Hyundai Excavator R210LC-7. Service and repair manual

8-85

Hammer

Sharpen punch

Ball bearing

Disassembly of ball bearing(21)

Remove the floating seal(31) from hub(1).
Turn the motor upside down.
Remove the ball bearing(21) from hub(1)
by applying a sharpen punch to ball
bearing(21) and hammering the punch.
When ball bearing(21) comes off from
hub(1), the ball bearing will drop. To
prevent damage due to the dropping,
place a receptacle covered with a rubber
under the work bench.

(7)

Disassembly spindle fittings

Remove the floating seal(31) from hub(1).
Remove the outer ring of tapered roller
bearing(22) from spindle(2).

(8)

Disassembly the outer ring of tapered
roller bearing(22) from hold flange(3)

Remove three outer rings of tapered roller
bearings(22) from hold flange(3).

(9)

Oil seal

Disassembly of oil seal(132)

Remove oil seal(132) from spindle(2) as
shown below.
Do not reuse removed oil seal(132).

(10)

25038TM17(1)

25038TM11(1)

25038TM11(2)

25038TM17(2)

8-86

Disassembly of ball bearing(149)

Place a retainer on the press work bench.
Insert shaft(102) into retainer.
Remove ball bearing(149) from shaft
(102) by pressing on the shaft end with a
press.
Do not remove ball bearing(149) if it is not
be replaced.
Do not reuse removed ball bearing(149).

(11)

8-87

4. ASSEMBLY

GENERAL PRECAUTIONS

Reassemble in work area that is clean and free from dust and grit.

Handle parts with bare hands to keep them free of linty contaminates.

Repair or replace the damaged parts.
Each parts must be free of burrs its corners.

Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.

Wash all parts thoroughly in a suitable solvent.
Dry thoroughly with compressed air.
Do not use the cloths.

When reassembling oil motor components of motor, be sure to coat the sliding parts of the motor
and valve with fresh hydraulic oil.(NAS class 9 or above)

Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.

(1)

(2)

(3)

(4)

(5)

(6)

(7)

8-88

ASSEMBLY OF BRAKE VALVE

Assembly of the check valve

Fit the O-ring(337) on the plug(326).
Insert the spring(330) and the valve(327)
into the plug(326), and then grease the
spring(330) and the valve(327) and
hand-lock the former.
Insert the plug(326) in conjunction with
the spring(330) and the valve(327) into
the rear flange(301), and tighten the plug
to the required torque.
Apply grease to the O-ring(337).
Tighten the plug(326) to a torque of
26 4kgf m(188 29lbf ft).

(1)

Assembly of the spool

Insert the spool(323) into the rear flange
(301).
Apply a working fluid to the spool(323)
and insert it into the rear flange(301).
Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
the spool due to contact.
Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.
Attach the O-ring(336) to the plug(324).
Apply grease to O-ring(336).

(2)

Install stopper(325) and the spring(328)
into both plugs(324) and tighten the
plugs(324) into the rear flange(301) at the
required torque.
Apply grease to the O-ring(355).
Required torque : 45 9kgf m

(325 65lbf ft)

Even if either the rear flange(301) or the
spool(323) is to be replaced, their entire
assembly(kit) must be replaced.

25038TM04(2)

25038TM04(1)

25038TM03(4)

8-89

Assembly of the two-speed control
valve

Fit O-ring(355) on plug(357).
Insert spring(366) in spool(363) and insert
spool(363) to rear flange(301).
Apply grease to O-ring(355).
Apply hydraulic oil to spool(363).
Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
the spool due to contact.
Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.

(3)

Tighten plug(357) to rear flange(301) with
specified torque.
Tightening torque : 10 2kgf m

(72.3 14.5lbf ft)

25038TM05(1)

25038TM04(4)

8-90

Assembly the inner parts of the rear
flange assembly

Insert steel ball(385) to rear flange(301).

(4)

Fit O-rings(383, 385) on plug(382).
Tighten plug(382) to rear flange(301) with
specified torque.
Tightening torque : 1.5 0.25kgf m

(10.8 1.8lbf ft)

Apply grease to O-rings(383, 384).

Insert piston(381) to rear flange(301).
Apply hydraulic oil to piston(381) and
then insert it into rear flange(301).
Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
the piston due to contact. The above
mentioned damage causes internal
leakage after reassembly, thus degrading
the motor performance.
Rear flange(301) and piston(381)
constitutes a rear flange kit. When
replacing either of them, therefore,
replace the rear flange kit.

25038TM06(1)

25038TM05(4)

25038TM05(3)

8-91

Fit O-ring(359) on plug(380).
Install plug(380) to rear flange(301), and
tighten plug(380) to rear flange(301) with
the specified torque.
Tightening torque : 6 1kgf m

(43.4 7.2lbf ft)

Assembly of the relief valve

Fit O-rings(208, 209, 219) and back up
rings(211, 217) on sleeve(202).
Fit O-ring(210) on plug(204).
Apply grease to the O-ring.
Insert shim(205) into plug(204).
Use the disassembled shim, because the
pressure adjustment made by shim.
When replacing the inner parts of relief
valve, therefore, the valve kit should be
replaced.

(5)

Piston seal

Valve

Fit piston seal(220) to valve(201).
Piston seal(220) consist of O-ring and
polyester ring, apply grease to them and
then fit the O-ring and after fit the
polyester ring to valve(201).

25038TM05(2)

25038TM06(3)

25038TM14

8-92

Insert valve(201), spring(206) and spring
retainer(203) to sleeve(202) and tighten
plug(204) fitted with shim(205) to the
specified torque.
Apply hydraulic oil to valve(201) and then
insert it to sleeve(202).
Align the center of hole in sleeve(202)
with the axial center of valve(201) to
prevent damage to the inner surface of
the sleeve and outer surface of the valve
due to contact.

Tightening torque : 10 2kgf m

(72.3 14.5lbf ft)

Use the disassembled parts, because
the relief valve is pressure adjusted.
When replacing the inner parts of the
relief valve, therefore, the valve kit should
be replaced.
Apply grease to mating surface of the
shim and then fit into the plug. The
above mentioned will keep the two faces
practically glued together, the shim will
not drop down when install the plug to
the sleeve.

25038TM07(2)

25038TM07(1)

25038TM06(4)

25038TM06(2)

8-93

ASSEMBLY OF REDUCTION GEAR AND HYDRAULIC MOTOR

Before reassembling the reduction gear and the hydraulic motor following completion of parts
replacement, one of the following two operations must be carried out:

Selecting a distance piece(12) of the appropriate thickness.
Selecting a thrust bearing(20) of the appropriate thickness.

Reassembling must be down only after clearance adjustment of these parts.
Prior to the start of reassembling, check for parts that require replacement.

If all of the above-name parts can be reused in reassembly, be sure to make these adjustments.
Disregard of these adjustments will result in malfunction or premature failure of the motor.

Parts
replacement

: Reassembling

(See page 8-103 through 8-109)

: Adjusting ball bearings

(See page 8-110 through 8-111)

Parts to be replaced

Hub kit
Spindle kit
Ball bearing(21)

: Adjusting axial clearance of

taper roller bearings

(See page 8-112 through 8-113)

Parts to be replaced

Spindle kit
RV gear assembly

Yes

8-94

A : REASSEMBLING

Assembly of the hub(1) section

Bring hub(1) in suspended state over to
the work stand, and lower it into the
stand slowly. Bolt the hub(1) to the
stand by using three fixing jigs.
Press ball bearing(21) into hub(1) by
using fitting jig and hammer.
Install floating seal into hub(1) by using
fitting jigs.
Do not use grease put on O-ring.
Install floating seal into hub(1) using
installation jigs in the following order.
Fitting jig, floating seal, then, fitting jig.
Press fitting jig until it comes to touch
fitting jig.
Check to be sure that it is true and
square in hub(1).

(1)

Assembly of the spindle(2)

Install floating seal into spindle(2) by
using fitting jigs.
Do not use grease put on O-ring.
Install floating seal into spindle(2) using
installation jigs in the following order.
Fitting jig, floating seal, then, fitting jig.
Press fitting jig until it comes to touch
fitting jig.
Check to be sure that it is true and
square in spindle(2).

(2)

Assembly of the hub(1) and spindle(2)

Install two eye bolts to tapped holes of
spindle(2) in opposite positions.
Lift and carry spindle(2) over in
suspended state to hub(1) and gently
lower it into hub(1).

(3)

25038TM10(4)

8-95

Remove two eye bolts and install two
fixing jigs to hold, hub(1) and spindle(2) in
opposite. Tighten two fixing jigs equally.
Turn over the work stand to bring the hub
(1) to top side.
Fit three outer races of taper roller
bearings(22) into spindle(2).
Please turn over 180 degrees.

Assembly of the RV gear assembly

Install lifter into center hole of RV gear
assembly.
Lift and carry RV gear assembly over in
suspended state to spindle(2) and gently
lower it into spindle(2).
Insert 24 parallel pins into between RV
gear A(4), B(5) and hub(1).
Apply gear oil to each pins before
inserting it.

(4)

Assembly of the ball bearing(21)

Press ball bearing(21) into hub(1) by
using fitting jig and hammer.
When pressing ball bearing(21) into
hub(1) be sure to keep it true and square
by shifting hammer around.
Install three outer races of taper roller
bearings on it.

(5)

Assembly of the hold flange(3)

Install hold flange(3) to spindle(2) by
inserting it into ball bearings(21).
Install hold flange(3) to spindle(2) in the
same position as before disassembly, as
indicated by the mating marks for spindle
(2) and crankshaft(9).

(6)

25038TM12(1)

25038TM12(2)

8-96

Assembly of the Parallel pins(34) and
tighten hexagon socket bolts

Apply loctite to tapped holes and install
plain washers into three bolts holes.
Tighten three hexagon socket bolts with
about 20kgf m(144.7lbf ft).
Drive parallel pins by air vibrator to the
bottom of parallel pins holes.
Does calking by calking jig to parallel
pins holes.
If parallel pins and hexagon socket bolts
are smeared with oil or grease, degrease
it with degreasing agent, clean it with
solvent and let it stand and get dry.
Do not make a mistake a position and a
direction.

(7)

Tighten tree hexagon socket bolts with a
torque of 72.3 11kgf m(522.9 79.6lbf
ft).

: Adjusting axial clearance of

taper roller bearings

(See page 8-111)

Parts to be replaced

Spindle kit
RV gear assembly

Proceed directly to

the next step.

No parts to

be replaced

25038TM12(3)

25038TM10(2)

8-97

Assembly of the distance pieces and
snap rings

Install distance pieces(13) into hold
flange(3).
Install snap rings(20) into the snap rings
grooves in hold flange(3).
Install distance pieces(13) and snap rings
(20) in the same position as before
disassembly as indicated by the
matching marks on hold flange(3).

(8)

Assembly of the spur gears(7)

Install three spur gears(7) to crank shafts
(9).
Install the gears to crank shafts in the
same position defined by the matching
marks, as illustrated here.

(9)

Install three snap rings(25) into the snap
rings grooves of crank shafts(9).
Snap rings(25) are possible to fly away.
Sharp edge face should be upward.

Assembly of the oil seal(132)

Turn the work stand upside down.
Install oil seal(132) into the oil seals hole
of spindle(2).
Apply lithium grease or withe petrolatum
to the lip portion of oil seal(132), position
the squarely over the bore of spindle(2).

(10)

25038TM12(4)

25038TM10(3)

25038TM10(1)

25038TM13(1)

8-98

Assembly of the shaft(102)

Install ball bearing(149) on shaft(102) by
shrunk fitting.
Wear thick leather groves in handling the
heated bearing.
Be sure to push the bearing all the way
down until inner race seats on the
shoulder.

(11)

Assembly of the piston assembly(161,
162)

Install spring(193) into piston assembly
(161, 162).
Install it into spindle(2).
Apply grease to spring(193).
Apply hydraulic oil to piston assembly
(161, 162).

(12)

Assembly of the pivots(167)

Fit two parallel pins(171) into spindle(2).
Fit two pivots(167) to parallel pins(171).
Apply grease to the hemisphere surface
of pivots(167).

(13)

Assembly of the cylinder block(104)

Insert washer(110), spring(114), washer
(110) in that order, into the shaft(102)
bore of cylinder block(104).
Set cylinder block(104) in the press in
order to compress spring(114).
Wear thick leather groves in handling the
heated bearing.
Be sure to push the bearing all the way
down until inner race seats on the
shoulder.

(14)

25038TM09(1)

25038TM09(3)

8-99

Place the retainer on the last inserted
washer(110) and push down this tool with
press arbor until the snap ring groove
becomes cleared. Fit snap ring(145) into
the groove and remove the push to leave
the spring in compresses state.
When working on the cylinder block as
above, protect its sliding face by covering
it with a vinyl sheet, as shown.
Snap ring(145) are possible to fly away.
Refer to right drawing, how to install
washers(110) and snap ring(145).

Assembly of the motor assembly

Install five needle rollers(151) to the pin
holes of cylinder block(104).
Install washer(111) onto five needle
rollers(151).
Install thrust bow(108) onto washer(111).

(15)

Insert nine piston assembly(105, 106)
into retainer plate(107).
Insert it into cylinder block(104).
Immerse the sub assembly in hydraulic
oil.

As usual under drawing, install swash
plate(103), thrust ball(108), washer(111),
retainer plate(107), needle rollers(151),
cylinder block(104), piston assembly(105,
106) to shaft(102) and set lifter.

25038TM09(2)

25038TM08(2)

25038TM13(2)

8-100

Assembly of the motor assembly

Lift the motor assembly slowly and install
it in spindle(2).
After installed, remove lifter.
Two pivots holes of swash plate(103)
adjust to matching two pivots(167).
Motor assembly does not injure by hitting
another one.
After installed motor, turn cylinder
block(104) by hand and check nothing
loose. If cylinder block(104) is loose,
again disassemble motor assembly and
reassemble.

(16)

Hyundai Excavator R210LC-7. Service and repair manual - page 33