Part of the Hyundai Repair Manuals.
Every one of the 458 pages in this Hyundai R160LC-3 service manual PDF exists for one reason: putting your crawler excavator back to work. You get full hydraulic schematics tracing the main and pilot circuits, electrical wiring circuits with component locations, and a mechatronics section that explains mode selection, automatic deceleration, and power boost so you can diagnose the smart systems, not just the iron. Behind that sits a full troubleshooting section plus step-by-step disassembly and assembly for the pump device, main control valve, swing and travel motors, and the boom, arm, and bucket cylinders. Swing motor mounting bolts call for 57.9 ± 8.7 kgf·m; travel motor bolts take 23 ± 2.5 kgf·m. Quit chasing pilot pressure problems on a hunch. Bookmarked with a real text layer, this PDF lets you search any spec and read it right off your phone in the cab.
What's Inside This Hyundai R160LC-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 9-28 | Safety, Specifications |
| Structure and Function | 29-107 | Pump Device, Main Control Valve, Swing Device, Travel Device, Rcv Lever, Rcv Pedal |
| Hydraulic System | 108-137 | Hydraulic Circuit, Main Circuit, Pilot Circuit |
| Electrical System | 138-182 | Component Location, Electrical Circuit |
| Mechatronics System | 183-218 | Outline, Mode Selection System, Automatic Deceleration System, Power Boost System, Travel Speed Control System |
| Maintenance Standard | 276-312 | Operational Performance Test, Major Component |
| Disassembly and Assembly | 313-458 | Precautions, Pump Device, Main Control Valve, Swing Device, Travel Device, Boom Arm and Bucket Cylinder |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Bypass relief valve opening pressure | 3.0kg/cm2 (43psi) | p. 110 |
| Play between piston(1) & shoe caulking section(3) | 0-0.1 mm | p. 297 |
| Thickness of shoe (t) | 3.9 mm | p. 25 |
| Swing motor mounting bolt | 57.9 ± 8.7 kgf·m | p. 317 |
| Travel motor mounting bolt | 23 ± 2.5 kgf·m | p. 317 |
| Swing bearing upper mounting bolt | 57.8 ± 6.4 kgf·m | p. 317 |
| Swing bearing lower mounting bolt | 57.8 ± 6.4 kgf·m | p. 317 |
| Operating weight | 16600 kg | p. 18 |
| Engine oil quantity | 11 L | p. 25 |
| Main pump maximum pressure | 320 kgf/cm2 | p. 25 |
| Swing motor relief pressure | 260 kgf/cm2 | p. 26 |
| Travel motor relief pressure | 350 kgf/cm2 | p. 26 |
Hyundai R160LC-3 Common Problems This Manual Covers
Hyundai R160LC-3 hydraulic pump whines and loses pressure after oil change, bucket lifts slow and weak
Check hydraulic oil level and top off before anything else. Drain the tank, clean the suction strainer, and replace the return filter; a plugged element opens the bypass relief at 3.0 kg/cm2 (43 psi), covered on page 110. Bleed air from the pump, then run the machine and confirm main relief pressure reaches 320 kgf/cm2.
Manual Section: Hydraulic System p. 110Hydraulic oil sprays out when loosening fittings during pump or swing motor removal
Relieve residual pressure before cracking any fitting. Shut the engine down, cycle all control levers several times, then loosen the tank breather slowly to vent trapped pressure. Follow the removal precautions starting on page 313. Remember this circuit runs up to 320 kgf/cm2; a charged line will spray oil hard enough to injure you.
Manual Section: Disassembly and Assembly p. 313Upperstructure drifts after swing stops, excessive play felt in the swing bearing
Measure swing bearing play using the maintenance standard procedures beginning on page 276 and compare readings against the wear limit. Check the bearing mounting hardware for looseness; torque upper and lower swing bearing bolts to 57.8 ± 6.4 kgf·m, spec on page 317. If play stays excessive with bolts tight, plan on bearing replacement.
Manual Section: Maintenance Standard p. 276Swing feels sluggish in both directions, cycle time slower than normal at operating temperature
Test swing performance with hydraulic oil at operating temperature per the operational performance test on page 276. Measure swing motor relief pressure; spec is 260 kgf/cm2, listed on page 26. Low relief pressure points to a worn relief valve or swing motor. If pressure checks good, inspect the swing reduction gear for wear.
Manual Section: Hydraulic and Mechanical System TroubleshootingAll hydraulic functions slow and weak at high hours, digging power drops when oil warms up
Test main pump relief pressure hot; spec is 320 kgf/cm2, found on page 25. If pressure is low and adjustment does not hold, pull the pump and measure play between the piston and shoe caulking section; standard is 0-0.1 mm, page 297. Replace the rotating group beyond that limit, then torque main pump mounting socket bolts to 22.1 ± 2.4 kgf·m.
Manual Section: Maintenance Standard p. 297Frequently Asked Questions
How do I clear recorded error codes on the Hyundai R160LC-3 monitor?
To delete all recorded error codes, select the recorded error (TIME Err) display on the cluster. Press the engine speed up and engine speed down switches simultaneously for at least 2 seconds. The cluster display will change to 'TIME Err : 00', indicating that the CPU controller has deleted all recorded errors from its memory. p. 199
What is the procedure for bleeding air from the hydraulic pump after installation?
After installing the pump, remove the air vent plug (2EA) from the pump. Start the engine and run it at low idling until oil comes out from the plug, then tighten the plug. Finally, run the engine at low idling for 3 to 5 minutes to circulate the oil through the system. p. 320
What is the tightening torque for the engine mounting bolts on the R160LC-3?
The tightening torque for the engine mounting bolts and nuts (M22 x 2.5) is 48 ± 2.0 kgf·m (347 ± 14.4 lbf·ft). p. 316
What is the standard hydraulic oil quantity for the R160LC-3?
The hydraulic oil quantity for the system is 210 liters. p. 319
How do I check the internal leakage of the boom cylinder?
Lower the bucket teeth to the ground with the bucket cylinder fully retracted and the arm cylinder rod retracted almost in full. Disconnect hose (A) from the rod side of the boom cylinder and drain the oil. Raise the bucket off the ground by retracting the arm cylinder rod; if oil leaks from the piping side, there is an internal leak in the cylinder. p. 241
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