Index Manuals Hyundai Excavator R210LC-7. Service and repair manual

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Hyundai Excavator R210LC-7. Service and repair manual - page 32

8-70

TOOLS AND TIGHTENING TORQUE

Tools

(1)

Tool name

Remark

Allen wrench

Socket for socket wrench, spanner

Torque wrench

Pliers

(-) Driver

Plastic and iron hammer

Steel rod approx

Monkey wrench

Oil seal inserting jig

Bearing pliers

Seal tape

Eye bolt

Press(0.5 ton)

Oil stone

Bearing assembling jig

Liquid packing

Screw lock

5, 6, 8, 10, 14

22, 30, 32, 41

5, 6, 8, 10, 14, 19

Socket

Rod

Capable of tightening with the specified torques

150mm

Wooden hammer allowed. Normal 1 or so

7 7 200mm

M12, M16

Loctite #577

Loctite #243

Part name

Item

Size

Torque

kgf m

lbf ft

Hexagon socket bolt

Hexagon socket plug

Hexagon socket bolt

Sleeve

Plug

Hexagon socket bolt

Plug

Hexagon socket plug

Plug

Hexagon socket plug

202

204

324

326

343

346

352

354

357

380

382

398

M24 3.0

PF 1/2

M12 1.75 32

PF 1

PF 1/2

M36 1.5

M16 2.0

PF 1/4

NTPF 1/16

PF 1/2

PF 3/8

PF 1/8

72.3 11.0

10.0 2.0

10.4 1.6

25.0 5.0

10.0 2.0

45.0 9.0

26.0 4.0

25.7 4.0

3.0 0.5

1.0 0.25

10.0 2.0

6.0 1.0

1.5 0.25

1.25 0.25

523 79.6

72.3 14.5

75.2 11.6

181 36.2

72.3 14.5

326 65.1

188 28.9

186 28.9

21.7 3.6

7.2 1.8

72.3 14.5

43.4 7.2

10.8 1.8

9.0 1.8

Tightening torque

(2)

8-71

3. DISASSEMBLY

GENERAL PRECAUTIONS

Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.

To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.

Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.

During disassembly, give a match mark to the mating surfaces of each part.

Arrange removed parts in order so that they will not become damaged or missing during
disassembly.

Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.

(1)

(2)

(3)

(4)

(5)

(6)

8-72

DISASSEMBLING PROCEDURE

Disassembling the brake valve section
and the hydraulic motor section

When inspecting or repairing the motor,
use the disassembling procedures
described below.
Numbers in parentheses ( ) following the
part name denote the item numbers
shown in the attached assembly
drawings.
Prior to disassembly, install the motor on
an inversion working bench.

(1)

Remove the rear flange kit(301) from the
spindle(2).
Pay attention, shaft(102) may pulled up
with the rear flange kit.
Proceed to pages 8-83 through 8-87 to
see the brake valve disassembling
procedure.

Remove the twelve hexagon socket
head bolts(343).

Remove valve kit from the rear flange
(301).
Remove the O-rings(208, 209, 210) and
back up rings(211, 217) from the valve
kit.
Do not reuse the O-ring after removal.

25038TM02(1)

25038TM02(2)

25038TM02(3)

25038TM02(4)

8-73

Remove the timing plate(109), the two
pins(341) and the ball bearing(150) from
the rear flange kit(301).
Remove the two O-ring(27) and O-ring
(29) from spindle(2).
Do not reuse the O-rings(27, 29) after
removal.
Proceed to pages 8-89 through 8-90 to
see the description of the hydraulic motor
disassembling procedure.

Disassembling the reduction gear/
Hydraulic motor shafts and oil seals

Turn the motor and cover(8) over.
Remove three plugs(33).
Remove twelve hexagon socket head
bolts(35).

Install two eye bolt(PF 1/2) to the threads
for plugs(33).
Fasten hook to the eye bolts then lift up
cover(8).
When cover(8) do not come up easily
due to friction of O-ring(30), bang cover
(8) evenly using a plastic hammer.
Remove O-ring(30) from cover(8).
Do not reuse the removed O-ring.
Drain lubricating oil from the reduction
gear.
Proceed to page 8-92 through 8-95 to
see the reduction gear disassembling
procedure.

(2)

25038TM03(1)

25038TM03(2)

25038TM03(3)

8-74

DISASSEMBLY OF BRAKE VALVE

Disassembly of the spool(323)

Remove the two plugs(324) from the rear
flange(301).
Remove the two O-ring(336) from the
plug(324).
Removal of the two plugs(324) from the
rear flange(301) is facilitated by
loosening plugs(324) with rear flange
(301) attached to the spindle(2).
Do not reuse the O-ring(336) after
removal.

(1)

Disassembly of the check valves

Remove the two plugs(326) from the rear
flange(301).
Removal of the two plug(326) from the
rear flange(301) is facilitated by
loosening plug(326) with the rear flange
(301) attached to the spindle(2).

(2)

Remove the two springs(328), the two
stoppers(325), and the spool(323) from
the rear flange(301).
Be careful not to damage the outer
surface of the spool(323) and the sliding
surface of the rear flange(301).
Spool is selectively fitted to the rear
flange(301). When replacing either or
them, therefore, the rear flange kit should
be replaced.

25038TM03(4)

25038TM04(1)

25038TM04(2)

8-75

Remove the two springs(330) and the
two valves(327) from the rear flange(301).
Be careful not to damage the seat
sections of the valves(327) or rear flange
(301).

Remove the O-ring(337) from the plug
(326).
Do not reuse the O-ring(337) after
removal.

Take out spool(363) from rear flange
(301).
Remove O-ring(355) from plug(357).
Do not reuse removed O-ring(355).

Disassembly of the spool(363) from
the rear flange(301)

Remove plug(357) from rear flange(301).
Removal of plug(357) from rear
flange(301) is facilitated by loosening
plugs(324) with rear flange(301) attached
to spindle(2).

(3)

25038TM04(3)

25038TM04(4)

25038TM05(1)

8-76

Removal inner parts of the rear flange
assembly

Remove the two plugs(380) from rear
flange(301).

(4)

Remove the two O-rings(359) from each
plug(380).
Take out piston(381) from rear flange
(301).
Do not reuse removed the O-rings(359).
Be careful not to scratch the outer
surface of the piston(381) and the sliding
surface of the rear flange(301).
Piston(381) is selectively fitted to rear
flange(301). When replacing either of
them, therefore, the rear flange kit should
be replaced.

Removed the two plugs(382) from rear
flange(301).

Take out each two O-rings(383, 384)
from each plug(382).
Do not reuse removed O-rings(383, 384).

25038TM05(2)

25038TM05(3)

25038TM05(4)

8-77

3Take out two steel balls(385) from the
rear flange.

Remove the O-ring(210) from plug(204).
Take out shim(205) from plug(204).
Do not reuse removed the O-ring(210).

Removal of the valve kit

Remove the plug(204) from sleeve(202).
The valve kit is pressure adjusted by
shim(205), when replacing of inner parts,
therefore, the valve kit should be
replaced.

(5)

25038TM06(1)

25038TM06(2)

25038TM06(3)

8-78

Take out spring retainer(203), spring
(206) and valve(201) in that order.

Remove piston seal(220) from valve
(201).

Piston seal

Valve

25038TM06(4)

25038TM07(1)

25038TM07(2)

25038TM14

8-79

DISASSEMBLY OF HYDRAULIC MOTOR

Disassembly of the parking brake parts

Remove the piston(112) by injecting
compressed air from the parking brake
access hole in the spindle(2).
Take care that abrupt injection of
compressed air(3~5kgf/cm

) may cause

the piston(112) to pop out.
To ensure your safety, apply a protective
cover to the piston.

(1)

Remove the two O-rings(135, 139) from
the piston(112).
Do not reuse O-rings(135, 139) after
removal.

Disassembly of the internal parts of
the motor

Lay the motor body on the side.
Drain out the oil from the motor.
Hold the cylinder block(104) with both
hands, and remove it from the spindle(2).
When laying the motor on its side, place
a receptacle under it to receive spilling
hydraulic oil.
Before pull out cylinder block(104), turn it
alternately clockwise & counterclockwise
two or three times to separate the piston
kit from swash plate(103). This means
that the parts attached to the cylinder
block(104) come out of it and fall in the
spindle.

(2)

25038TM07(3)

25038TM07(4)

25038TM08(1)

8-80

3Detach the two friction plates(115) and
two mating plates(116) from cylinder
block(104) which has been taken out in
step .
Separate the piston assembly(105, 106),
retainer plate(107), thrust ball(108),
washer(111) and five needle rollers(151)
from cylinder block(104) which has been
taken out in step .
Cylinder block(104), piston assembly,
retainer plate, etc. which are included in
cylinder & piston kit and are not supplied
one by one, therefore, cylinder & piston
kit should be replaced.(Refer to class
shown in parts list.)

Take out swash plate(103) from spindle
(2).

Take out shaft(102) from spindle(2). At
this time, ball bearing(149) is also taken
out together with shaft(102).
Oil seal(132) cannot be taken out.
Lightly shaft(102) end on the reduction
gear side with a plastic hammer to make
the removal easier.
Take notice when removing the shaft
(102) rap strongly and swiftly, the shaft
will come quickly free from the spindle.
Take out two pivots(167) and two pins
(171) from spindle(2).

25038TM08(2)

25038TM08(3)

25038TM08(4)

8-81

Remove the piston assembly and spring
(193) by compressed air(3~5kgf/cm

)

trough the passage for the piston
assembly in spindle(2).
Piston(161) and shoe(162) are included
in the piston assembly and are not
supplied one by one, therefore, the piston
assembly should be replaced.
Abrupt compressed air causes the piston
assembly to spring out which dangerous.
The piston assembly can be taken out
safely by putting a protective cover or the
lie on it.

Disassembly of the cylinder block

Place the cylinder block on the work
bench and take out snap ring(145) with
the snap ring pliers while pressing the
retainer against washer(110).
Before compressing spring(114), make
sure that cylinder block(104), retainer and
press arbor are in good alignment: This is
for galling or denting cylinder block(104).
Put a vinyl cover on the sliding surface of
cylinder block(104) for protection.
Slacking the press force slowly, until free
of the spring force.
Do not remove spring(114) if it not to be
replaced.
When disassembling there is a possibility
that the spring may be injured.
Slacking very slowly in order to prevent
injury to the spring.

(3)

Remove the snap ring(145), washer(110),
spring(114) and washer(110).

25038TM09(1)

25038TM09(2)

25038TM09(3)

8-82

DISASSEMBLY OF REDUCTION GEAR

Disassembly of Input gear

Remove steel ball(36) and input gear(6)
from coupling(15).

(1)

Disassembly of Spur gear

Remove the three snap rings(25) from
each crank shaft(9).
Remove the three spur gears(7) from
each crank shaft.
Take notes when removing the snap ring
with a snap ring plier, the snap ring will
spring out form its groove.

(2)

Disassembly of Coupling

Remove coupling(15) from shaft(102).

(3)

25038TM09(4)

25038TM10(1)

25038TM10(3)

8-83

Removal of the hold flange

Turn the motor upside down, bringing the
spindle to top.
Install two fixing jigs to fasten down
spindle(2) to hub(1). At the same time
the fixing jig screwed symmetry.
Fasten hub(1) and spindle(2) securely
before removing hold flange(3) so that
spindle(2) will not fall from the work
bench.
Turn the motor upside down once again,
bringing the hold flange(3) to top.
Remove three snap rings(20) and three
distance pieces(13) from hold flange(3).
Put an identification marks on distance
pieces(13) and hold flange(3) as to their
location. Hold flange(3) and distance
pieces(13) must be reassembled in its
original position.
Remove the caulking portion of hold
flange(3) for six parallel pins(34) with air
grinder.
Wear a protection glasses and a mask
when removing the caulking portion.
Install puller and screwed puller bolt to
parallel pin(34) and screwed the puller
nut then parallel pin is pulled up. Pulling
up parallel pin until reaches to surface of
the puller.

(4)

Remove hold flange(3) from spindle(2).
Put an identification marks on hold flange
(3) and spindle(2) as to their location.
Hold flange(3) and spindle(2) must be
reassembled in its original position.

Slowly remove three hexagon socket
head bolts(19).
The thread lock compound used on
hexagon socket head bolts(19) may
cause the bolts to seize during removal.
The hexagon socket head bolts should
be removed slowly by hand.

25038TM15

25038TM10(2)

8-84

Disassembly of spindle(2)

Fasten two eye bolts to spindle(2).
Remove spindle(2) from hub(1).
When hanging up spindle(2), be careful
not to scratch the retainer of ball bearing
(21).

(5)

Hammer

Sharpen punch

Ball bearing

Removal the RV gear assembly, ball
bearing(21) and pin(17)

Remove ball bearing(21) from hub(1)
using a sharpen punch with hammering
to pin(17). At the same time the RV
gear assembly and pins(17) also
removed.
When removing ball bearing(21), move a
sharpen punch to one of three or four
equidistant positions along the side of
pins(17) end each after hammering the
sharpen punch so as to keep the
distortion of ball bearing(21).
When ball bearing(21) comes off from
hub(1), ball bearing(21), RV gear
assembly and pins(17) will drop. To
prevent damage due to the dropping,
place a receptacle covered with a rubber
under the work bench.
The RV gear kit, crank shaft(9), spacer
(12), tapered roller bearing(22) and
needle bearing(2) are included in the RV
gear assembly and are not supplied one
by one, therefore, the RV gear assembly
should be replaced.

(6)

25038TM10(4)

25038TM16

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