Hyundai Excavator R210LC-7. Service and repair manual

7 - 10

Unit : mm

SWING BEARING PLAY

Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.

Preparation

Check swing bearing mounting cap
screws for loosening.
Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
Install a dial gauge on the track frame as
shown, using a magnetic base.
Position the upperstructure so that the
boom aligns with the tracks facing
towards the front idlers.
Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
Bucket should be empty.

Measurement

With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading(h1).
Lower the bucket to the ground and use
it to raise the front idler 50cm.
Record the dial gauge reading(h2).
Calculate bearing play(H) from this
data(h1 and h2) as follows.

H=h2-h1

Evaluation

R210LC-7

Measurement : (h1)

Measurement : (h2)

R210LC-7

(1)

(2)

(3)

The measured drift should be within the following specifications.

(4)

Model

R210LC-7

Standard

0.5 ~ 1.5

Maximum allowable

3.0

Remarks

(210-7) 7-10(1)

21077MS09

7 - 11

Boom cylinder

Raise

Lower

Roll in

Roll out

0.5m

Roll in

Roll out

Arm cylinder

Bucket cylinder

HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.

Preparation

To measure the cycle time of the boom
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown.
To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5m
above the ground.
To measure the cycle time of the bucket
cylinder.
The empty bucket should be positioned
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Mode selector : H mode
To measure cylinder cycle times.
Boom cylinders.
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly
as possible.

(1)

(2)

(3)

21077MS10

7 - 12

Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the
bucket at one stroke end, then move the
control lever to the other stroke end as
quickly as possible.
Repeat each measurement 3 times and
calculate the average values.

Evaluation

The average measured time should meet the following specifications.

Unit : Seconds

(4)

Model

R210LC-7

Function

Boom raise

Boom lower

Arm in

Arm out

Bucket load

Bucket dump

Standard

3.0 0.4

3.2 0.4

2.8 0.3

3.8 0.4

2.5 0.3

Maximum allowable

3.8

4.0

3.5

4.8

3.1

Remarks

7 - 13

R210LC-7

DIG FUNCTION DRIFT CHECK

Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.

Preparation

Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
W=M

1.5

Where :

= Bucket heaped capacity(m

)

1.5= Soil specific gravity

Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Stop the engine.
Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
Repeat step

three times and calculate

the average values.

10)

(1)

(2)

(3)

The measured drift should be within the following specifications.

Unit : mm / 5min

Model

R210LC-7

Drift to be measured

Boom cylinder

Arm cylinder

Bucket cylinder

Standard

40 below

60 below

40 below

Maximum allowable

Remarks

(4)

21077MS11

7 - 14

Unit : kgf

CONTROL LEVER OPERATING FORCE

Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.

Preparation

Keep the hydraulic oil temperature at
50 5 C.

Measurement

Start the engine.
Select the following switch positions.
Mode selector : H mode
Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
Repeat steps

and

three times and

calculate the average values.

Evaluation

11)

(1)

(2)

(3)

The measured operating force should be within the following specifications.

Model

R210LC-7

Kind of lever

Boom lever

Arm lever

Bucket lever

Swing lever

Travel lever

Standard

1.6 or below

2.1 or below

Maximum allowable

2.0

3.15

Remarks

(4)

7 - 15

Unit : mm

CONTROL LEVER STROKE

Measure each lever stroke at the lever top
using a ruler.
When the lever has play, take a half of this
value and add it to the measured stroke.

Preparation

Keep the hydraulic oil temperature at
50 5 C.

Measurement

Stop the engine.
Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
Repeat step

three times and calculate

the average values.

Evaluation

12)

(1)

(2)

(3)

The measured drift should be within the following specifications.

(4)

Model

R210LC-7

Kind of lever

Boom lever

Arm lever

Bucket lever

Swing lever

Travel lever

Standard

87 10

142 10

Maximum allowable

109

178

Remarks

7 - 16

PILOT PRIMARY PRESSURE

Preparation

Stop the engine.
Remove the top cover of the hydraulic
tank oil supply port with a wrench.
Loosen and remove plug on the pilot
pump delivery port and connect pressure
gauge.
Start the engine and check for oil
leakage from the port.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Mode selector : H mode
Auto decel switch : OFF
Measure the primary pilot pressure in the
H mode.

Evaluation

13)

(1)

(2)

The average measured pressure should meet the following specifications:

Unit : kgf / cm

Pm2

Pm1

Psv

(3)

Model

R210LC-7

Engine speed

H mode

Standard

35 5

Allowable limits

Remarks

21077MS12

7 - 17

Preparation

Stop the engine.
Remove the top cover of the hydraulic
tank oil supply port with a wrench.
Push the pressure release button to
bleed air.
To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint P port as shown.
Start the engine and check for on
leakage from the adapter.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Travel mode switch : 1 speed

2 speed

Mode selector

: H mode

Measure the travel speed selecting
pressure in the Hi or Lo mode.
Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
Repeat steps

and

three times and

calculate the average values.

Evaluation

FOR TRAVEL SPEED SELECTING PRESSURE:

(1)

(2)

The average measured pressure should be within the following specifications.

Unit : kgf / cm

14)

(3)

Model

R210LC-7

Travel speed mode

1 Speed

2 Speed

Standard

35 5

Maximum allowable

Remarks

21077MS13

7 - 18

Preparation

Stop the engine.
Remove the top cover of the hydraulic
tank oil supply port with a wrench.
The pressure release L wrench to bleed
air.
Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
Start the engine and check for oil
leakage from the adapter.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Mode selector : H mode
Operate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
applied.
Repeat step

three times and calculate

the average values.

Evaluation

(1)

(2)

The average measured pressure should be within the following specifications.

Unit : kgf / cm

SWING PARKING BRAKE RELEASING PRESSURE

15)

(3)

Model

R210LC-7

Description

Brake disengaged

Brake applied

Standard

Allowable limits

26~44

Remarks

21077MS14

7 - 19

Pm2

Pm1

Psv

MAIN PUMP DELIVERY PRESSURE

Preparation

Stop the engine.
Remove the top cover of the hydraulic
tank oil supply port with a wrench.
Push the pressure release button to
bleed air.
To measure the main pump pressure.
Install a connector and pressure gauge
assembly main pump gauge port as
shown.
Start the engine and check for oil
leakage from the port.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Mode selector : H mode
Measure the main pump delivery
pressure in the H mode(High idle).

Evaluation

16)

(1)

(2)

The average measured pressure should meet the following specifications.

Unit : kgf / cm

Model

R210LC-7

Engine speed

High ilde

Standard

40 5

Allowable limits

Remarks

(3)

21077MS15

7 - 20

Pm2

Pm1

Psv

Preparation

Stop the engine.
Remove the top cover of the hydraulic
tank oil supply port with a wrench.
Push the pressure release button to
bleed air.
To measure the system relief pressure.
Install a connector and pressure gauge
assembly main pump gauge port, as
shown.
Start the engine and check for oil
leakage from the port.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Mode selector : H mode
Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
In the swing function, place bucket
against an immovable object and
measure the relief pressure.
In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.

Evaluation

(1)

(2)

The average measured pressure should be within the following specifications.

Unit : kgf / cm

( ) : Power boost

SYSTEM PRESSURE REGULATOR RELIEF SETTING

17)

(3)

Model

R210LC-7

Function to be tested

Boom, Arm, Bucket

Travel

Swing

Standard

330(360) 10

330 10

240 10

Maximum allowable

390 10

21077MS15

7 - 21

1. MAIN PUMP

9 5 6 4 7 8

GROUP 2 MAJOR COMPONENT

Part name & inspection item

Standard

dimension

Recommended

replacement

value

Counter measures

Clearance
between piston(1) & cylinder
bore(2)
(D-d)

Play between
piston(1) & shoe caulking
section(3)
(

)

Thickness of shoe
(t)

Free height of cylinder
spring(4)
(L)

Combined height of set
plate(5) & spherical
bushing(6)
(H-h)

Surface roughness for valve
plate(Sliding face)(7,8),
swash plate (shoe plate
area)(9), &
cylinder(2)(Sliding face)

0.039

0.067

Replace piston

or cylinder.

0-0.1

0.3

4.9

4.7

41.1

40.3

23.0

22.0

Standard surface roughness
(Corrected value)

Replace

assembly of

piston & shoe.

Replace cylinder

spring.

Replace retainer

or set plate.

0.4z or lower

Lapping

Surface roughness
necessary to be corrected

d D

h H

(210-7) 7-21

7 - 22

2. MAIN CONTROL VALVE

Part name

Inspection item

Criteria & measure

Existence of scratch, rusting or corrosion.

Existence of scratch, gnawing, rusting or
corrosion.

O-ring seal sections at both ends.

Insert spool in casing hole, rotate and
reciprocate it.

Damage of poppet or spring

Insert poppet into casing and function it.

Rusting, corrosion, deformation or breaking
of spring, spring seat, plug or cover.

External oil leakage.

Rusting, corrosion or deformation of seal
plate.

External rusting or damage.

Contacting face of valve seat.

Contacting face of poppet.

Abnormal spring.

O-rings, back up rings and seals.

In case of damage in following section,
replace part.

- Sliding sections of casing fore and spool,

especially land sections applied with
holded pressure.

- Seal pocket section where spool is inserted.

- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,

travel, and port.

- Other damages that may damage normal

functions.

Replacement when its outside sliding
section has scratch(Especially on seals-
contacting section).

Replacement when its sliding section has
scratch.

Correction or replacement when O-ring is
damaged or when spool does not move
smoothly.

Correction or replacement when sealing is
incomplete.

Normal when it can function lightly without
being caught.

Replacement for significant damage.

Correction or replacement.

Replacement.

Replacement when damaged.

Replacement.

100

replacement in general.

Casing

Spool

Poppet

Around spring

Around seal
for spool

Main relief valve,
port relief valve &
negative control
relief valve

Part name

Inspection item

Remedy

Worn less than 0.03mm

Worn more than 0.03mm

Sliding surface has a seizure(Even through
small).

Sliding surface has a damage.

Sliding surface depression( )
dimension less than 0.45mm or has a large
damage.

Sliding surface has a seizure(Even though
small).

Sliding surface has a seizure.

Sliding surface has a damage.

In case 3000hour operation.

Rolling surface has a damage.

Lapping

Replacement

Replacement
Lapping

Replace parts or motor

Replace motor

Replacement

Balance plate

Shoe of piston
assembly

Piston of piston
assembly

Piston hole of
cylinder assembly

Taper roller bearing
Needle bearing
Roller bearing

7 - 23

3. SWING DEVICE

7 - 24

4. TRAVEL DEVICE

Disassembling and inspection of the motor must be done in strict accordance with the servicing
standards described here. During servicing, handle each part very carefully not to damage them,
especially for their movable or sliding sections.

SEALS

Once the seals(O-rings, oil seals, and floating seals) have been disassembled, they must be
replaced with new ones even if no damage is observed.

TABLE OF MAINTENANCE STANDARD

Replace all parts having a seriously damaged appearance.

Replace the part if any one of the states(Symptoms) listed in the table below is observed.

(1)

(2)

Situation

Standard dimension

Part name

Maximum allowable

value(Criteria)

Seriously damaged in
appearance.

Galling or other forms of
excessive wear are observed.

The tooth surface of the cluster
gear(6) is nonuniformly worn out
and damaged.

The cluster gear(6) does not
move smoothly.

The tooth surface is
nonuniformly worn out and
damaged.

The tooth surface is
nonuniformly worn out and
damaged.
The spline section is worn.

Excessive wear or pitching is
observed on the tooth surface.

The spline section is worn.

Worn out.

Spindle kit

Spindle assembly

Spindle
Coupling gear

Carrier assembly

Carrier
Cluster gear
Shaft
Thrust collar
Needle bearing
Dowel pin

Ring gear A

Ring gear B

Sun gear

Coupling gear

Coupling

Thrust bearing

Clearance : 0.8mm

Axial clearance
between coupling
gear(8) and cover(13)
: 0.3 to 0.6m

Item

No.

2
8

3
6
9

14
25
34

7 - 25

The sliding surface is damaged.

The sliding surface is excessively

worn out.

Dents are present.

Flaking develops.

Nonuniform wear is present.

The movable section contacting

the spool(123) is damaged.

The clearance against the spool

(123) is too large.

The surface contacting the valve

(127) is damaged.

The depth to the surface

contacting the valve (127) is too
large.

The outer surface is damaged.

The outer surface is

nonuniformly worn out.

The surface contacting the oil

seal(132) is worn out.

The spline section is worn out.

Seizure is observed.

The spline section is worn out.

The bore inner surface is worn

out too much.

The sliding surface that contacts

the timing plate(109) is damaged
or nonuniformly worn out.

An axial clearance is present

between the piston(105) and the
shoe(106).

The shoe is excessively worn out.

The shoe is nonuniformly worn

out.

The peripheral edge is

nonuniformly worn out.

Distance piece

Ball bearing

Rear flange kit

Rear flange

Spool

Shaft

Swash plate

Cylinder block

Piston assembly

Piston
shoe

Retainer plate

Linear clearance :
20

Clearance : 0.15mm

Linear clearance :
10 to 20

Clearance : 0.05mm

101

123

102

103

104

105
106

107

Situation

Standard dimension

Part name

Maximum allowable

value(Criteria)

Item

No.

Hyundai Excavator R210LC-7. Service and repair manual - page 24