battery

Specification

Cummins B3.9-C
4-cycle turbocharged, after cooled and low emission

diesel engine
Water cooling
4 cylinders, in-line
1-3-4-2
Direct injection type
102ź120

mm

(4.02"ź4.72")

3900cc(238cu in)

16.5 : 1
110

Hp

at 2200

rpm

(82

kW

at 2200

rpm

)

45.9

kgfşm

(332

lbfşft

)

11ֻ(2.9U.S.

gal

)

329

kg

(725lb)

2450*50

rpm

950Ź100

rpm

169.9

g/Psşhr
Delco Remy 28MT(24V)
DAC(24

V

- 60

AMP

)

2ź12

V

ź100

Ah

Item

Type
Capacity
Maximum pressure
Rated oil flow
Rated speed

Specification

V ariable displacement tandem axis piston pumps
2ź64

cc/rev

320

kgf/cm2(4550

psi

)[350

kgf/cm2(4980

psi

)]

2ź140

ֻ/min

(40U.S.

gpm

/ 30.8U.K.

gpm

)

2200

rpm

2)

[ ] : Power boost

1-18

GEAR PUMP

MAIN CONTROL V AL VE

SWING MOTOR

TRA VEL MOTOR

Item

Type
Capacity
Maximum pressure
Rated oil flow

Specification

Fixed displacement gear pump single stage
10cc/rev
40

kgf/cm2(570

psi

)

22ֻ

/min

(5.8U.S.

gpm/

4.8U.K.

gpm

)

Item

Type
Operating method
Main relief valve pressure
Overload relief valve pressure

Specification

9 spools two-block
Hydraulic pilot system
320

kgf/cm2(4550

psi

)[350

kgf/cm2(4980

psi

)]

380

kgf/cm2(5405

psi

)

Item

Type
Capacity
Relief pressure
Braking system
Braking torque
Brake release pressure
Reduction gear type
Swing speed

Specification

Fixed displacement axial piston motor

99.2

cc/rev

260

kgf/cm2(391 1

psi

)
Automatic, spring applied, hydraulic released
42

kgfşm

(304

lbfşft

)

4.5~20

kgf/cm2(64~284

psi

)

2 - stage planetary

12.1

rpm

Item

Type
Relief pressure
Capacity(max / min)
Reduction gear type
Braking system
Brake release pressure
Braking torque

Specification

V ariable displacement axial piston motor
350

kgf/cm2(4980

psi

)

87.3/55.5

cc/rev
3-stage planetary
Automatic, spring applied, hydraulic released
11

kgf/cm2(156

psi

)

1060~1780

kgfşm

(7667~12874

lbfşft

)

[ ] : Power boost

3)

4)

5)

6)

1-19

REMOTE CONTROL V AL VE

CYLINDER

SHOE

Item

Type

Specification

Pressure reducing type

5.5

kgf/cm

2

(78

psi

)

19.5

kgf/cm2(277

psi

)

82.7

mm

(3.3in)

123

mm

(4.8in)

Operating pressure

Minimum
Maximum
Lever
Pedal

Single operation stroke

Item

Specification

ٻ110źٻ80ź1 180

mm
Extend only
ٻ120źٻ85ź 1320

mm
Extend and retract
ٻ105źٻ75ź 1005

mm
Extend only

Bore diaźRod diaźStroke
Cushion
Bore diaźRod diaźStroke
Cushion
Bore diaźRod diaźStroke
Cushion

Boom cylinder

Arm cylinder

Bucket cylinder

Item

Width

600

mm

(24")

500

mm

(20")

700

mm

(28")

800

mm

(32")

Ground pressure

0.40

kgf/cm2(5.69

psi

)

0.47

kgf/cm2(6.68

psi

)

0.35

kgf/cm2(4.98

psi

)

0.31

kgf/cm2(4.41

psi

)

Link quantity

49
49
49
49

Overall width

2590

mm

( 8' 6")

2490

mm

( 8' 2")

2690

mm

( 8' 10")

2790

mm

( 9' 2")

STD

OPT

9)

7)

8)

BUCKET

Capacity

PCSA heaped CECE heaped

Without side cutter With side cutter

Width

Item

T ooth

quantity

STD

OPT

0.65

m3(

0.85

yd3)

0.39

m3(

0.51

yd3)

0.57

m3(

0.75

yd3)

0.70

m3(

0.92

yd3)

0.80

m3(

1.05

yd3)

0.55

m3(

0.72

yd3)

0.35

m3(

0.46

yd3)

0.50

m3(

0.65

yd3)

0.60

m3(

0.78

yd3)

0.70

m3(

0.92

yd3)

5
3
4
5
5

930mm(37")
620

mm

(24")

840

mm

(33")

990

mm

(39")

1080

mm

(43")

1050

mm

(41")

740

mm

(29")

960

mm

(38")

1110

mm

(44")

1200

mm

(47")

10)

1-20

9. RECOMMENDED OILS

Use only oils listed below or equivalent.
Do not mix different brand oil.

Capacity

ֻ(U.S. gal)

Service point Kind of fluid

Engine oil 11(2.9)

Hydraulic tank Hydraulic oil

Gear oil

Fuel tank Diesel fuel 250(66.1)

Ambient temperature ŞC(ŞF)

Ethylene glycol base permanent type

Engine

oil pan

Fitting

(Grease nipple)

Radiator

(Reservoir tank)

Grease As required

Tank;
120(31.7)

System;
210(55.5)

24(6.3)

-20 -10 0 10 20 30 40

(-4) (14) (32) (50) (68) (86) (104)

SAE : Society of Automotive Engineers
API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material

Mixture of
antifreeze
and water

50 : 50

SAE 30

SAE 10W

SAE 10W-30

SAE 15W-40

SAE 85W-140

ISO VG 32

ASTM D975 NO.1

ASTM D975 NO.2

NLGI NO.1

NLGI NO.2

ISO VG 46

ISO VG 68

3.4(0.9)

4.4ź2

(1.2ź2)

Swing drive

Final drive

2-1

1. STRUCTURE

The pump device consists of main pump, regulator and gear pump.

SECTION 2 STRUCTURE AND FUNCTION

GROUP 1 PUMP DEVICE

Regulator

Qmin Adjusting screw Qmax Adjusting screw

Rear pump

Valve block

Front pump

Pi2

a4

Dr

Pi1

Qmin Adjusting screw

Regulator

Pilot pump

Pf

A3

B3

B3

B1

Pi1

Dr

Dr

Pi2

a1 a2

a3

Pi1

A1 A2

B1 B3 a3

Pi2

a4

Hydraulic circuit

a1 a2

Dr

A3

Pf

Front Rear

Port

A

1,2

B1
Dr

P

f

Pi1,

i2

a

1,2,3,4

A

3

B

3

Port name

Delivery port

Suction port

Drain port

Power shift port

(For decreasing)

Pilot po

rt

Gauge port

Gear pump delivery port

Gear pump suction port

Port size

SAE6000psi 3/4"

SAE2500psi 2 1/2"

PF 1/2 - 19
PF 1/4 - 15
PF 1/4 - 15

PF 1/4 - 15
PF 1/2 - 19

PF 3/4 - 20.5