Hyundai Excavator R210LC-7. Service and repair manual

8-21

TOOLS AND TIGHTENING TORQUE

Tools

The tools necessary to disassemble/reassemble the pump are shown in the follow list.

(1)

Name

Adjustable angle wrench

Screw driver

Hammer

Pliers

Steel bar

Torque wrench

Pincers

Bolt

Small size, Max 36mm

Minus type screw driver, Medium size, 2 sets

Plastic hammer, 1 set

For snap ring, TSR-160

4 100mm

Capable of tightening with the specified torques

M4, Length : 50mm

Tool name & size

Part name

Hexagon socket

head bolt

PT plug

(PT thread)

PO plug

(PF thread)

Hexagon socket

head setscrew

M 5

M 6

M 8

Hexagon head

bolt

M 8

Hexagon nut

M 8

VP plug

(PF thread)

BP-1/16

BP-1/8

BP-1/4

PO-1/4

M 8

M10

M12, M14

Allen wrench

Double ring spanner,

socket wrench, double(Single)

open end spanner

8-22

Tightening torque

(2)

Part name

Hexagon socket head bolt

Material : SCM435)

PT Plut(Materal : S45C)

Wind a seal tape 1 1/2 to 2

turns round the plug

PF Plut(Materal : S35C)

M 5

M 6

M 8

M10

M12

M14

M16

M18

M20

PT1/16

PT 1/8

PT 1/4

PT 3/8

PT 1/2

PF 1/4

PF 1/2

PF 3/4

PF 1

PF 1 1/4

PF 1 1/2

0.7

1.2

3.0

5.8

10.0

16.0

24.0

34.0

44.0

0.7

1.05

1.75

3.5

5.0

3.0

10.0

15.0

19.0

27.0

28.0

5.1

8.7

21.7

42.0

72.3

116

174

246

318

5.1

7.59

12.7

25.3

36.2

21.7

72.3

109

137

195

203

0.16

0.20

0.24

0.31

0.39

0.47

0.55

0.67

0.16

0.20

0.24

0.31

0.39

0.24

0.39

0.55

0.67

Bolt size

Torque

Wrench size

kgf m

lbf ft

8-23

DISASSEMBLY

Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.

Choose a place for disassembly.
Choose a clean place.
Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.

Remove dust, rust, etc. from surfaces of
regulator with clean oil.

(1)

(2)

Remove hexagon socket head screw
(438) and remove cover(C,629)
Cover(C) is fitted with adjusting screw
(C,QI) (628, 925), adjusting ring(C, 627),
lock nut(630), hexagon nut(801) and
adjusting screw(924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.

(4)

Remove hexagon socket head screw
(412, 413) and remove regulator main
body from pump main body.
Take care not to lose O-ring.

(3)

(210-7) REG01

(210-7) REG02

8-24

Remove locking ring(858) and take out
fulcrum plug(614) and adjusting plug
(615).
Fulcrum plug(614) and adjusting plug
(615) can easily be taken out with M6 bolt.

(8)

Remove snap ring(814) and take out
spring seat(653), return spring(654) and
sleeve(651).
Sleeve(651) is fitted with snap ring(836).
When removing snap ring(814), return
spring(654) may pop out.
Take care not to lose it.

(7)

Remove hexagon socket head screws
(436, 438) and remove pilot cover(641).
After removing pilot cover, take out set
spring(655) from pilot section.

(6)

After removing cover(C, 629) subassembly,
take out outer spring(625), inner spring
(626) and spring seat(C, 624) from
compensating section.
Then draw out adjusting ring(Q, 645), pilot
spring(646) and spring seat(644) from
pilot section.
Adjusting ring(Q,645) can easily be drawn
out with M4 bolt.

(5)

(210-7) REG03

(210-7) REG04

(210-7) REG05

(210-7) REG06

8-27

ASSEMBLY

For assembly, reverse disassembly
procedures, but pay attention to the
following items.

Always repair parts that were scored at
disassembly.
Get replacement parts ready beforehand.
Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
Always tighten bolts, plugs, etc. to their
specified torques.
Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Replace seals such as O-ring with new
ones as a rule.

(1)

Spool

Feedback lever

Put compensating rod(623) into
compensating hole of casing(601).

Put pin force-fitted in lever(1, 612) into
groove of compensating rod and fit lever
(1) to pin force-fitted in casing.

(2)

(3)

Fit spool(652) and sleeve(651) into hole in
spool of casing.
Confirm that spool and sleeve slide
smoothly in casing without binding.
Pay attention to orientation of spool.

(4)

(210-7) 8-27

8-28

Lever (1) side

Lever (2) side

(Fulcrum plug of

adjusting plug side)

Fit return spring(654) and spring seat
(653) into spool hole and attach snap ring
(814).

(10)

Fit fulcrum plug(614) so that pin force-
fitted in fulcrum plug(614) can be put into
pin hole of lever(2).
Then fix locking ring(858).

Insert adjusting plug(615) and fit locking
ring.
Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding.

(8)

(9)

Put pilot piston(643) into pilot hole of
casing.
Confirm that pilot piston slides smoothly
without binding.

Put pin force-fitted in lever(2, 613) into
groove of pilot piston.
Then fix lever(2).

(6)

(7)

Fit feedback lever(611), matching its pin
hole with pin hole in spool.
Then insert pin(874).
Insert pin in feedback lever a little to ease
operation.
Take care not to mistake direction of
feedback lever.

(5)

(210-7) 8-28

(210-7) REG11

(210-7) REG12

(210-7) REG13

8 - 30

1. REMOVAL AND INSTALL OF MOTOR

REMOVAL

Lower the work equipment to the ground
and stop the engine.

Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.

Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.

Remove bolts and disconnect pipe.

Disconnect pilot line hoses.

Disconnect pilot piping.

Sling the control valve assembly and
remove the control valve mounting bolt.

Weight : 200kg(441lb)

Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.

INSTALL

Carry out installation in the reverse order
to removal.

Bleed the air from below items.

Cylinder(Boom, arm, bucket)
Swing motor
Travel motor
See each item removal and install.

Confirm the hydraulic oil level and
recheck the hydraulic oil leak or not.

GROUP 4 MAIN CONTROL VALVE

Atl

Btl

Atr

Btr

Ba1

Aa1

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(1)

(2)

(3)

13031GE18

21078MC01

21078MC02

21078MC03

8 - 31

2. STRUCTURE(1/5)

551

561

521

511

551

561

521

511

325

324

338

391

Cp2

601

357

551

252

101

102

252

251

425
424
438

401

254

104

561

103

153

561

153

561

159

101

Casing A

102

Casing B

103

Block

104

Block

153

Plug

159

Plug

251

Control valve

252

Lock valve

254

Logic valve

324

Spring

325

Spirng

338

Stopper

357

Orifice

391

Travel spool

401

Spool

424

Spring

425

Spring

438

Rod

511

Poppet

521

Spring

551

Plug

561

O-ring

601

Main relief valve

21078MC04

8 - 32

STRUCTURE(2/5)

201

203

333

331
334

328

329

331
262

310

336

332
335
379

370

332

262

302

392

551

159

261

203

331

377

378

337

331

333

201

336

332
335

370

379

332
261

305

201

336

332
339

374

372

332
261

307

395

164

556

KAWASAKI

T(L)

561
611

602

551

561

611

KAWASAKI

T(L)

273

164

154

Plug

159

Plug

164

O-ring

201

Cover

203

Cover

261

O-ring

262

O-ring

273

Socket screw

302

Arm1 spool

305

Swing spool

307

Boom2 spool

310

Travel spool

331

Seat

332

Seat

333

Bolt

334

Stopper

335

Stopper

336

Bolt

337

Stopper

339

Stopper

370

Spring

372

Spring

374

Spring

377

Spring

378

Spring

379

Spring

392

By pass cut spool

395

Spool

551

Plug

556

Plug

561

O-ring

602

Port relief valve

611

Nega con relief valve

21078MC05

8 - 33

STRUCTURE(3/5)

561

516

511

521

561

169

332

201

561

551

153

552

561

523

515

521

561

551

202

339

376

370
332
336

273

164
556

264

204

264

204

169

202

261

551

KAWASAKI

T(L)

164
154

153

Plug

154

Plug

164

O-ring

169

O-ring

201

Cover

202

Cover

204

Cover

261

O-ring

264

O-ring

273

Socket screw

332

Seat

336

Bolt

339

Stopper

370

Spring

376

Spring

511

Poppet

515

Poppet

516

Poppet

521

Spring

523

Spring

551

Plug

552

Plug

556

Plug

561

O-ring

21078MC06

8 - 34

STRUCTURE(4/5)

333

331

334

329

328

331

262

201

261

262

201

203

273

155

154

167

164

306

332

374

372

335

332

336

335

332

304

303

309

301

370

379

336

332

332
335
379

332

261

328

329

334

331

333

370

331

T(R)

OPT

553
561

602

553

561

602

159

158

156

163

154

Plug

155

Plug

156

Plug

158

Plug

159

Plug

163

O-ring

164

O-ring

167

O-ring

201

Cover

203

Cover

261

O-ring

262

O-ring

273

Socket screw

301

Travel spool

303

Boom1 spool

304

Bucket spool

306

Arm2 spool

309

Option spool

328

Spring

329

Spring

331

Seat

332

Seat

333

Bolt

334

Stopper

335

Stopper

336

Bolt

370

Spring

372

Spring

374

Spring

377

Spring

379

Spring

553

Plug

561

O-ring

602

Port relief valve

21078MC07

8 - 35

STRUCTURE(5/5)

551

561

154

164

971

209

971

975

165

209

165

169

204

202

273

264

Opt

511

551

561

521

T(R)

OPT

974

976

516

552

561

523

165

166

168

204

154

Plug

164

O-ring

165

O-ring

166

O-ring

168

O-ring

169

O-ring

202

Cover

204

Cover

209

Flange

264

O-ring

273

Socket screw

511

Poppet

516

Poppet

521

Spring

523

Spring

551

Plug

552

Plug

561

O-ring

971

Screw

974

Screw

975

Screw

976

Screw

21078MC08

8 - 36

3. DISASSEMBLY AND ASSEMBLY

GENERAL PRECAUTIONS

All hydraulic components are manufactured to a high precision. Consequently, before
disassembling and assembling them, it is essential to select an especially clean place.

In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.

When a control valve is to be remove from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working.
Spread paper or a rubber mat on the bench, and disassemble the valve on it.

Support the body section carefully when carrying or transferring the control valve. Do not lift by
the exposed spool, end cover section etc.

After disassembling and assembling of the component it is desired to carry out various tests(For
the relief characteristics, leakage, flow resistance, etc.), but hydraulic test equipment is necessary
for these tests. Therefore, even when its disassembling can be carried out technically, do not
disassemble such components that cannot be tested, adjusted, and so on. Additionally one
should always prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.

TOOLS

Before disassembling the control valve, prepare the following tools beforehand.

(1)

(2)

(3)

(4)

(5)

Vice mounted on bench(Soft jaws)

Hexagon wrench

Socket wrench

Spanner

1 unit

Each 1 piece

Name of tool

Quantity

Size(mm)

5, 6, 10, 12 and 14

27 and 32

32(Main relief valve)

Hyundai Excavator R210LC-7. Service and repair manual - page 28