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HYUNDAI PDF OPERATING & SERVICE MANUALS

http://vk.od.ua/manuals
The operator manual contains a number of instructions and safety recommendations
regarding driving, handing, lubrication, maintenance, inspection and adjustment of the
equipments.
The manual is to promote safety maintenance and enhance machine performance.
The service manual has been prepared as an aid to improve the quality of repairs by giving
the serviceman an accurate understanding of the product and showing him the correct way to
perform repairs and make judgments. Make sure you understand the contents of this manual
and use it to full effect at every opportunity.
This service manual mainly contents the necessary technical information for operation
performed in a service workshop.
Ask manuals brovertekgr@gmail.com. Specify machine and model what you need.
Example: Crawler Excavator R210LC-7.
See sample contents and sample pages for R210LC-7 Crawler Excavator below.

Operating Manual Crawler Excavator


R210LC-7 http://vk.od.ua
CONTENTS
Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-1

6. Traveling of the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-15

Before servicing this machine - - - - - - - - - - - - - - - - - - - - - - - - - - 0-2

7. Efficient working method - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18

EC regulation approved - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-3

8. Operation in the special work sites - - - - - - - - - - - - - 4-23

Table to enter S/No and distribution - - - - - - - - - - - - - - - - - - - - - - 0-4

9. Normal operation of excavator - - - - - - - - - - - - - - - - - - - 4-24

Safety labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-5

10. Attachment lowering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25

Guide(Direction, S/No, Symbol) - - - - - - - - - - - - - - - - - - - - - - - - 0-15

11. Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-26


12. RCV lever operating pattern - - - - - - - - - - - - - - - - - - - - - - - 4-28

SAFETY HINTS

13. Switching hydraulic attachment circuit - - - - - - - - 4-29

1. Before operating the machine - - - - - - - - - - - - - - - - - - - - 1-1


2. During operating the machine - - - - - - - - - - - - - - - - - - - - 1-6

TRANSPOTATION

3. During maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

1. Preparation for transportation - - - - - - - - - - - - - - - - - - - - 5-1

4. Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

2. Dimension and weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2


3. Loading the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4

SPECIFICATIONS
1. Major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

4. Fixing the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6


5. Loading and unloading by crane - - - - - - - - - - - - - - - - 5-7

2. Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
3. Working range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

MAINTENANCE

4. Weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8

1. Instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

5. Lifting capacities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-11

2. Tightening torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-6

6. Bucket selection guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-18

3. Fuel, coolant and lubricants - - - - - - - - - - - - - - - - - - - - - - - 6-9

7. Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20

4. Maintenance check list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11

8. Specification for major components - - - - - - - - - - - 2-22

5. Maintenance chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16

9. Recommended oils - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-26

6. Service instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18


7. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-40

CONTROL DEVICES

8. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - 6-43

1. Cab devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1


2. Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

TROUBLESHOOTING GUIDE

3. Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9

1. Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

4. Levers and pedals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14

2. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2

5. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - 3-17

3. Others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3

6. Others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-20

HYDRAULIC BREAKER AND QUICK CLAMP


OPERATION

1. Selecting hydraulic breaker - - - - - - - - - - - - - - - - - - - - - - - - 8-1

1. Suggestion for new machine - - - - - - - - - - - - - - - - - - - - - - 4-1

2. Circuit configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2

2. Check before starting the engine - - - - - - - - - - - - - - - 4-2

3. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-3

3. Starting and stop the engine - - - - - - - - - - - - - - - - - - - - - - 4-3

4. Precaution while operating the breaker - - - - - - 8-4

4. Mode selection system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7

5. Quick clamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6

5. Operation of the working device - - - - - - - - - - - - - - - - - 4-14

INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1

Sample pages

Operating Manual Crawler Excavator R210LC-7

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8. SPECIFICATIONS FOR MAJOR COMPONENTS


1) ENGINE
Specification

Item
Model

Cummins B5.9-C

Type

4-cycle turbocharged diesel engine, low emission

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type

Cylinder borestroke

102120mm(4.02"4.72")

Piston displacement

5880cc(359cu in)

Compression ratio

17.4 : 1

Rated gross horse power(SAE J1995

*Cummins 6BTAA

*17.3 : 1

155Hp at 2100rpm(116kW at 2100rpm)


*150Hp at 1950rpm(112kW at 1950rpm)

Maximum torque at 1600rpm

*at 1500rpm

62.1kgfm(450lbfft)
*62.6kgfm(453lbfft)

Engine oil quantity

24(6.3U.S. gal)

Dry weight

400kg(882lb)

*496kg(1094lb)

High idling speed

2250 50rpm

*2180 50rpm

Low idling speed

950100rpm

*1050100rpm

Rated fuel consumption

171.5g/Hphr at 2100rpm

*164.8g/Hphr at 1950rpm

Starting motor

Nippon denso(24V-5.5kW)

*(24V-4.5kW)

Alternator

Delco Remy (24V-50A)

Battery

212V100Ah

* : TIER II

2) MAIN PUMP
Item

Specification

Type

Variable displacement tandem axis piston pumps

Capacity

2105cc/rev

Maximum pressure

330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]

Rated oil flow

2220/min (58.1U.S. gpm/ 48.4U.K. gpm)

Rated speed

2100rpm

] : Power boost

* : TIER II

2-22

*2113cc/rev

*1950rpm

Sample pages

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3) GEAR PUMP
Item

Specification

Type

Fixed displacement gear pump single stage

Capacity

15cc/rev

Maximum pressure

35kgf/cm2(500psi)

Rated oil flow

29.3/min(7.7U.S. gpm/6.4U.K. gpm)

4) MAIN CONTROL VALVE


Item

Specification

Type

9 spools mono-block

Operating method

Hydraulic pilot system

Main relief valve pressure

330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]

Overload relief valve pressure

390kgf/cm2(5550psi)

[ ]: Pooer boost

5) SWING MOTOR
Item

Specification

Type

Two fixed displacement axial piston motor

Capacity

151cc/rev

Relief pressure

240kgf/cm2(3414psi)

Braking system

Automatic, spring applied hydraulic released

Braking torque

59kgfm(427lbfft)

Brake release pressure

33~50kgf/cm2(470~711psi)

Reduction gear type

2 - stage planetary

Swing speed

12.5rpm

6) TRAVEL MOTOR
(1) TRAVEL MOTOR(GM35VL, up to #2078)
Item

Specification

Type

Variable displacement axial piston motor

Relief pressure

330kgf/cm2(4695psi)

Reduction gear type

3-stage planetary

Braking system

Automatic, spring applied hydraulic released

Brake release pressure

6kgf/cm2(85psi)

Braking torque

40.6kgfm(294lbfft)

2-23

Sample pages

Operating Manual Crawler Excavator R210LC-7

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(2) TRAVEL MOTOR(RMV147, #2079 and up)


Item

Specification

Type

Variable displacement axial piston motor

Relief pressure

330kgf/cm2(4695psi)

Reduction gear type

2-stage planetary

Braking system

Automatic, spring applied hydraulic released

Brake release pressure

11kgf/cm2(156psi)

Braking torque

49.3kgfm(357lbfft)

325kgf/cm2(4625psi)

11kgf/cm2(157psi)
49.3kgfm(357lbfft)

: HIGH WALKER

7) REMOTE CONTROL VALVE


Item

Specification

Type

Pressure reducing type

Operating pressure

Single operation stroke

Minimum

6.5kgf/cm2(92psi)

Maximum

26kgf/cm2(370psi)

Lever

61mm(2.4in)

Pedal

123mm(4.84in)

8) CYLINDER
Specification

Item
Boom cylinder

Arm cylinder

Bucket cylinder

Bore diaRod diaStroke

120851290mm

Cushion

Extend only

Bore diaRod diaStroke

1401001510mm

Cushion

Extend and retract

Bore diaRod diaStroke

125851055mm

Cushion

Extend only

#140951460mm
#10070870mm

Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
Discoloration does not cause any harmful effect on the cylinder performance.
# : LONG REACH

2-24

Sample pages

Operating Manual Crawler Excavator R210LC-7

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9) SHOE
Item

Width

Ground pressure

Link quantity

Overall width

600mm(24")

0.46kgf/cm2(6.54psi)

49

2990mm(9' 10")

700mm(28")

0.40kgf/cm2(5.69psi)

49

3090mm(10' 2")

800mm(32")

0.35kgf/cm2(4.98psi)

49

3190mm(10' 6")

Standard

800mm(32")

0.42kgf/cm2(5.97psi)

49

3190mm(10' 6")

Standard

600mm(24")

0.49kgf/cm2(6.97psi)

49

3395mm(11' 2")

700mm(28")

0.43kgf/cm2(6.12psi)

49

3495mm(11' 6")

800mm(32")

0.38kgf/cm (5.40psi)

49

3595mm(11' 10")

710mm(28")

0.43kgf/cm2(6.12psi)

49

3505mm(11' 6")

Standard
R210LC-7
R210LC-7
LONG REACH

Option

R210LC-7
HIGH WALKER

Option

: Double grouser.

10) BUCKET
Capacity

Item

SAE heaped

CECE heaped

0.92m (1.20yd )

0.80m3(1.05yd3)

1150mm(45.3")

1270mm(50.0")

0.51m3(0.67yd3)

0.45m3(0.59yd3)

700mm(27.6")

820mm(32.3")

0.80m (1.05yd )

0.70m (0.92yd )

1000mm(39.4")

1120mm(44.1")

1.10m3(1.44yd3)

0.96m3(1.26yd3)

1320mm(52.0")

1440mm(56.7")

1.20m (1.57yd )

1.00m (1.31yd )

1400mm(55.1")

1520mm(59.8")

1.34m3(1.75yd3)

1.15m3(1.50yd3)

1550mm(61.0")

1670mm(65.7")

0.74m (0.97yd )

0.65m (0.85yd )

985mm(38.8")

0.90m3(1.18yd3)

0.80m3(1.05yd3)

1070mm(42.0")

1.05m (1.37yd )

0.92m (1.20yd )

1290mm(50.8")

0.87m3(1.14yd3)

0.75m3(0.98yd3)

1140mm(44.9")

1.20m (1.57yd )

1.00m (1.31yd )

1410mm(55.5")

0.75m3(0.98yd3)

0.65m3(0.85yd3)

1790mm(70.5")

STD

R210LC-7

Width
Tooth
quantity Without side cutter With side cutter

OPT

: Heavy duty bucket


: Rock bucket(Heavy)
: Slope finishing bucket

2-25

Sample pages

Operating Manual Crawler Excavator R210LC-7

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4. MAINTENANCE CHECK LIST


1) DAILY SERVICE BEFORE STARTING
Check items

Service

Page

Fuel tank

Check, Refill

6-25

Hydraulic oil level

Check, Add

6-30

Engine oil level

Check, Add

6-18

Coolant level

Check, Add

6-20

Control panel & pilot lamp

Check, Clean

6-40

Water separator(~#3341)

Check, Drain

6-26

Prefilter(#3342~)

Check, Clean

6-26

Fan belt tension

Check, Adjust

6-24

Service

Page

Drain

6-25

Check, Adjust

6-35

Lubricate

6-33

Swing reduction gear oil

Check, Add

6-33

Swing reduction gear grease

Check, Add

6-33

Lubricate

6-39

Visual check

2) EVERY 50 HOURS SERVICE


Check items
Fuel tank(Water sediment)
Track tension
Swing bearing grease

Lubricate pin and bushing


Boom cylinder tube end
Boom foot
Boom cylinder rod end
Arm cylinder tube end
Arm cylinder rod end
Boom + Arm connecting
Bucket cylinder tube end
Bucket cylinder rod end
Arm + Bucket connecting
Arm + Link, Bucket control
Bucket control rod

6-11

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Operating Manual Crawler Excavator R210LC-7

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3) INITIAL 50 HOURS SERVICE


Check items

Service

Page

Engine oil

Change

6-18, 19

Engine oil filter

Replace

6-18, 19

Prefilter(#3342~)

Replace

6-26-1

Pilot line filter

Replace

6-32

Hydraulic return filter

Replace

6-31

Drain filter cartridge

Replace

6-32

Fuel filter element

Replace

6-26-1

Check, Tight

6-8

Bolts & Nuts


Sprocket mounting bolts
Travel motor mounting bolts
Swing motor mounting bolts
Swing bearing mounting bolts
Engine mounting bolts
Counterweight mounting bolts
Turning joint locating bolts
Track shoe mounting bolts and nuts
Hydraulic pump mounting bolts

Service the above items only for the new machine, and thereafter keep the normal service interval.

4) EVERY 100 HOURS SERVICE


Check items

Service

Page

Return filter

Replace

6-31

Pilot line filter

Replace

6-32

Air breather element

Replace

6-32

Drain cartridge filter

Replace

6-32

Replace 4 filters for continuous hydraulic breaker operation only.

5) INITIAL 250 HOURS SERVICE


Check items
Swing reduction gear oil

6-12

Service

Page

Change

6-33

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6) EVERY 250 HOURS SERVICE


Check items

Service

Page

Check, Add

6-40

Hydraulic oil return filter

Replace

6-31

Drain filter cartridge

Replace

6-32

Pilot line filter

Replace

6-32

Check

6-44

Replace

6-32

Check, Tight

6-8

Service

Page

Change

6-34

Service

Page

Engine oil

Change

6-18, 19

Engine oil filter

Replace

6-18, 19

Radiator, cooler fin and charge air cooler

Check, Clean

6-23

Air cleaner element(Primary)

Check, Clean

6-25

Fuel filter element

Replace

6-26-1

Prefilter(#3342~)

Change

6-26

Battery electrolyte

Aircon & heater flesh filter


Air breather element
Bolts & Nuts
Sprocket mounting bolts
Travel motor mounting bolts
Swing motor mounting bolts
Swing bearing mounting bolts
Engine mounting bolts
Counterweight mounting bolts
Turning joint locating bolts
Track shoe mounting bolts and nuts
Hydraulic pump mounting bolts

7) INITIAL 500 HOURS SERVICE


Check items
Travel reduction gear oil

8) EVERY 500 HOURS SERVICE


Check items

If you use high sulfur containing fuel above than 0.5% or use low grade of engine oil reduce change
interval.
Clean the primary element only after 500 hours operation or when the air cleaner warning lamp blinks.
Replace primary element and safety element after 4 times cleanings of primary element.

6-13

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9) EVERY 1000 HOURS SERVICE


Check items

Service

Page

Travel motor reduction gear oil

Change

6-34

Swing reduction gear oil

Change

6-33

Grease in swing gear and pinion

Change

6-33

Service

Page

Change

6-31

Check, Clean

6-31

Change

6-20, 21, 22, 23

10) EVERY 2000 HOURS SERVICE


Check items
Hydraulic tank
Oil
Suction strainer
Coolant

Change oil every 600 hours of continuous hydraulic breaker operation.

6-14

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11) WHEN REQUIRED


Whenever you have trouble in the machine, you must perform the service of related items, system
by system.
Service

Page

Drain or Clean

6-25

Water separator(~#3341)

Drain or Replace

6-26

Prefilter(#3342~)

Clean or Replace

6-26

Fuel filter element

Replace

6-26-1

Engine oil

Change

6-18, 19

Engine oil filter

Replace

6-18, 19

Coolant

Add or Change

6-20, 21, 22, 23

Radiator

Clean or Flush

6-20, 21, 22, 23

Check

6-23

Replace

6-25

Hydraulic oil

Add or Change

6-30

Return filter

Replace

6-31

Drain line filter

Replace

6-32

Pilot line filter

Replace

6-32

Element of breather

Replace

6-32

Clean

6-31

Check, Adjust

6-35

Tooth

Replace

6-37

Side cutter

Replace

6-37

Adjust

6-36

Replace

6-36

Clean, Replace

6-43

Clean

6-44

Check items
Fuel system
Fuel tank

Engine lubrication system

Engine cooling system

Charge air cooler


Engine air system
Air cleaner element
Hydraulic system

Suction strainer
Under carriage
Track tension
Bucket

Linkage
Bucket assy
Air conditioner and heater
Fresh filter
Recirculation filter

6-15

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Operating Manual Crawler Excavator R210LC-7

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7. ELECTRICAL SYSTEM
1) WIRING, GAUGES
Check regularly and repair loose or malfunctioning
gauges when found.

13036MI29

2) BATTERY
(1) Check and repair
Check the electrolyte level and fill with distilled
water to the prescribed level as necessary.
Wash the terminal with hot water if it is
contaminated, and apply grease to the
terminals after washing.
Do not stain clothes or skin with electrolyte
as it is acid.
Be careful not to get the electrolyte in eyes.
Wash with clean water and go to the doctor
if it enters the eyes.
Remove the fire and spark around battery.

Plug

Upper level
Lower level
10 ~15mm

13036MI30

(2) Specific gravity of battery


Judge the charging rate of battery by the specific
gravity. The specific gravity changes by the
ambient temperature.
Check the charging rate by referring to the chart
below.
Temperature

20
C
(68
F)

10
C
(50
F)

-10
C
(14
F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

Charging rate

(3) Method of removing the battery cable


Remove the cable from the ground connection
first( terminal side) and reconnect it last when
reassembling.

Specific
gravity meter
Height of sight
Battery

13036MI31

Ground

Battery relay
13036MI32

6-40

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3) STARTING THE ENGINE WITH A BOOSTER CABLE


Keep following order when you are going to start
engine using booster cable.
(1) Connection of booster cable
Use the same capacity of battery for starting.
Make sure that the starting switches of the
normal machine and trouble machine are both
at the OFF position.
Connect the red terminal of booster cable to the
battery (+) terminal between exhausted and
new battery.
Connect the black terminal of the booster cable
between new battery (-) terminal and chassis of
trouble machine.
Keep firmly all connection, the spark will be
caused when connecting finally.

Connection of booster cable


Red

Trouble(Exhausted)
Normal(New)
machine
machine
Black

To chassis of trouble machine

Connection order :
13036MI33

(2) Starting the engine


Starting the engine of the normal machine and
keep it to run at high idle.
Start engine of the trouble machine with starting
switch.
If you can not start it by one time, restart the
engine after 2 minutes.

(3) Taking off the booster cable


Take off the booster cable(black).
Take off the booster cable(red) connected to the
(+) terminal.
Run engine with high idle until charging the
exhausted battery by alternator, fully.
Explosive gas is generated while using the
battery or charging it. Keep away flame and
be careful not to cause the spark.
Charge the battery in the well ventilated
place.
Place the machine on the earth or concrete.
Avoid charging the machine on the steel
plate.
Do not connect (+) terminal and (-) terminal
when connecting booster cable because it
will be shorted.

6-41

START
ON
OFF

21076MA29

Disconnection of booster cable

Red

Trouble(Exhausted)
Normal(New)
machine
machine
Black

To chassis of trouble machine

Disconnection order :

13036MI33

Sample pages

Operating Manual Crawler Excavator R210LC-7

(4) Welding repair


Before start to welding, follow the below
procedure.
Shut off the engine and remove the starting
switch.
Disconnect ground cable from battery by
master switch.
Before carrying out any electric welding on the
machine, the battery cables should be
disconnected and the connectors pulled out of
the electronic control units(CPU, cluster etc).
Connect the earth(ground) lead of the welding
equipment as close to the welding point as
possible.
Do not weld or flame cut on pipes or tubes
that contain flammable fluids. Clean them
thoroughly with nonflammable solvent before
welding or flame cutting on them.
Do not attempt to welding work before carry
out the above.
If not, it will caused serious damage at
electric CAPO system.

http://vk.od.ua/manuals

C0L
45 10
EX 21
OB -3
L:R NB
DE :21
MORT NO
PA

-51

CN
-50

CN

CPU
Controller

OFF

Master switch
DA

Cluster

UN

HY

de

r Mo

we

Po

rk
Wo

Tra

de
Mo

er

Us

d
ee
Sp

t
lec
Se

cel

to
Au

Battery

vel

de
Mo
De

CN-56

21076MI35

6-42

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
Prolix 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)

SECTION 6
TROUBLESHOOTING
Group 1
Before troubleshooting
Group 2
Hydraulic and Mechanical System
Group 3
Electrical System
Group 4
Mechatronics System
Mechatronics System(#1001 and up,Tier 2)
Group 5
SECTION 7
MAINTENANCE STANDARD
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

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GROUP 6 AUTOMATIC WARMING UP FUNCTION

Engine

Coolant
temp sensor

Main pump
Accel
actuator

Fuel injection
pump

Pilot pump

Max flow
CO valve

P M

Motor drive signal

Potentiometer signal

Coolant temperature signal

EPPR valve

Drive signal
Warming up lamp signal

CPU controller

21075MS08

1. CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant
C, it increases the engine speed from key start rpm to 1200rpm. At this
temperature is less than 30
time the mode does not change.
2. In case of the coolant temperature increases up to 30
C,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

Actuated

- Coolant temperature :
Less than 30
C(After engine run)
- Accel dial position is under 3

- Mode : Default(S mode)


- Warming up time : 10 minutes(Max)
- Warming up lamp : ON
- Default mode
- Default mode
- Changed mode

Canceled

- Coolant temperature : Above 30


C
- Warming up time : Above 10 minutes
- Changed mode set by operator
- Increase engine speed by rotating accel
dial clockwise
If any of the above conditions is
applicable, the automatic warming up
function is canceled
- Coolant temperature : Above 30
C

- Warming up lamp : OFF

Warming up lamp

5-9

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Service Manual Crawler Excavator R210LC-7

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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 breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.

13031GE18

9
74

(4) Loosen the drain plug under the hydraulic


tank and drain the oil from the hydraulic
tank.
Hydraulic tank quantity : 180

(5) Remove socket bolts(74) and disconnect


pipe(9).

72

(6) Disconnect pilot line hoses(4, 5, 6, 7, 8, 9).

21078DA01

(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.

69

55

58

64
a4
1

i1

(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
disconnected.

Ps

71

3
B

49

P
i2
2

48
78

8-7

21078DA02

Sample pages

Service Manual Crawler Excavator R210LC-7

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(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 hydraulic oil leak or not.

8-8

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Sample pages

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2. MAIN PUMP(1/2)
1) STRUCTURE
A
702
789, 732 532 214 548 531 724 792 534 901 808 954 717 151 152 211 113

04

535
806
953
886
717
406
261
774

111
824
127
710
123
251
212
490

04
111
113
114
123
124
127
141
151
152
153
156
157
158
211
212
214

153

156 158 157 468 313 124 312 114 466


728
725

Gear pump
Drive shaft(F)
Drive shaft(R)
Spline coupling
Roller bearing
Needle bearing
Bearing spacer
Cylinder block
Piston
Shoe
Set plate
Bushing
Cylinder spring
Spacer
Shoe plate
Swash plate
Bushing

251
261
271
312
313
314
401
406
466
468
490
531
532
534
535
548
702

885

Support
Seal cover(F)
Pump casing
Valve block
Valve plate(R)
Valve plate(L)
Hexagon socket bolt
Hexagon socket bolt
VP Plug
VP Plug
Plug
Tilting pin
Servo piston
Stopper(L)
Stopper(S)
Pin
O-ring

8-9

314

141

271

401
(210-7) 8-9

710
717
724
725
728
732
774
789
792
806
808
824
885
886
901
953
954

O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Oil seal
Back up ring
Back up ring
Hexagon head nut
Hexagon head nut
Snap ring
Pin
Spring pin
Eye bolt
Set screw
Set screw

Sample pages

Service Manual Crawler Excavator R210LC-7

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MAIN PUMP(2/2)

544

543
545
541

079

VIEW A

541
543

Seat
Stopper 1

544
545

Stopper 2
Steel ball

8-10

(210-7) 8-10

079

Proportional reducing valve

Sample pages

Service Manual Crawler Excavator R210LC-7

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2) TOOLS AND TIGHTENING TORQUE


(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size

Part name

Name

Hexagon socket
head bolt

PT plug
(PT thread)

PO plug
(PF thread)

Hexagon socket
head setscrew

Allen wrench

M 5

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

17

M20, M22

PO-1, 1 1/4, 1 1/2

Double ring spanner,


socket wrench, double(Single)
open end spanner
B

BP-1

Hexagon socket
head bolt

Henagon nut

VP plug
(PF thread)

19

M12

M12

VP-1/4

24

M16

M16

27

M18

M18

VP-1/2

30

M20

M20

36

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. 108200

Torque wrench

Capable of tightening with the specified torques

8-11

Sample pages

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(2) Tightening torque


Part name
Hexagon socket head bolt
Material : SCM435)

PT Plug(Materal : S45C)
Wind a seal tape 1 1/2 to 2
turns round the plug

PF Plug(Materal : S45C)

Bolt size

Torque

Wrench size

kgfm

lbfft

in

mm

M 5

0.7

5.1

0.16

M 6

1.2

8.7

0.20

M 8

3.0

21.7

0.24

M10

5.8

42.0

0.31

M12

10.0

72.3

0.39

10

M14

16.0

116

0.47

12

M16

24.0

174

0.55

14

M18

34.0

246

0.55

14

M20

44.0

318

0.67

17

PT1/16

0.7

5.1

0.16

PT 1/8

1.05

7.59

0.20

PT 1/4

1.75

12.7

0.24

PT 3/8

3.5

25.3

0.31

PT 1/2

5.0

36.2

0.39

10

PF 1/4

3.0

21.7

0.24

PF 1/2

10.0

72.3

0.39

10

PF 3/4

15.0

109

0.55

14

PF 1

19.0

137

0.67

17

PF 1 1/4

27.0

195

0.67

17

PF 1 1/2

28.0

203

0.67

17

8-12

Sample pages

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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.

(210-7) MP01

(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.

(210-7) MP02

8-13

Sample pages

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(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.
(210-7) MP03

(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.

(210-7) MP04

(10) Tapping lightly fitting flange section of


swash plate support(251) on its pump
casing side, separate swash plate support
from pump casing.

(210-7) MP05

(11) Remove shoe plate(211)and swash


plate(212) from pump casing(271).

(210-7) MP06

8-14

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(12) Tapping lightly shaft ends of drive shafts


(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.

(210-7) MP07

(13) Remove valve plates(313, 314) from valve


block(312).
These may be removed in work(6).

(210-7) MP08

(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

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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
casing(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.

(210-7) MP09

8-16

Sample pages

Service Manual Crawler Excavator R210LC-7

(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.

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(210-7) MP10

(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.

(210-7) MP11

(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.
For tandem type pump, fit rear cover(263)
and seal cover(262) similarly.

(210-7) MP12

(6) Assemble piston cylinder subassembly


cylinder block(141), piston subassembly
(151, 152), set plate(153), spherical bush
(156), spacer(158) and cylinder spring
(157).
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
(210-7) MP13

8-17

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(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.

(210-7) MP14

(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.

(210-7) MP16

(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.

(210-7) MP17

(10) Fit drain port plug(468).


This is the end of reassembling procedures.

8-18

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3. REGULATOR
1) STRUCTURE(1/2)
412

875

874

755
A

897

858

614

612

615
613
A

611

647
648

KR3G-9C32

P2
Pf

723
642

438
801

801

Pm
Pi

924
641

730

643

708

644

645

646

728

SECTION B-B
(210-7) 8-19

413

438

656

438
735
722

496

724

725

436

VIEW C

8-19

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REGULATOR(2/2)
734

653

654

836

651 652

601

624

629

630

628

655

641

801
C
925

814
898
631

627

732

733

732

622

621

623

625

626

887

763

756

SECTION A-A
(210-7) 8-20

412
413
436
438
496
601
611
612
613
614
615
621
622
623
624
625
626
627
628
629

Hexagon socket screw


Hexagon socket screw
Hexagon socket screw
Hexagon socket screw
Plug
Casing
Feed back lever
Lever(1)
Lever(2)
Fulcrum plug
Adjust plug
Compensator rod
Piston case
Compensator rod
Spring seat(C)
Outer spring
Inner spring
Adjust stem(C)
Adjust screw(C)
Cover(C)

630
631
641
642
643
644
645
646
647
648
651
652
653
654
655
656
708
722
724
725

Nut
Sleeve
Pilot cover
Pilot cover(QMC)
Pilot piston
Spring seat(Q)
Adjust stem(Q)
Pilot spring
Stopper
Piston(QMC)
Sleeve
Spool
Spring seat
Return spring
Set spring
Block cover
O-ring
O-ring
O-ring
O-ring
8-20

728
730
732
733
734
735
755
756
763
801
814
836
858
874
875
887
897
898
924
925

O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Nut
Snap ring
Snap ring
Snap ring
Pin
Pin
Pin
Pin
Pin
Set screw
Adjust screw(Q)

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2) TOOLS AND TIGHTENING TORQUE


(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size
Name
Allen wrench
B

Double ring spanner,


socket wrench, double(Single)
open end spanner

Part name
B

Hexagon socket
head bolt

PT plug
(PT thread)

PO plug
(PF thread)

Hexagon socket
head setscrew

M 5

BP-1/16

M 8

M 6

BP-1/8

M10

M 8

BP-1/4

PO-1/4

M12, M14

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

4100mm

Torque wrench

Capable of tightening with the specified torques

Pincers

Bolt

M4, Length : 50mm

8-21

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(2) Tightening torque


Part name
Hexagon socket head bolt
Material : SCM435)

PT Plut(Materal : S45C)
Wind a seal tape 1 1/2 to 2
turns round the plug

PF Plut(Materal : S35C)

Bolt size

Torque

Wrench size

kgfm

lbfft

in

M 5

0.7

5.1

0.16

M 6

1.2

8.7

0.20

M 8

3.0

21.7

0.24

M10

5.8

42.0

0.31

M12

10.0

72.3

0.39

10

M14

16.0

116

0.47

12

M16

24.0

174

0.55

14

M18

34.0

246

0.55

14

M20

44.0

318

0.67

17

PT1/16

0.7

5.1

0.16

PT 1/8

1.05

7.59

0.20

PT 1/4

1.75

12.7

0.24

PT 3/8

3.5

25.3

0.31

PT 1/2

5.0

36.2

0.39

10

PF 1/4

3.0

21.7

0.24

PF 1/2

10.0

72.3

0.39

10

PF 3/4

15.0

109

0.55

14

PF 1

19.0

137

0.67

17

PF 1 1/4

27.0

195

0.67

17

PF 1 1/2

28.0

203

0.67

17

8-22

mm

Sample pages

Service Manual Crawler Excavator R210LC-7

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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) Choose 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.

(210-7) REG01

(4) Remove hexagon socket head screw


(438) and remove cover(C,629)
Cover(C) is fitted with adjusting screw
(C,QI) (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 pressureflow setting will vary.

(210-7) REG02

8-23

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Service Manual Crawler Excavator R210LC-7

(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.

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(210-7) REG03

(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.

(210-7) REG04

(7) Remove snap ring(814) 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.

(210-7) REG05

(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.

(210-7) REG06

8-24

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Service Manual Crawler Excavator R210LC-7

http://vk.od.ua/manuals

(210-7) REG07

(9) Remove lever(2, 613). Do not draw out


pin(875).
Work will be promoted by using pincers or
so on.

(210-7) REG08

(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) REG09

(210-7) REG10

8-25

Sample pages

Service Manual Crawler Excavator R210LC-7

(11) Remove lever(1, 612).


pin(875).

Do not draw out

(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

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Sample pages

Service Manual Crawler Excavator R210LC-7

http://vk.od.ua/manuals

4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, 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)
compensating hole of casing(601).

into

(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.
Spool
Feedback lever
(210-7) 8-27

8-27

Sample pages

Service Manual Crawler Excavator R210LC-7

(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.

Lever (1) side

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Lever (2) side


(Fulcrum plug of
adjusting plug side)

(210-7) 8-28

(6) Put pilot piston(643) into pilot hole of


casing.
Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever(2, 613) into
groove of pilot piston.
Then fix lever(2).
(210-7) REG11

(8) Fit fulcrum plug(614) so that pin forcefitted 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.

(210-7) REG12

(10) Fit return spring(654) and spring seat


(653) into spool hole and attach snap ring
(814).

(210-7) REG13

8-28

Sample pages

Service Manual Crawler Excavator R210LC-7

http://vk.od.ua/manuals

(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).

(210-7) REG14

(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.

(210-7) REG15

(13) Install cover(C, 629) fitted with adjusting


screws(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.

(210-7) REG16

8-29