Hyundai Excavator R210LC-7. Service and repair manual

8-107-26

6.1 ASSEMBLY REDUTION GEAR

General notes

Clean every part by kerosene and dry them by air blow.
Surfaces to be applied by locktite must be decreased by solvent.
Check every part for any abnormals.
Each hexagon socket head bolt should be used with locktite No.
262 applied on its threads.
Apply gear oil slightly on each part before assembling.
Take great care not to pinch your hand between parts or tools while assembling nor let fall parts on
your foot while lifting them.

■

Inspection before reassembling

hrust washer

Check if there are seizure, abnormal
wear or uneven wear.
Check if wear is over the allowable limit.

Gears

Check if there are pitting or seizure on
the tooth surface.
Check if there are cracks on the root of
tooth by die check.

Bearigs

Rotate by hand to see if there are
something unusual such as noise or
uneven rotation.

Floating seal

Check flaw or score on sliding surfaces or
O-ring.

21078TM98

Assembling No.1 carrier

Put No.1 carrier(91-1) on a flat place.

Install No.1 needle bearing(91-5) into No.1
planetary gear(91-4), put 2EA of No.1
thrust washer(91-6) on both sides of
bearing, and then, install it into carrier.

21078TM99

(1)

(2)

8-107-27

Install No.1 pin(91-5) into No.1 carrier
where the holes for No.1 pin(91-5) are to
be in line with those of No.1 carrier, and
then, install spring pins into the holes.

(3)

21078TM100

Caulk carrier holes as shown on the
picture.

Assembly ring thrust(90-7) into carrier.

(4)

(5)

21078TM101

Assembling No.2 carrier

Put No.2 carrier(90-1) on a flat place.

Install No.2 needle bearing(90-3) into No.2
planetary gear(90-2), put 2EA of No.2
thrust washer(90-4) on both sides of
bearing, and then, install it into carrier.

0.5

1.0 - 2.0

Pin & Caulk

Caulk these two in 180

Depth for pinning

21078TM102

(1)

(2)

Install No.2 pin(90-5) into No.2 carrier
where the holes for No.2 pin(90-5) are to
be in line with those of No.2 carrier, and
then, install spring pins into the holes.

(3)

21078TM103

8-107-28

Caulk carrier holes as shown on the
picture.

Assembly ring thrust(90-7) into carrier.

(4)

(5)

21078TM104

Assembling floating seal(83) and main
bearing(82)

Assemble floating seal into motor by use
of pressing jig. Grease the contact parts
for floating seal which is assembled into
motor.

Heat bearing at 60~70

。

C and then, put

into the motor side.

21078TM105

(1)

(2)

Be sure to maintain it vertical with the
ground when assembling bearing and
floating seal.

※

21078TM106

Assembling housing

Heat housing at 60~70

。

C while clearing it

out and then, assemble foating seal into
housing by use of pressing jig.
Be sure to maintain it vertical with the
ground when assembling floating seal.

)

21078TM705

(1)

※

8-107-29

Installing housing assembly

Install 2EA of M12 eye-bolt into housing
assembly.

Assemble housing into motor by use of
hoist and eye-bolt.

Be sure to tighten eye-bolt deep enough.

21078TM108

(1)

(2)

※

21078TM109

Installing main bearing(82)

Heat main bearing at 60~70

。

C and then,

install.
Be sure to maintain it vertical with the
ground when assembling bearing.

(1)

※

nstalling retainer(86) and shim(85)

Measure clearance between main bearing
and retainer by use of jig to decide the
thickness of shim and select an
appropriate shim, and then, assemble
retainer.

Apply locktite(#262) on M12 hexagon
head bolt, and then, bolt.

21078TM110

(1)

(2)

Installing coupling

Install coupling on spline of the motor.

21078TM111

(1)

8-107-30

Installing ring gear

Apply three bone #1104(locktite #515) on
housing for ring gear without gap.

Insert lock pin into housing hole.

Install M14 eye-bolt on the tap of ring
gear.

Lift ring gear and then, assemble into
housing in order for hole of ring gear and
parallel pin of housing to be in line.

Temporarily secure 4EA of M12 hexagon
socket bolt and shim with cover thickness
having appropriate torque.

21078TM112

(1)

(2)

(3)

(4)

(5)

21078TM113

Installing No.2 carrier sub assembly

Install M10 eye-bolt on No.2 carrier
assembly.

Lift No.2 carrier assembly and then, slowly
put it down on ring gear.

Rotate planetary gear by hands and install
on ring gear.

10)

21078TM114

(1)

(2)

(3)

8-107-31

Installing No.2 sun gear(91-2)

Install No.2 sun gear on the spline of No.2
carrier and No.2 planetary gear, matching
teeth of them.

11)

21078TM115

(1)

Install No.2 sun gear on the spline of No.2
carrier and No.2 planetary gear, matching
teeth of them.

(2)

21078TM116

Installing No.1 carrier sub assembly

Install M10 eye-bolt on No.2 carrier
assembly.

Lift No.1 carrier assembly and then, slowly
put it down on ring gear.

Rotate planetary gear by hands and install
on ring gear.

12)

21078TM117

(1)

(2)

(3)

Installing No.1 sun gear(92)

Put down No.1 sun gear on No.1 carrier,
maintaining it vertical with spline of
coupling.

Install No.1 sun gear on No.1 planetary
gear, matching their teeth.

13)

21078TM118

(1)

(2)

8-107-32

Installing cover(93)

Beat pad(94) with plastic hammer, and
press it into the center of cover.

Apply three bond #1104(locktite#515) on
the ring gear for cover without gap.

Put cover on ring gear, apply locktite
(#262) on M12 hexagon socket head bolt,
and then, bolt.

14)

21078TM119

(1)

(2)

(3)

Fill gear oil(7.5liter) into drain port.

Apply gear oil on PF3/4 hydraulic plug(97)
and then, bolt.

(4)

(5)

21078TM120

8- 108

1. REMOVAL AND INSTALL

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.

Loosen the socket bolt(1).

Remove the cover of the console box.

Disconnect pilot line hoses(3).

Remove the pilot valve assembly(2).
When removing the pilot valve assembly,
check that all the hoses have been
disconnected.

INSTALL

Carry out installation in the reverse order
to removal.

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

GROUP 7 RCV LEVER

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(1)

(2)

13031GE18

21078DA06

8- 110

Case

Plug

O-ring

Spool

Shim

Spring

Spring seat

Stopper

Spring

Plug

Rod seal

O-ring

Push rod

Plate

Bushing

Joint assembly

Swash plate

Adjusting nut

Lock nut

O-ring

Handle connector

Nut

Insert

Boot

Handle

Switch assembly

Screw

Switch assembly

Switch cover

Boot

8- 111

TOOLS AND TIGHTENING TORQUE

Tools

(1)

Tool name

Remark

Allen wrench

Spanner

(+) Driver

(-) Driver

Torque wrench

Length 150

Width 4~5

Capable of tightening with the specified torques

Part name

Item

Size

kgf m

lbf ft

Torque

Plug

Joint

Swash plate

Adjusting nut

Lock nut

Screw

PT 1/8

M14

M 3

3.0

3.5

5.0 0.35

0.05

21.7

25.3

36.2 2.5

0.36

Tightening torque

(2)

8- 112

DISASSEMBLY

Clean pilot valve with kerosene.
Put blind plugs into all ports

Fix pilot valve in a vise with copper(or
lead) sheets.

Remove end of boot(25) from case(1) and
take it out upwards.

(1)

(2)

(3)

Loosen lock nut(20) and adjusting nut(19)
with spanners on them respectively, and
take out handle section as one body.

(4)

For valve with switch, remove cord also
through hole of casing.

Remove the boot(40)

(5)

1408DA62

1408DA63

1408DA64

1408DA61

8- 113

Turn joint anticlockwise to loosen it,
utilizing jig(Special tool).
When return spring(10) is strong in force,
plate(15), plug(11) and push rod(14) will
come up on loosening joint.
Pay attention to this.

(7)

Loosen adjusting nut(19) and plate(18)
with spanners on them respectively, and
remove them.

(6)

36078RL01

36078RL02

36078RL03

36078RL04

8- 114

Loosen hexagon socket head plug(2) with
hexagon socket screw key.

(11)

Remove reducing valve subassembly
and return spring(10) out of casing.
Record relative position of reducing valve
subassembly and return springs.

(10)

When return spring(10) is weak in force,
plug(11) stays in casing because of
sliding resistance of O-ring.
Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
During taking out, plug may jump up due
to return spring(10) force.
Pay attention to this.

(9)

Remove plate(15).

(8)

36078RL05

36078RL06

36078RL07

36078RL08

8- 115

Separate spool(5), spring seat(8),
spring(7) and shim(6) individually.
Until being assembled, they should be
handled as one subassembly group.

(13)

For disassembling reducing valve section,
stand it vertically with spool(5) bottom
placed on flat workbench. Push down
spring seat(8) and remove two pieces of
semicircular stopper(9) with tip of small
minus screwdriver.
Pay attention not to damage spool
surface.
Record original position of spring seat(8,
31).
Do not push down spring seat more than
6mm.

(12)

Remove O-ring(13) and seal(12) from
plug(11).
Use small minus screwdriver or so on to
remove this seal.

(15)

Take push rod(14) out of plug(11).

(14)

36078RL09

36078RL10

36078RL11

36078RL12

Hyundai Excavator R210LC-7. Service and repair manual - page 36