Hyundai Manuals - Service Manual

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 [email protected]. 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

http://vk.od.ua/manuals

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 boreÝstroke

102Ý120mm(4.02"Ý4.72")

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

62.1kgfÂm(450lbfÂft) *62.6kgfÂm(453lbfÂft)

Engine oil quantity

24˶(6.3U.S. gal)

Dry weight

400kg(882lb)

*496kg(1094lb)

High idling speed

2250 50rpm

*2180 50rpm

Low idling speed

950Ü100rpm

*1050Ü100rpm

Rated fuel consumption

171.5g/HpÂhr at 2100rpm

*164.8g/HpÂhr at 1950rpm

Starting motor

Nippon denso(24V-5.5kW)

*(24V-4.5kW)

Alternator

Delco Remy (24V-50A)

Battery

2Ý12VÝ100Ah

* : TIER II

2) MAIN PUMP Item

[

Specification

Type

Variable displacement tandem axis piston pumps

Capacity

2Ý105cc/rev

Maximum pressure

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

Rated oil flow

2Ý220˶/min (58.1U.S. gpm/ 48.4U.K. gpm)

Rated speed

2100rpm

] : Power boost

* : TIER II

2-22

*2Ý113cc/rev

*1950rpm

Sample pages



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

59kgfÂm(427lbfÂft)

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



6kgf/cm2(85psi)

Braking torque

40.6kgfÂm(294lbfÂft)

2-23

Sample pages



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

ø

Specification

Type

Variable displacement axial piston motor

Relief pressure

330kgf/cm2(4695psi)

Reduction gear type

2-stage planetary

Braking system



11kgf/cm2(156psi)

ø

Braking torque

49.3kgfÂm(357lbfÂft)

ø

ø

325kgf/cm2(4625psi)

11kgf/cm2(157psi) 49.3kgfÂm(357lbfÂft)

: 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 diaÝRod diaÝStroke

͚120Ý͚85Ý1290mm

Cushion

Extend only


͚140Ý͚100Ý1510mm

Cushion

Extend and retract


͚125Ý͚85Ý1055mm

Cushion

Extend only

#͚140Ý͚95Ý1460mm #͚100Ý͚70Ý870mm

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

2-24

Sample pages



9) SHOE Item

Width

Ground pressure

Link quantity

Overall width

600mm(24")

0.46kgf/cm2(6.54psi)

49

2990mm(9' 10")

700mm(28")


49

3090mm(10' 2")

800mm(32")


49

3190mm(10' 6")

Standard

800mm(32")


49

3190mm(10' 6")

Standard

600mm(24")


49

3395mm(11' 2")

700mm(28")


49

3495mm(11' 6")

800mm(32")

0.38kgf/cm (5.40psi)

49

3595mm(11' 10")

ö710mm(28")


49

3505mm(11' 6")

Standard R210LC-7 R210LC-7 LONG REACH

Option

R210LC-7 HIGH WALKER

Option

2

ö : Double grouser.

10) BUCKET Capacity

Item

SAE heaped

CECE heaped

0.92m (1.20yd )

0.80m3(1.05yd3)

5

1150mm(45.3")

1270mm(50.0")

0.51m3(0.67yd3)

0.45m3(0.59yd3)

3

700mm(27.6")

820mm(32.3")

0.80m (1.05yd )

0.70m (0.92yd )

5

1000mm(39.4")

1120mm(44.1")

1.10m3(1.44yd3)

0.96m3(1.26yd3)

5

1320mm(52.0")

1440mm(56.7")

1.20m (1.57yd )

1.00m (1.31yd )

6

1400mm(55.1")

1520mm(59.8")

1.34m3(1.75yd3)

1.15m3(1.50yd3)

6

1550mm(61.0")

1670mm(65.7")

ľ0.74m (0.97yd )

0.65m (0.85yd )

5

985mm(38.8")

ľ0.90m3(1.18yd3)

0.80m3(1.05yd3)

5

1070mm(42.0")

ľ1.05m (1.37yd )

0.92m (1.20yd )

5

1290mm(50.8")

Ľ0.87m3(1.14yd3)

0.75m3(0.98yd3)

5

1140mm(44.9")

Ľ1.20m (1.57yd )

1.00m (1.31yd )

5

1410mm(55.5")

Ŀ0.75m3(0.98yd3)

0.65m3(0.85yd3)

-

1790mm(70.5")

3

STD

3

3

3

3

R210LC-7

Width Tooth quantity Without side cutter With side cutter

OPT

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

ľ : Heavy duty bucket Ľ : Rock bucket(Heavy) Ŀ : Slope finishing bucket

2-25

Sample pages



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 ÂBoom cylinder tube end ÂBoom foot ÂBoom cylinder rod end ÂArm cylinder tube end ÂArm cylinder rod end ÂBoom + Arm connecting ÂBucket cylinder tube end ÂBucket cylinder rod end ÂArm + Bucket connecting ÂArm + Link, Bucket control ÂBucket control rod

6-11

Sample pages



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 ÂSprocket mounting bolts ÂTravel motor mounting bolts ÂSwing motor mounting bolts ÂSwing bearing mounting bolts ÂEngine mounting bolts ÂCounterweight mounting bolts ÂTurning joint locating bolts ÂTrack shoe mounting bolts and nuts ÂHydraulic 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

ø Return filter

Replace

6-31

ø Pilot line filter

Replace

6-32

ø Air breather element

Replace

6-32

ø Drain cartridge filter

Replace

6-32

ø 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

Sample pages




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

øEngine oil

Change

6-18, 19

øEngine 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 ÂSprocket mounting bolts ÂTravel motor mounting bolts ÂSwing motor mounting bolts ÂSwing bearing mounting bolts ÂEngine mounting bolts ÂCounterweight mounting bolts ÂTurning joint locating bolts ÂTrack shoe mounting bolts and nuts ÂHydraulic pump mounting bolts

7) INITIAL 500 HOURS SERVICE Check items Travel reduction gear oil


ø 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

Sample pages




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 øÂOil ÂSuction strainer Coolant

øChange oil every 600 hours of continuous hydraulic breaker operation.

6-14

Sample pages



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

ÂWater separator(~#3341)

Drain or Replace

6-26

ÂPrefilter(#3342~)

Clean or Replace

6-26

ÂFuel filter element

Replace

6-26-1

ÂEngine oil

Change

6-18, 19

ÂEngine oil filter

Replace

6-18, 19

ÂCoolant

Add or Change

6-20, 21, 22, 23

ÂRadiator

Clean or Flush

6-20, 21, 22, 23

Check

6-23

Replace

6-25

ÂHydraulic oil

Add or Change

6-30

ÂReturn filter

Replace

6-31

ÂDrain line filter

Replace

6-32

ÂPilot line filter

Replace

6-32

ÂElement of breather

Replace

6-32

Clean

6-31

Check, Adjust

6-35

ÂTooth

Replace

6-37

ÂSide cutter

Replace

6-37

Adjust

6-36

Replace

6-36

Clean, Replace

6-43

Clean

6-44

Check items Fuel system ÂFuel tank

Engine lubrication system

Engine cooling system

ÂCharge air cooler Engine air system ÂAir cleaner element Hydraulic system

ÂSuction strainer Under carriage ÂTrack tension Bucket

ÂLinkage ÂBucket assy Air conditioner and heater ÂFresh filter ÂRecirculation filter

6-15

Sample pages



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

13036MI29

2) BATTERY (1) Check and repair Η Check the electrolyte level and fill with distilled water to the prescribed level as necessary. Θ 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. ö 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

20Á C (68Á F)

10Á C (50Á F)

-10Á C (14Á 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

Sample pages



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 ö Use the same capacity of battery for starting. Η Make sure that the starting switches of the normal machine and trouble machine are both at the OFF position. Θ Connect the red terminal of booster cable to the battery (+) terminal between exhausted and new battery. Ι Connect the black terminal of the booster cable between new battery (-) terminal and chassis of trouble machine. ö Keep firmly all connection, the spark will be caused when connecting finally.

Connection of booster cable Red Ι

Η

Θ

Trouble(Exhausted) Normal(New) machine machine Black Κ To chassis of trouble machine

Connection order : ΗĄΘĄΙĄΚ 13036MI33

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

(3) Taking off the booster cable Η Take off the booster cable(black). Θ Take off the booster cable(red) connected to the (+) terminal. Ι 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. ö Charge the battery in the well ventilated place. ö Place the machine on the earth or concrete. Avoid charging the machine on the steel plate. ö 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 Ι

Θ

Η

Trouble(Exhausted) Normal(New) machine machine Black Κ To chassis of trouble machine

Disconnection order : ΚĄΙĄΘĄΗ

13036MI33

Sample pages


(4) Welding repair Before start to welding, follow the below procedure. Η Shut off the engine and remove the starting switch. Θ Disconnect ground cable from battery by master switch. Ι 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). Κ Connect the earth(ground) lead of the welding equipment as close to the welding point as possible. ö 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.


Y

R

G

7

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

I

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


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

Sample pages



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

2

A

(4) Loosen the drain plug under the hydraulic tank and drain the oil from the hydraulic tank. ・ Hydraulic tank quantity : 180ℓ

1

A

(5) Remove socket bolts(74) and disconnect pipe(9).

72

3

(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

3

A

64 a4 1

i1

m

P

P

(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.

r

D

v

Ps

71

3 B

49

P i2 2

m

P

48 78

8-7

21078DA02

Sample pages


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. ① Remove the air vent plug(2EA). ② Tighten plug lightly. ③ Start the engine, run at low idling, and check oil come out from plug. ④ 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


Sample pages



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



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



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

B

Hexagon socket head bolt

PT plug (PT thread)

PO plug (PF thread)

Hexagon socket head setscrew

Allen wrench

4

M 5

BP-1/16

-

M 8

5

M 6

BP-1/8

-

M10

6

M 8

BP-1/4

PO-1/4

M12, M14

8

M10

BP-3/8

PO-3/8

M16, M18

17

M20, M22

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

-

B

Double ring spanner, socket wrench, double(Single) open end spanner B

BP-1

-


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. 10×8×200

Torque wrench

Capable of tightening with the specified torques

8-11

Sample pages



(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

kgf・m

lbf・ft

in

mm

M 5

0.7

5.1

0.16

4

M 6

1.2

8.7

0.20

5

M 8

3.0

21.7

0.24

6

M10

5.8

42.0

0.31

8

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

4

PT 1/8

1.05

7.59

0.20

5

PT 1/4

1.75

12.7

0.24

6

PT 3/8

3.5

25.3

0.31

8

PT 1/2

5.0

36.2

0.39

10

PF 1/4

3.0

21.7

0.24

6

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



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



(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

Sample pages



(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

Sample pages



4) ASSEMBLY (1) For reassembling reverse the disassembling procedures, paying attention to the following items. ① Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. ② Clean each part fully with cleaning oil and dry it with compressed air. ③ Do not fail to apply clean working oil to sliding sections, bearings, etc. before assembling them. ④ In principle, replace seal parts, such as O-rings, oil seals, etc. ⑤ For fitting bolts, plug, etc., prepare a torque wrench or so on, and tighten them with torques shown in page 8-11, 12. ⑥ 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


(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.


(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

Sample pages



(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

Sample pages



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

875

874

755 A

897

858

B

614

612

615 613 A

611

B

647 648

KR3G-9C32

A

P2 Pf

723 642

438 801

801

Pm Pi

924 641

730

643

708

644

645

646

728

B

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

413

438

656

438 735 722

496

724

725

436

VIEW C

8-19

Sample pages



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)

Sample pages



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


PT plug (PT thread)

PO plug (PF thread)

Hexagon socket head setscrew

4

M 5

BP-1/16

-

M 8

5

M 6

BP-1/8

-

M10

6

M 8

BP-1/4

PO-1/4

M12, M14

-

Hexagon head bolt

Hexagon nut

VP plug (PF thread)

6

M 8

M 8

-

B

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

4×100mm

Torque wrench

Capable of tightening with the specified torques

Pincers

-

Bolt

M4, Length : 50mm

8-21

Sample pages



(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

kgf・m

lbf・ft

in

M 5

0.7

5.1

0.16

4

M 6

1.2

8.7

0.20

5

M 8

3.0

21.7

0.24

6

M10

5.8

42.0

0.31

8

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

4

PT 1/8

1.05

7.59

0.20

5

PT 1/4

1.75

12.7

0.24

6

PT 3/8

3.5

25.3

0.31

8

PT 1/2

5.0

36.2

0.39

10

PF 1/4

3.0

21.7

0.24

6

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



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

Sample pages


(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.


(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

Sample pages



(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


(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


Sample pages



4) ASSEMBLY (1) For assembly, reverse disassembly procedures, but pay attention to the following items. ① Always repair parts that were scored at disassembly. ② 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. ③ Always tighten bolts, plugs, etc. to their specified torques. ④ Do not fail to coat sliding surfaces with clean hydraulic oil before assembly. ⑤ 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


(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


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



(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

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