Hyundai Excavator R210LC-7. Service and repair manual - page 38

8-133

7

8

9

6

Install

Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Bleed the air from the boom cylinder.
Conformed the hydraulic oil level and
check the hydraulic oil leak or not.

(2)

Remove bolt(9) and pull out pin(8).
Remove boom cylinder assembly(6).

Weight : 182kg(386lb)

Disconnect boom cylinder hoses(7) and
put plugs on cylinder pipe.

8-134

2.  DISASSEMBLY AND ASSEMBLY

STRUCTURE

Bucket cylinder

1)

(1)

28,29

Internal detail

24

25

23

28,29

9,10 6,7 8 4,5 22

27 26 3 11,12

1

2

13 14

15,16 17 18 19 20 21

1

Tube assembly

2

Rod assembly

3

Gland

4

DD2 bushing

5

Snap ring

6

Rod seal

7

Back up ring

8

Buffer ring

9

Dust wiper

10

Snap ring

11

O-ring

12

Back up ring

13

Cushion ring

14

Piston

15

O-ring

16

Back up ring

17

Piston seal

18

Wear ring

19

Dust ring

20

Lock washer

21

Lock nut

22

Hexagon socket head bolt

23

Band assembly

24

Pipe assembly(R)

25

Pipe assembly(B)

26

O-ring

27

Hexagon socket head bolt

28

Pin bushing

29

Dust seal

8-135

Arm cylinder

(2)

1

Tube assembly

2

Rod assembly

3

Gland

4

DD2 bushing

5

O-ring

6

rod seal

7

Back up ring

8

Buffer ring

9

Dust wiper

10

Snap ring

11

O-ring

12

Back up ring

13

Cushion ring

14

Piston

15

O-ring

16

Back up ring

17

Piston seal

18

Wear ring

19

Dust ring

20

Cushion spear

21

Check valve

22

Coil spring

23

Stop ring

24

Lock washer

25

Lock nut

26

Hexagon socket head bolt

27

Band assembly(R)

28

Band assembly(B)

29

Pipe assembly(R)

30

Pipe assembly(B)

31

O-ring

32

Hexagon socket head bolt

33

Hexagon socket head bolt

34

Pin bushing

35

Dust seal

34,35

27

34,35

28

29

30

Internal detail

9,10 6,7 8 4,5 26

32 31 3 11,12

1

2

13 14

15,16 17 18 19 24

22,23

25

20,21

33

8-136

Boom cylinder

(3)

1

Tube assembly

2

Rod assembly

3

Gland

4

DD2 bushing

5

Snap ring

6

Rod seal

7

Back up ring

8

Buffer ring

9

Dust wiper

10

Snap ring

11

O-ring

12

Back up ring

13

Cushion ring

14

Piston

15

O-ring

16

Back up ring

17

Piston seal

18

Wear ring

19

Dust ring

20

Lock washer

21

Lock nut

22

Hexagon socket head bolt

23

Band assembly

24

Pipe assembly(R)

25

Pipe assembly(B)

26

O-ring

27

Hexagon socket head bolt

28

Pin bushing

29

Pin bushing

30

Dust seal

28,30

Internal detail

23

9,10 6,7 8 4,5 22

27 26 3 11,12

1

2

13 14

15,16 17 18 19 20 21

29,30

24

25

8-137

TOOLS AND TIGHTENING TORQUE

Tools

(1)

2)

Allen wrench

Spanner

(-) Driver

Torque wrench

6

8

14

17

7

8

Small and large sizes

Capable of tightening with the specified torques

Part name

Item

Size

Torque

kgf m

lbf ft

Socket head bolt

Socket head bolt

Lock nut

Piston

Bucket cylinder

Boom cylinder

Arm cylinder

Bucket cylinder

Boom cylinder

Arm cylinder

Bucket cylinder

Boom cylinder

Arm cylinder

Bucket cylinder

Boom cylinder

Arm cylinder

22

22

26

27

27

32

33

21

21

25

14

14

14

M16

M16

M18

M10

M10

M12

M10

M60

M60

M70

-

-

-

23.0 2.0

23.0 2.0

32.0 3.0

5.4 0.5

5.4 0.5

9.4 1.0

5.4 0.5

100 10.0

100 10.0

100 10.0

150 15.0

150 15.0

150 15.0

166 14.5

166 14.5

232 21.7

39.1 3.6

39.1 3.6

68.0 7.2

39.1 3.6

723 72.3

723 72.3

723 72.3

1085 109

1085 109

1085 109

Tightening torque

(2)

B

8-138

DISASSEMBLY

Remove cylinder head and piston rod

Hold the clevis section of the tube in a
vise.
Use mouth pieces so as not to damage
the machined surface of the cylinder
tube.   Do not make use of the outside
piping as a locking means.

2

200mm

2

22

Hexagon
socket wrench

Cover here
with rag

Turn counter
clockwise

Full straight
sideways

Lift

Oil pan

(1)

3)  

Draw out cylinder head and rod assembly
together from tube assembly(1).
Since the rod assembly is heavy in this
case, lift the tip of the rod assembly(2)
with a crane or some means and draw it
out.    However, when rod assembly(2)
has been drawn out  to approximately
two thirds of its length, lift it in its center to
draw it completely.

Loosen and remove socket bolts(22) of
the gland in sequence.
Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation.

Pull  out  rod  assembly(2)  about  200mm
(7.1in).    Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.

8-139

Piston assy

Wooden block

21

22

14

15

16

13

Pull straight

Lift with a crane

Plastic
hammer

Remove the cylinder head assembly
from rod assembly(2).
If it is too heavy to move, move it by
striking the flanged part of cylinder head
with  a plastic hammer.
Pull  it straight with cylinder  head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing
(5,6,7,8,9,10) by the threads of rod
assembly(2).

Remove piston and cylinder head

Remove lock nut(21).
Since lock nut(21) and lock washer(22)
is tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the lock
nut(21) and lock washer (22).
Remove piston assembly(14), back up
ring(16), and O-ring(15).

Place the removed rod assembly on a
wooden V-block that is set level.
Cover a V-block with soft rag.

Note  that  the plated  surface of rod
assembly(2) is to be lifted.   For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.

(2)

8-140

10

9 6 7 8

12 11

4 5

19

18

17 18 19

Disassemble cylinder head assembly

Remove back up ring(12) and O-ring
(11).
Remove snap ring(10), dust wiper(9).
Remove back up ring(7), rod seal(6) and
buffer ring(8).
Exercise care in this operation not to
damage the grooves.
Do not remove seal and ring, if does not
damaged.

(4)

Disassemble the piston assembly

Remove wear ring(18).
Remove dust ring(19) and piston seal
(17).
Exercise care in this operation not to
damage the grooves.

(3)

8-141

Press here
(Straight down)

9

Metal

Push bar

6

Right

Wrong

Rod seal(6) has its own fitting direction.
Therefore, confirm it before fitting them.
Fitting rod seal(6) upside down may
damage its lip.  Therefore check the
correct direction that is shown in fig.

Fit back up ring(7), rod seal(6) and buffer
ring(8) to corresponding grooves, in that
order.
Coat each packing with hydraulic oil
before fitting it.
Insert the backup ring until one side of it
is inserted into groove.

Coat dust wiper(9) with grease and fit
dust wiper(9) to the bottom of the hole of
dust seal.
At this time, press a pad metal to the
metal ring of dust seal.
Fit snap ring(10) to the stop face.

ASSEMBLY

Assemble cylinder head assembly

Check for scratches or rough surfaces if
found smooth with an oil stone.
Coat the inner face of gland(3) with
hydraulic oil.

(1)

3)  

8-142

12

11

17

19

18

17 18

19

14

Fit wear ring(18) and dust ring(19) to
piston(14).

Fit piston seal(17) to piston.
Put the piston seal in the warm water of
60~100 C for more than 5 minutes.
After assembling the piston seal, press its
outer  diameter to fit in.

Fit back up ring(12) to gland(3).
Put the backup ring in the warm water of
30~50 C.
Fit O-ring(11) to gland(3).

Assemble piston assembly

Check for scratches or rough surfaces.
If found smooth with an oil stone.
Coat the outer face of piston(14) with
hydraulic oil.

(2)

8-143

Rod assembly

Cylinder head assembly

Insert

Piston assembly

20

13

Item

Bucket

Boom

Arm

21

21

25

100 10

100 10

100 10

723.3 72.3

723.3 72.3

723.3 72.3

kgf m

lbf ft

Fit lock nut(20) to piston.

Tightening torque :

Fit piston assembly to rod assembly.

Tightening torque : 100 10kgf m

(723 72lbf ft)

Insert cushion ring(13) to rod assembly.
Note that cushion ring(13) has a direction
in which it should be fitted.

Install piston and cylinder head

Fix the rod assembly to the work bench.
Apply hydraulic oil to the outer surface of
rod assembly(2), the inner surface of
piston and cylinder head.
Insert cylinder head assembly to rod
assembly.

(3)

8-144

Straight

Lift

Appply liquid packing

Fix with a bar

Place rag

Turn clockwise

Apply loctite

Overall assemble

Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane.
Be careful not to damage piston seal by
thread of tube assembly.
Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a
specified torque.
Refer to the table of tightening torque.

(3)

SECTION  9  COMPONENT MOUNTING TORQUE

Group   1  Introduction guide

9-1

Group   2  Engine system

9-2

Group   3  Electric system

9-4

Group   4  Hydraulic system

9-6

Group   5  Undercarriage

9-10

Group   6  Structure

9-11

Group   7  Work equipment

9-14

9-1

This section shows bolt specifications and
standard torque values needed when
mounting components to the machine.

Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.

Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
Before installation, clean all the components
with a non-corrosive cleaner.   Bolts and
threads must not be worn or damaged.

SECTION   9  COMPONENT MOUNTING TORQUE

GROUP  1  INTRODUCTION GUIDE

1.

2.

9-2

6

4

4

Muffler

4

4

Engine

6

6

3

Fan

1

8

9

7

A

B

TO CAB

Accel
actuator

2

A

Air cleaner

2

2

B

7

Throttle lever

5

6

GROUP  2  ENGINE SYSTEM

Item

Tightening torque

1

2

3

4

5

M 6 1.0

M 8 1.25

M10 1.5

M10 1.5

M12 1.5

0.92 0.2

2.5 0.5

4.4 0.9

6.9 1.4

12.5 3.0

6.7 1.4

18.1 3.6

31.8 6.5

49.9 10.1

92.6 21.7

Size

kgf m

lbf ft

Item

6

7

8

9

-

M12 1.75

M12 1.75

M20 2.5

M24 3.0

-

10.0 2.0

12.8 3.0

55 3.5

90 7.0

-

72.3 14.5

92.6 21.7

398 25.3

651 51

-

Size

kgf m

lbf ft

ENGINE AND ACCESSORIES MOUNTING

9-3

2

5

Water

seperator

Fuel tank

Hyd tank

VIEW   A

3

Needle valve

6

A

LIQUID-A

DISCHARGE

1

2

3

Cooler & radiator

2

Air compressor

Air con

idle pully

Receiver drier

Condenser

3

4

HYUNDAI

FULL

LOW

2

Radiator

3

Oil cooler

2

Fan guard

Shroud

4

3

Reservoir

tank

4

4

4

Item

Tightening torque

1

2

3

M 6 1.0

M 8 1.25

M10 1.5

1.05 0.2

2.5 0.5

6.9 1.4

7.6 1.45

18.1 3.6

49.9 10.1

Size

kgf m

lbf ft

Item

4

5

6

M12 1.75

M20 2.5

-

12.8 3.0

45 5.1

2.3 0.6

92.6 21.7

325 36.9

16.6 4.3

Size

kgf m

lbf ft

COOLING SYSTEM AND FUEL TANK MOUNTING