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1. 210 7 MPO2 8 13 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 7 Pull cylinder block 141 out of pump casing 271 straightly over drive shaft 111 Pull out also pistons 151 set plate 153 spherical bush 156 and cylinder springs 157 simultaneously Take care not to damage sliding surfaces of cylinder spherical bushing shoes swash plate etc 8 Remove hexagon socket head bolts 406 and then seal cover F 261 Fit bolt into pulling out tapped hole of seal cover F and cover can be removed easily Since oil seal is fitted on seal cover F take care not to damage it in removing cover 9 Remove hexagon socket head bolts 408 and then seal cover R 262 In case fitting a gear pump first remove gear pump 10 Tapping lightly fitting flange section of swash plate support 251 on its pump casing side separate swash plate support from pump casing 11 Remove shoe plate 211 and swash plate 212 from pump casing 271 8 14 210 7 MPO3 210 7 MP04 210 7 MPO5 210 7 MPO6 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 12 Tapping lightly shaft ends of drive shafts 111 113 with plastic hammer take out drive shafts from swash plate supports 13 Remove valve plates 313 314 from valve bl2. 8 18 http engine od ua hyundai tech 210 7 MP14 210 7 MP17 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 3 REGULATOR 1 STRUCTURE 1 2 412 875 874 755 897 A 647 KR3G 9C32 7 648 723 P2 PGE 1 642 438 aL uk Pm 1 801 t Pi 801 924 641 730 643 708 644 645 646 728 L SECTION B B 413 438 656 no AONTA p SOL O74 722 496 724 125 436 210 7 8 19 ECA VIEW C 8 19 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech REGULATOR 22 734 653 654 836 651 652 601 624 629 630 628 655 641 no gt a 801 o gt Alt 814 i ae 925 898 f 631 oe za 627 th 732 i 732 622 621 623 625 626 887 763 756 SECTION A A 210 7 8 20 4
3. Hexagon head bolt Hexagon nut VP plug PF thread M 8 M 8 Adjustable angle wrench Small size Max 36mm Screw driver Minus type screw driver Medium size 2 sets Hammer Plastic hammer 1 set Pliers For snap ring TSR 160 Steel bar 4x 100mm Torque wrench Capable of tightening with the specified torques Pincers Bolt M4 Length 50mm 8 21 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 2 Tightening torque Wrench size Part name Bolt size h Hexagon socket head bolt M5 i 0 16 Material SCM435 M 6 0 20 M 8 0 24 M10 0 31 M12 0 39 M14 0 47 M16 0 55 M18 0 55 M20 0 67 PT Plut Materal S45C PT1 16 0 16 Wind a seal tape 1 1 2 to 2 PT 1 8 0 20 turns round the plug PT 1 4 0 24 PT 3 8 0 31 PT 1 2 0 39 PF Plut Materal S35C PF 1 4 i 0 24 PF 1 2 0 39 PF 3 4 0 55 PF 1 0 67 PF 1 1 4 0 67 PF 1 1 2 0 67 8 22 Sample pages 3 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 1 Choos
4. 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 L 210 7 REGOS 8 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 D al SWETER gt s 210 7 REGOS AA 8 24 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 9 Remove lever 2 613 Do not draw out pin 875 Work will be promoted by using pincers or so on 210 7 REGO8 10 Draw out pin 874 and remove feedback lever 611 Push out pin 874 4mm in dia from above with slender steel bar so that it may not interfere with lever 1 612 210 7 REGO9 210 7 REG10 8 25 Sample pages Service Manual Crawler Excavator R210LC 7 11 Remove lever 1 612 Do not draw out pin 875 12 Draw out pilot piston 643 and spool 652 13 Draw out piston case 622 compensating piston 621 and compensating rod 623 Piston case 622 can be taken out by pushing compensating rod 623 at opposite side of piston case This completes disassembly 8 26 http engine od ua hyundai tech Sample pages 4 ASSEMBLY 1 For assembly reverse disassembly proced
5. 628 925 adjusting ring C 627 lock nut 630 hexagon nut 801 and adjusting screw 924 Then tighten them with hexagonal socket head screws 438 This completes assembly 8 29 210 7 REG14 gt 210 7 REG15 210 7 REG16
6. 079 Proportional reducing valve 548 Stopper 1 545 Steel ball 8 10 Sample pages 2 TOOLS AND TIGHTENING TORQUE 1 Tools Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech The tools necessary to disassemble reassemble the pump are shown in the follow list Tool name amp size Part name Name Hexagon socket head bolt PT plug PT thread PO plug PF thread Hexagon socket head setscrew Allen wrench M5 BP 1 16 M 8 M 6 BP 1 8 M10 M 8 BP 1 4 PO 1 4 M12 M14 M10 BP 3 8 PO 3 8 M16 M18 M20 M22 BP 1 PO 1 1 1 4 1 1 2 Double ring spanner socket wrench double Single open end spanner Hexagon socket head bolt Henagon nut VP plug PF thread Mi2 Mi2 VP 1 4 M16 M16 M18 M18 VP 1 2 M20 M20 VP 3 4 Adjustable angle wrench Medium size 1 set Screw driver Minus type screw driver Medium size 2 sets Hammer Plastic hammer 1 set Pliers For snap ring TSR 160 Steel bar Steel bar of key material approx 10x 8x 200 Torque wrench Capable of tightening with the specified torques Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 2 Tightening torque Wrench size Part name Bolt size in Hexagon socket head bolt M5 i 0 16 Material S
7. 12 Hexagon socket screw 630 Nut 728 O ring 413 Hexagon socket screw 631 Sleeve 730 O ring 436 Hexagon socket screw 641 Pilot cover 732 O ring 438 Hexagon socket screw 642 Pilot cover QMC 733 O ring 496 Plug 643 Pilot piston 734 O ring 601 Casing 644 Spring seat Q 735 O ring 611 Feed back lever 645 Adjust stem Q 755 O ring 612 Lever 1 646 Pilot spring 756 O ring 613 Lever 2 647 Stopper 763 O ring 614 Fulcrum plug 648 Piston QMO 801 Nut 615 Adjust plug 651 Sleeve 814 Snap ring 621 Compensator rod 652 Spool 836 Snap ring 622 Piston case 653 Spring seat 858 Snap ring 623 Compensator rod 654 Return spring 874 Pin 624 Spring seat C 655 Set spring 875 Pin 625 Outer spring 656 Block cover 887 Pin 626 Inner spring 708 O ring 897 Pin 627 Adjust stem C 722 O ring 898 Pin 628 Adjust screw C 724 O ring 924 Set screw 629 Cover C 725 O ring 925 Adjust screw Q 8 20 Sample pages Service Manual Crawler Excavator R210LC 7 2 TOOLS AND TIGHTENING TORQUE 1 Tools http engine od ua hyundai tech The tools necessary to disassemble reassemble the pump are shown in the follow list Tool name amp size Part name Name Hexagon socket head bolt PT plug PT thread PO plug PF thread Hexagon socket head setscrew Allen wrench M5 BP 1 16 M 8 M 6 BP 1 8 M10 M 8 BP 1 4 PO 1 4 M12 M14 Double ring spanner socket wrench double Single open end spanner B HE
8. CM435 M 6 0 20 M 8 0 24 M10 0 31 M12 0 39 M14 0 47 M16 0 55 M18 0 55 M20 0 67 PT Plug Materal 845C PT1 16 0 16 Wind a seal tape 1 1 2 to 2 PT 1 8 0 20 turns round the plug PT 1 4 0 24 PT 3 8 0 31 PT 1 2 0 39 PF Plug Materal S45C PF 1 4 i 0 24 PF 1 2 0 39 PF 3 4 0 55 PF 1 0 67 PF 1 1 4 0 67 PF 1 1 2 0 67 8 12 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 3 DISASSEMBLY 1 Select place suitable to disassembling Select clean place Spread rubber sheet cloth or so on on overhaul workbench top to prevent parts from being damaged 2 Remove dust rust etc from pump surfaces with cleaning oil or so on 3 Remove drain port plug 468 and let oil out of pump casing Front and rear pump 4 Remove hexagon socket head bolts 412 413 and remove regulator 5 Loosen hexagon socket head bolts 401 which tighten swash plate support 251 pump casing 271 and valve block 312 If gear pump and so on are fitted to rear face of pump remove them before starting this work 6 Place pump horizontally on workbench with its regulator fitting surface down and separate pump casing 271 from valve block 312 Before bringing this surface down spread rubber sheet on workbench without fail to prevent this surface from being damaged
9. Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech SECTION 6 TROUBLESHOOTING Group 1 Before troubleshooting Group 2 Hydraulic and Mechanical System Group 3 Electrical System Group 4 Mechatronics System Group 5 Mechatronics System 1001 and up Tier 2 SECTION 7 MAINTENANCE STANDARD Sample pages SERVICE MANUAL CRAWLER EXCAVATOR R210LC 7 Content FOREWORD INDEX SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications SECTION 2 STRUCTUREND FUNCTION Group 1 Pump Device Group 2 Main Control Valve Group 3 Swing Device Group 4 Travel Device Group 5 RCV Lever Group 6 RCV Pedal SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit Group 2 Main Circuit Group 3 Pilot Circuit Group 4 Single Operation Group 5 Combined Operation SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location Group 2 Electrical Circuit up to 1000 Group 3 Electrical Component Specification Group 4 Connectors Group 5 Electrical Circuit 1001 and up Tier 2 SECTION 5 MECHATROMICS SYSTEM Group 1 Outline up to 1000 Group 2 Mode selection System up to 1000 Group 3 Automatic Deceleration System Group 4 Power Boost System Group 5 Travel Speed Control System Group 6 Automatic Warming Up Function Group 7 Engine Overheat Prevention Function Group 8 Anti Restart System Group 9 Self Diagnostic System Group 10 Engine Control System Group 11 EPPR Electro Proportional Pressure Reducing Valve Group 12 Pro
10. asing 271 tapping the former lightly with a hammer After servo piston tilting pin stopper L and stopper S are removed fit them soon to pump casing in advance for reassembling In tightening servo piston and tilting pin use a protector to prevent tilting pin head and feedback pin from being damaged In addition apply loctite Medium strength to their threaded sections 8 16 Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 210 7 MPO9 Sample pages 3 Place pump casing with its regulator fitting surface down fit tilting bush of swash plate to tilting pin 531 and fit swash plate 212 to swash plate support 251 correctly Confirm with fingers of both hands that swash plate can be removed smoothly Apply grease to sliding sections of swash plate and swash plate support and drive shaft can be fitted easily 4 To swash plate support 251 fit drive shaft 111 set with bearing 123 bearing spacer 127 and snap ring 824 Do not tap drive shaft with hammer or so on Assemble them into support tapping outer race of bearing lightly with plastic hammer Fit them fully using steel bar or so on 5 Assemble seal cover F 261 to pump casing 271 and fix it with hexagon socket head bolts 406 Apply grease lightly to oil seal in seal cover F Assemble oil seal taking full care not to damage it x For tandem type pump fit rear cover 263 and sea
11. e 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 2 Remove dust rust etc from surfaces of regulator with clean oil 3 Remove hexagon socket head screw 412 413 and remove regulator main body from pump main body Take care not to lose O ring 4 Remove hexagon socket head screw 438 and remove cover C 629 Cover C is fitted with adjusting screw C Ql 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 Service Manual Crawler Excavator R210LC 7 8 23 http engine od ua hyundai tech 210 7 REGO1 210 7 REGO2 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 5 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 6 Remove hexagon socket head screws 436 438 and remove pilot cover 641 After removing pilot cover take out set spring 655 from pilot section _ pz PRZ 210 7 REGO4 7 Remove snap ring 814
12. force fitted in lever 2 613 into groove of pilot piston Then fix lever 2 8 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 9 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 10 Fit return spring 654 and spring seat 653 into spool hole and attach snap ring 814 8 28 Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech Lever 1 side Lever 2 side Fulcrum plug of adjusting plug side 210 7 8 28 210 7 REG11 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 11 Fit set spring 655 to spool hole and put compensating piston 621 and piston case 622 into compensating hole Fit pilot cover 641 and tighten it with hexagonal socket head screws 436 438 12 Put spring seat 644 pilot spring 646 and adjusting ring Q 645 into pilot hole Then fix spring seat 624 inner spring 626 and outer spring 625 into compensating hole When fitting spring seat take care not to mistake direction of spring seat 13 Install cover C 629 fitted with adjusting screws
13. hrough the temperature sensor and if the coolant temperature is less than 30 C it increases the engine speed from key start rom to 1200rpm At this time the mode does not change 2 In case of the coolant temperature increases up to 30 the engine speed is decreased to key start speed And if an operator changes mode set during the warming up function the CPU controller cancels the automatic warming up function 3 LOGIC TABLE Description Condition Function Coolant temperature Less than 30 0 After engine run Accel dial position is under 3 Actuated Mode Default S mode Warming up time 10 minutes Max Warming up lamp ON Coolant temperature Above 30 C Warming up time Above 10 minutes Changed mode set by operator Increase engine speed by rotating accel dial clockwise X If any of the above conditions is applicable the automatic warming up function is canceled Canceled Default mode Default mode Changed mode Warming up lamp Coolant temperature Above 30 C 5 9 Warming up lamp OFF Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech GROUP 3 PUMP DEVICE 1 REMOVAL AND INSTALL 1 REMOVAL 1 Lower the work equipment to the ground and stop the engine 2 Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping 3 Loosen the b
14. hydraulic oil leak or not Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech 2 MAIN PUMP 1 2 1 STRUCTURE A 702 789 732 582 214 548531 724 792 534 901 808 954 717 151 152 211 113 04 111 palam MP 824 z 127 i 710 123 251 RR oe 490 153 156 158 157 468 313 124 312 114 466 885 314 141 271 M 128 125 210 7 8 9 04 Gear pump 251 Support 710 O ring 111 Drive shaft F 261 Seal cover F 717 O ring 113 Drive shaft R 271 Pump casing 724 O ring 114 Spline coupling 312 Valve block 725 O ring 123 Roller bearing 313 Valve plate R 728 O ring 124 Needle bearing 314 Valve plate L 732 O ring 127 Bearing spacer 401 Hexagon socket bolt 774 Oil seal 141 Cylinder block 406 Hexagon socket bolt 789 Back up ring 151 Piston 466 VP Plug 792 Back up ring 152 Shoe 468 VP Plug 806 Hexagon head nut 153 Set plate 490 Plug 808 Hexagon head nut 156 Bushing 531 Tilting pin 824 Snap ring 157 Cylinder spring 532 Servo piston 885 Pin 158 Spacer 534 Stopper L 886 Spring pin 211 Shoe plate 535 Stopper S 901 Eye bolt 212 Swash plate 548 Pin 953 Set screw 214 Bushing 702 O ring 954 Set screw 8 9 Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech MAIN PUMP 2 2 544 543 545 541 079 210 7 8 10 541 Seat 544 Stopper 2
15. l cover 262 similarly 6 Assemble piston cylinder subassembly 0 cylinder block 141 piston subassembly 151 152 set plate 153 spherical bush 156 spacer 158 and cylinder spring 1570 Fit spline phases of retainer and cylinder Then insert piston cylinder subassembly into pump casing Service Manual Crawler Excavator R210LC 7 8 17 http engine od ua hyundai tech 210 7 MP10 __ 210 7 MP13 Sample pages Service Manual Crawler Excavator R210LC 7 7 Fit valve plate 313 to valve block 312 entering pin into pin hole Take care not to mistake suction delivery directions of valve plate 8 Fit valve block 312 to pump casing 271 and tighten hexagon socket head bolts 401 At first assemble this at rear pump side and this work will be easy Take care not to mistake direction of valve block Clockwise rotation Viewed from input shaft side Fit block with regulator up and with delivery flange left viewed from front side Counter clockwise rotation Viewed from input shaft side Fit block with delivery flange right viewed from front side 9 Putting feedback pin of tilting pin into feedback lever of regulator fit regulator and tighten hexagon socket head bolts 412 413 Take care not to mistake regulator of front pump for that of rear pump 10 Fit drain port plug 468 This is the end of reassembling procedures
16. lix Switch up to 0179 Group 13 Monitoring System Group 14 Outline 1001 and up Tier 2 Group 15 Mode selection system 1001 and up Tier 2 Group 1 Operational Performance Test Group 2 Major Components Group 3 Track and Work Equipment SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution Group 2 Tightening Torque Group 3 Pump Device Group 4 Main Control Valve Group 5 Swing Device Group 6 Travel Device Group 7 RCV Lever Group 8 Turning Joint Group 9 Boom Arm and Bucket Cylinder Group 10 Undercarriage Group 11 Work Equipment SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide Group 2 Engine system Group 3 Electric system Group 4 Hydraulic system Group 5 Undercarriage Group 6 Structure Group 7 Work equipment Sample pages Service Manual Crawler Excavator R210LC 7 http engine od ua hyundai tech GROUP 6 AUTOMATIC WARMING UP FUNCTION Engine 7 Coolan temp sensor EL Main pump i i Accel Fuel injection actuator pump Max flow CO valve EPPR valve aeeaer ECOCCOO ON ian OUCCCCOCC F A E Ala gt 4 Eseje _ Power edo Warming up lamp signal gt CPU controller User Mode Pilot pump 21075MS08 1 CPU controller reads engine coolant temperature t
17. ock 312 These may be removed in work 6 210 7 MPO8 14 If necessary remove stopper L 534 stopper S 535 servo piston 532 and tilting pin 531 from pump casing 271 and needle bearing 124 and splined coupling 114 from valve block 312 In removing tilting pin use a protector to prevent pin head from being damaged Since loctite is applied to fitting areas of tilting pin and servo piston take care not to damage servo piston Do not remove needle bearing as far as possible except when it is considered to be out of its life span Do not loosen hexagon nuts of valve block and swash plate support If loosened flow setting will be changed 8 15 Sample pages 4 ASSEMBLY 1 For reassembling reverse the disassembling procedures paying attention to the following items Do not fail to repair the parts damaged during disassembling and prepare replacement parts in advance Clean each part fully with cleaning oil and dry it with compressed air Do not fail to apply clean working oil to sliding sections bearings etc before assembling them In principle replace seal parts such as O rings oil seals etc For fitting bolts plug etc prepare a torque wrench or so on and tighten them with torques shown in page 8 11 12 For the double pump take care not to mix up parts of the front pump with those of the rear pump 2 Fit swash plate support 251 to pump c
18. reather slowly to release the pressure inside the hydraulic tank A Escaping fluid under pressure can penetrate the skin causing serious injury 4 Loosen the drain plug under the hydraulic tank and drain the oil from the hydraulic 5 Remove socket bolts 74 and disconnect 6 Disconnect pilot line hoses 4 5 6 7 8 9 7 Remove socket bolts 72 and disconnect pump suction tube 3 When pump suction tube is disconnected the oil inside the piping will flow out so catch it in oil pan 8 Sling the pump assembly and remove the pump mounting bolts Weight 120kg 265lb Pull out the pump assembly from housing When removing the pump assembly check that all the hoses have been Hydraulic tank quantity 1802 13031GE18 21078DA01 21078DA02 8 7 Sample pages 2 INSTALL 1 Carry out installation in the reverse order to removal 2 Remove the suction strainer and clean it 2 3 Replace return filter with new one 4 Remove breather and clean it 5 After adding oil to the hydraulic tank to the specified level 6 Bleed the air from the hydraulic pump Remove the air vent plug 2EA Tighten plug lightly Start the engine run at low idling and check oil come out from plug Tighten plug 7 Start the engine run at low idling 3 5 minutes to circulate the oil through the system 8 Confirm the hydraulic oil level and check the
19. ures 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 2 Put compensating rod 623 into compensating hole of casing 601 3 Put pin force fitted in lever 1 612 into groove of compensating rod and fit lever 1 to pin force fitted in casing 4 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 Service Manual Crawler Excavator R210LC 7 8 27 http engine od ua hyundai tech TU ar 1 IE D 1 KR Spool y Feedback lever 210 7 8 27 Sample pages 5 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 6 Put pilot piston 643 into pilot hole of casing Confirm that pilot piston slides smoothly without binding 7 Put pin
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