Dx210wa (950106-01517e) 1412 SM en (#5001 - 2014) PDF

Shop Manual
DX210WA Excavator
Serial Number 5001 and Up
DOOSAN and the DOOSAN logo are registered

trademarks of DOOSAN Corporation in the United
States and various other countries around the 950106-01517E
world. November 2014
Copyright DOOSAN 2014 Original Instructions

1NOTICE
Date Contents Section No. Page
11/07/2014 1st Edition

1Table of Contents
1 Safety 1 Wheel Excavator Maintenance Safety
2 Specifications 1 Specifications
3 General Maintenance 1 General Maintenance Instructions

2 Standard Torques
4 Engine -
5 Upper Structure 1 Cabin (Non-Rops)

2 Cabin (Rops)
3 Counterweight
4 Hydraulic Oil Tank
5 Fuel Tank
6 Main Pump
7 Drive Coupling (Main Pump)
8 Main Control Valve
9 Swing Device
10 Joystick Valve (Work Lever)
11 Gear Pump (Brake and Steering)
12 Brake System
13 Brake Filter
14 Brake Supply Valve
15 Brake Pedal Valve
16 Accelerator Pedal Valve
17 Accumulator (Brake and Pilot)
18 Steering System
19 Steering Valve
20 Priority Valve
21 Dozer Joystick Valve
22 Solenoid Valve (3 Functions)
24 Gear Pump (Rotating)
25 One Spool Valve (Rotating)
Table of Contents
Page I
6 Lower Structure and Chassis 1 Swing Bearing
2 Front Axle
3 Rear Axle
4 Center Joint
5 Travel Motor
6 Driveshaft
7 Transmission
7 Front 1 Boom and Arm

2 Bucket
3 Cylinders
8 Hydraulic System 1 Hydraulic System

2 Hydraulic System Testing and Adjustment
9 Electrical System 1 Electrical System
10 Options 1 One Way

2 Two-way
3 Rotating
4 Quick Coupler
11 Schematic 1 Hydraulic Schematic/Electrical Schematic
Table of Contents
Page II
1Safety
Wheel Excavator
Maintenance
Safety
Edition 1
DX210WA Wheel Excavator Maintenance Safety

1-1-1
MEMO
Wheel Excavator Maintenance Safety DX210WA

1-1-2
Table of Contents
Wheel Excavator Maintenance Safety

Safety Instructions ..........................................1-1-5
Safety Messages ............................................1-1-5
General ...........................................................1-1-6
Transportation ..............................................1-1-19
Operation ......................................................1-1-21
Maintenance .................................................1-1-39
Environment and Circumstances..................1-1-53

1-1-3
MEMO

1-1-4
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
SAFETY MESSAGES
Replace with Safety Messages Section on pages III and IV in
the Doosan Operation & Maintenance Manual.

1-1-5
GENERAL
Safe Operation is Operator's Responsibility

Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of
drugs or alcohol. An operator who is taking prescription
drugs must get medical advice to determine if he or she
can safely operate a machine.
• When working with other personnel on a work site, be sure
that all personnel know nature of work and understand all
hand signals that are to be used.
• Be sure that all guards and shields are installed in their
proper location. Have guards and shields repaired or
replaced immediately if damaged.
• Be sure that you understand the use and maintenance of
all safety features such as safety lever and seat belt. Use
them properly.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of underground
and overhead utility lines before excavating.
• Failure to use and maintain safety features according to
instructions in this manual, Safety Manual and Shop
Manual can result in death or serious injury.
Know Your Machine

Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.

1-1-6
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in this
manual. Because DOOSAN cannot anticipate, identify or test all
attachments that owners may want to install on their machines,
contact DOOSAN for written authorization and approval of
attachments, and their compatibility with optional kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure FG018457
to do so can result in death or serious injury. Figure 1
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.

1-1-7
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Flying or Falling Objects

On work sites where there is a potential hazard that flying or
falling objects can hit operator's cabin, select and use a guard to
match operating conditions for additional operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on available protective
guards. HAOA110L
Figure 2
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA100L
Figure 3

1-1-8
Personal Protective Equipment (PPE)
Do not wear loose clothing and accessories. Secure long hair.
These items can snag on controls or on other parts of
equipment.
Do not wear oily clothes. They are highly flammable.
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries. Breathing masks and/or ear protection may
HAOA020L
be required.
Figure 4
Wear a hard hat, safety shoes, safety goggles, mask, leather
gloves, earplugs and other protective equipment, as required.
While working on machine, never use inadequate tools. They
could break or slip, or they may not adequately perform intended
functions.
Correction of Machine Problems

If any machine problems are found during operation and
maintenance (noise, vibration, smell, incorrect gauges, smoke,
oil leakage, etc.), or if any abnormal warning alerts are displayed
on display monitor, stop the machine and take the necessary
corrective actions. Do not operate machine until problem has
been corrected.
Crushing and Cutting

Keep objects away from moving fan blades. Fan blades can
throw and cut objects.
Do not use a wire rope that is kinked or frayed, or a wire rope
with any loss of diameter. Wear leather gloves when handling a
wire rope.
When striking a loose retainer pin, it can fly out and can cause a
serious injury. Make sure that area is clear of personnel when
striking a retainer pin. To avoid injury to your eyes, wear safety
goggles when striking a retainer pin.
Do not put your hand, arm or any other part of your body
between movable parts. If going between movable parts is
necessary, always position and secure work equipment so it
cannot move. Properly support equipment before performing
any work or maintenance under raised equipment.
If control levers are operated, clearance between machine and
work equipment will change and this may lead to serious
damage or can result in death or serious injury. Stay clear of
areas that may have a sudden change in clearance with
machine movement or equipment movement. Stay clear of all
rotating and moving parts. Unless instructed, never attempt
adjustments while machine is moving or while engine is running.

1-1-9
Do not depend on hydraulic cylinders to support raised
equipment. Equipment can fall if a control is moved, or if a
hydraulic line breaks, is loosened or disconnected.
If it is necessary to remove guards to perform maintenance,
always install guards after maintenance is completed.
HDO1010L
Figure 5
Hot Coolant and Oils - Burn Prevention

Do not touch any part of an operating engine. Immediately after
operations are stopped, coolant, engine oil, and hydraulic oil are
at their highest temperatures. The radiator and hydraulic tank
are still under pressure. Always wait for temperature to cool
down. Attempting to remove caps, drain oil or coolant, or
replacing filters may lead to serious burns, if done when hot.
Relieve all pressure in air system, hydraulic oil system,
lubrication system, fuel system, and cooling system, before any
lines, fittings or related items are disconnected. FG019095
Figure 6
To prevent hot oil or coolant from spraying out, stop engine, wait
for oil and coolant to cool. Using gloves, slowly loosen cap to
relieve pressure.
FG019096
Figure 7

1-1-10
Fire and Explosion Prevention
All fuels, most lubricants and some coolant mixtures are
flammable and can cause a fire resulting in death or serious
injury, and property damage. Flammable fluids that are leaking
or spilled onto hot surfaces or onto electrical components can
cause fire.
Inspect for and remove all flammable materials such as spilled
fuel and oil, and debris from machine. Do not allow any
flammable materials to accumulate on machine.
HDO1015I
Always observe the following:
Figure 8
• Add fuel, oil, antifreeze and hydraulic fluid to machine only

in a well ventilated area. Machine must be parked with
controls, lights and switches turned "OFF". Engine must be
"OFF" and any flames, glowing embers, auxiliary heating
units or spark causing equipment must be extinguished, or
turned "OFF" and kept well clear of machine.
• Dust that is generated from repairing or grinding
nonmetallic hoods or nonmetallic fenders can be toxic,
flammable and explosive. Repair these components in a
well ventilated area away from flames or sparks and wear
dust mask when grinding painted parts. FG018458
Figure 9
Maintenance
The machine and some attachments have components that are
at high temperatures under normal operating conditions. The
primary source of high temperatures are the engine and exhaust
system. If damaged or incorrectly maintained, the electrical
system can be a source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it can
cause a fire hazard. Clean machine often to avoid this
accumulation. Flammable debris in an engine compartment is a
potential fire hazard.
The operator's area, engine compartment and engine cooling
system must be inspected every day and cleaned. This is
necessary to prevent fire hazards and overheating.
Operation
Do not use machine where exhaust, arcs, sparks or hot
components can contact flammable material, explosive dust or
gases.
Do not operate machine near any flame.
Exhaust shields (if equipped) protect hot exhaust components
from oil spray or fuel spray in case of a break in a line, hose, or
seal. Exhaust shields must be correctly installed.

1-1-11
Electrical
Check all electrical wiring and connections for damage daily.
Keep battery terminals clean and tight. Repair or replace any
damaged part or wires that are loose or frayed. Clean all
electrical connections and tighten all electrical connections.
Never check battery charge by placing a metal object across
terminal posts. Use a voltmeter or a hydrometer.
Battery gas can explode and can result in death or serious
injury. Follow procedures in this manual for connecting battery
and for jump-starting. Do not jump-start or charge a frozen or
damaged battery. Keep any flames or sparks away from
batteries. Do not smoke in battery charging area.
Improper jumper cable connections can cause an explosion that
can result in death or serious injury. Refer to “Starting Engine
With a Booster Cable” on page 3-12, for proper procedure in this
manual.
Do not charge a frozen battery. This can cause an explosion.
After market radios or other electric operated equipment in cabin
must have a fuse in the electrical circuit.
Hydraulic System
Check hydraulic tubes, hoses and fittings for damage, wear or
for leaks. Hydraulic lines and hoses must be properly routed and
have adequate support and secure clamps. Leaks can cause
fires. Never use a flame or bare skin to check for leaks.
Tighten or replace any parts that show leakage.
Check that all hose and tube clamps, guards, and cushions are
securely attached. If they are loose, they can vibrate during
operation and rub against other parts. This can cause damage
to hoses and cause high-pressure oil to spray on hot surfaces,
causing a fire and death or serious injury.
Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
EX1400129
Figure 10

1-1-12
Fueling
Use caution when you are refueling a machine.
Fuel is flammable and can catch fire if it is brought close to a
flame.
Stop engine and let it cool before adding fuel. Do not smoke
while you are refueling a machine. Do not refuel a machine near
flames or sparks. Fill fuel tank outdoors.
Keep fuel and other fluid reservoir caps tight and do not start
engine until caps have been secured.
Store fuels and lubricants in properly marked containers away
from unauthorized personnel. Store oily rags and any flammable
materials in protective containers.
Static electricity can produce dangerous sparks at fuel filling
EX1400130
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep tip of fuel nozzle in constant Figure 11
contact with neck of fuel filling nozzle, to provide a ground.
Always place plastic fuel containers on the ground before filling.
Never Use Ether Starting Aids

Do not use ether or starting fluids on any engine that has glow
plugs, or an electric grid type manifold heater. These starting
aids can cause an explosion and result in death or serious
injury.
Use procedures in this manual for connecting battery and for
jump-starting.
FG018458
Figure 12
Welding and Grinding

Always clean machine and attachment, set battery disconnect
switch to "OFF" position, and disconnect wiring from electronic
controllers before welding. Cover rubber hoses, battery and all
other flammable parts. Keep a fire extinguisher near machine
when welding.
Toxic dust or gas can be produced when grinding or welding
painted parts. Grinding or welding painted parts must be done in
a well ventilated area. Wear dust mask when grinding painted
parts.
Dust generated from repairing nonmetallic parts such as hoods,
fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away from
flames or sparks.
Do not weld on lines or on tanks that contain flammable fluids.
Do not flame cut lines or tanks that contain flammable fluid.
Clean any such lines or tanks thoroughly with a nonflammable
solvent before welding or flame cutting.

1-1-13
If a Fire Occurs
If a fire occurs:
• Do not attempt to move machine or continue operations.
• Turn starter switch to "O" (OFF) position to stop engine.
• Use handrails and steps to get off machine.
• Immediately call for help or fire station.
• When using a fire extinguisher, always aim extinguisher at
base of fire. FG018459
• If an optional fire extinguishing system is in place, be Figure 13
familiar with its operating procedures.
NOTE: Depending on job conditions, other procedures
could be necessary if a fire occurs.
Fire Extinguisher and First-Aid Kit

(Emergency Medical Kit)
To be prepared in the event of a fire:
• Be sure that fire extinguishers have been provided and
read labels to ensure that you know how to use them. It is
recommended that an appropriately sized (2.27 kg (5 lb) or
larger) multipurpose A/B/C fire extinguisher be mounted in
cabin. Check and service fire extinguisher at regular
intervals and make sure that all work site crew members
HDO1009L
are adequately trained in its use.
Figure 14
• Inspect fire extinguisher and service fire extinguisher
regularly.
• Follow instructions on extinguisher instruction plate.
• Keep a first aid kit in storage compartment (Figure 15) and
keep another kit at work site. Check kit periodically and
keep it properly supplied.
• Keep emergency numbers for doctor, ambulance service,
hospital and fire department readily available.
WE1400090
Figure 15

1-1-14
Electrical System and Electrical Shock
Never short across starter terminals or across batteries.
Shorting could damage electrical system and engine neutral
start system.
When engine is running or immediately after it has stopped, high
voltage is generated at injector terminal and inside engine
controller, so there is a potential for an electrical shock. Never
touch injector terminal or inside of engine controller.
NOTE: If it is necessary to touch injector terminal or inside
engine controller, contact your DOOSAN distributor.
Rollover Protective Structure (ROPS)

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and this can
result in death or serious injury. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and perform operations
without it.
• Never modify the operator's cabin by welding, grinding,
drilling holes or adding attachments unless instructed by
DOOSAN in writing. Changes to the cabin can cause loss
of operator protection from rollover and falling objects, and
result in death or serious injury.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to adequately protect the operator.
Contact your DOOSAN distributor if you have any
questions about the ROPS. Never repair a damaged
ROPS cabin.
• Always wear your seat belt when operating machine.

1-1-15
ROPS Certification
This DOOSAN excavator has an operator's cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 16) is found on the left side
of the cabin on most models. It may vary slightly in its location
on some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware EX1300529
if damaged. See your DOOSAN distributor for parts.
Figure 16
ROPS − Roll-over Protective Structure complies with
ISO 12117-2:2008, EN 13531:2001.
WARNING
Never modify the operator cabin by welding, grinding,
drilling holes or adding attachments unless instructed in
writing by DOOSAN. Changes to the cabin can cause loss
of operator protection from rollover and falling objects, and
can result in death or serious injury.

1-1-16
Protecting Cabin from Flying or Falling Objects (Optional)
In a work site where additional operator protection is necessary
from falling or flying objects, install adequate protective guards
on the cabin.
For breaker operation, install a front guard (1, Figure 17) and
apply a laminated coating sheet to front glass. Contact your
DOOSAN distributor for recommendations. 1
When performing demolition or cutting operation, install a front
guard and top guard.
Apply a protective laminated coating sheet to outside of front
window. This will prevent glass from being scratched by dust
when cleaning it or running wipers.
FG015809
Figure 17
When working in mines, quarries or other work sites where there

is a hazard of falling rocks, install Operator Protection Guard
(OPG) (2, Figure 18) and apply a laminated coating sheet to
front glass.
When OPG is installed, and front window needs to be cleaned,
loosen bolts marked with arrows (Figure 18). Be sure to tighten
bolts when done.
Never attempt to alter or modify any protective structure 2
reinforcement system, by drilling holes, welding, remounting or
relocating fasteners. Any serious impact or damage to system
requires a complete inspection of the structure. Reinstallation,
recertification and/or replacement of system may be necessary.
Contact your DOOSAN distributor for available safety guards
and/or recommendations to protect against objects that could
strike operator's cabin. Make sure that all other work site crew
members are kept away from excavator when operating.
If any glass on machine is broken, replace it with new glass
FG015810
immediately.
Figure 18
NOTE: The preceding instructions assume that conditions
are for standard operations, but it may be necessary
to add additional guards depending on operating
conditions or local rules or regulations for the work
site. Always contact your DOOSAN distributor for
advice.

1-1-17
Emergency Exit from Operator's Station
This machine is equipped with a glass breaking tool. It is found
on left pillar of cabin. This tool can be used to break the glass to
exit from cabin in an emergency. Grip handle firmly and use
sharp point to break glass.
• Be careful also not to slip on broken pieces of glass on
ground.
WARNING EX1300679
Figure 19
Protect your eyes when breaking the glass.

1-1-18
TRANSPORTATION
Obey State and Local Over-the-Road

Regulations
Check federal, state and local laws and regulations regarding
weight, width and length of a load before making preparations
for transporting on public roads or highways.
The hauling vehicle, trailer and load must be in compliance with
applicable regulations for the shipping route.
Partial disassembly of excavator may be necessary to meet
travel restrictions or particular conditions at work site. See Shop
Manual for information on partial disassembly.
Refer to “Transportation” on page 5-1, for information on
loading, unloading and towing.
The machine can be disassembled into parts for transporting.
Contact your DOOSAN distributor for assistance with
disassembly.
Loading and Unloading

To prevent machine tipping or rollover when loading or
unloading machine, always do the following:
• Perform loading and unloading only on firm and level
ground. Maintain a safe distance from edge of road or
drop-off.
• Never use work equipment to load or unload machine. The
machine may fall or tip over.
• Always use loading ramps of adequate strength and
capacity. Be sure that ramps are wide, and long enough to
provide a safe loading slope. Take steps to prevent ramps
from moving out of position or coming off.
• Clean ramp surfaces so they are free of grease, oil, ice and
loose materials. Remove dirt from machine tires, dozer,
outriggers and lower structure. On a rainy day, be careful
since ramp surfaces can be slippery.
• Turn auto idle selector button "OFF".
• Set machine travel speed to "LOW".
• "ENGAGE" swing lock to prevent upper structure from
moving.
• Run engine at low speed and travel slowly.
• When on ramps, do not operate any control lever except
for travel lever.
• Never correct your steering on ramps. If necessary, drive
off ramps, correct machine direction, then drive back onto
ramps.

1-1-19
• When driving up or down ramps, the center of gravity of
machine will change suddenly causing the tires to drop
down to the ramps or trailer. This will occur at the joint
between the ramps and trailer. Travel slowly over this
point.
• Cover the exhaust pipe to prevent turbocharger damage.
Lock the cabin door and lower the antenna.
• After loading, block each tire and secure the machine with
tie-downs of adequate load rating, so the machine cannot
move.
• For machines equipped with a cabin, always lock door
after loading machine to prevent door from suddenly
opening during transportation.
Transporting Machine
When transporting machine on a trailer or truck, do the following:
• The weight, transportation height, and overall length of
machine may change depending on work equipment
attached to it. Always check the machine dimensions and
work equipment's dimensions before transporting.
• When passing over bridges or structures on private land,
check that structure is strong enough to support weight of
machine. Before traveling on public roads, check with
appropriate authorities and follow their instructions.

1-1-20
OPERATION
Always make sure that the machine is properly maintained.
Before Engine Starting
Machine Condition
Every day before starting engine for first time, perform the
following checks and repair machine before operating, as
necessary. If these checks are not properly done death or
serious injury could result.
• Check coolant, fuel, and hydraulic tank oil levels, and
check for clogged air cleaner and damage to electrical
wiring.
• Check operation of gauges, cameras (if equipped) and
angle of mirrors, and check that safety lever is in LOCKED
position.
• Check that work equipment and travel controls move
freely, and work controls return to "NEUTRAL" when
released.
• Check that attachment is properly attached and locked.
IMPORTANT
Only use Ultra Low Sulfur Diesel (ULSD) fuel and API CJ-4/
ACEA E9 grade engine oil with this machine.
Make sure that the machine is equipped with a lighting system

that is adequate for job conditions and lights are working
properly.
Before moving machine, check position of lower structure. The
normal travel position is with dozer blade to front under cabin
and outriggers (stabilizers) to rear. When lower structure is
rotated in reversed position, directional or travel controls must
be operated in opposite directions.
Before performing checks, move machine to an area where
there are no obstructions, and operate slowly. Do not allow
personnel near machine.
Know maximum operating dimensions of your machine.

1-1-21
Work Site
Before starting operations, thoroughly check work area for any
hazards, such as underground utility lines, overhead electrical
lines, unstable ground, excessive slopes, etc.
Before starting engine and moving machine, make sure that no
one is underneath machine, around machine, or on machine.
Know width and length of your machine and work equipment to
maintain proper clearance when you operate machine or work
equipment near fences or near boundary obstacles.
Know appropriate work site hand signals and personnel that are DANGER
No Entry
authorized to give hand signals. Follow hand signals from only WE1400008
one person. Figure 20
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around work site.
Erect barricades or fences, post "No Entry" signs, and take other
steps to prevent people from coming close to or entering work
site. If people come too close to a moving machine, they may be
struck or caught by machine, and this can result in death or
serious injury.

1-1-22
Mounting/Dismounting
Before getting on or off machine, if there is any oil, grease, or
mud on handrails and steps, wipe it off immediately. Always
keep these parts clean. Repair any damage and tighten any
loose bolts.
Never jump on or off machine. In particular, never get on or off a
moving machine. These actions can result in death or serious
injury.
When getting on or off machine, always face machine. Maintain
three-point contact (both feet and one hand or one foot and both
hands) with handrails and steps to ensure that you support
yourself securely.
Never hold onto any control levers when getting on or off WE1400091
machine. Figure 21
Securely latch door. If you grip handrail inside door when

climbing on top and door latch is not securely engaged, door
may move and cause you to fall.
Use points marked by arrows in diagram when getting on or off
machine.
Do not carry tools or supplies when you mount or dismount the
machine.
WE1400092
Figure 22
EX1301113
Figure 23

1-1-23
Cleaning
Remove all straw, wood chips, leaves, grass, paper and other
flammable debris accumulated in engine compartment, mufflers
and around battery. Remove any dirt from window glass,
mirrors, handrails, and steps.
Do not leave tools or spare parts in operator's cabin. Vibration of
machine during operation can cause tools or spare parts to fall
and damage or break control levers or switches. Tools and
spare parts can also get caught in spaces between control
levers and cause accidental movement of work equipment
causing death or serious injury.
When entering operator's cabin, always remove all mud and oil
from your shoes. If you operate travel pedal with mud or oil stuck
to your shoes, your foot could slip off the control, or dirt and
debris may interfere with proper operation of control levers.
After using ashtray, make sure that any matches or cigarettes
are properly extinguished, and be sure to close ashtray.
Clean window glass and working lights for good visibility.
Do not stick suction pads to window glass. Suction pads act as a
lens and can cause fire.
Never bring flammable or explosive items into operator's cabin.
Do not leave cigarette lighters laying around operator's cabin. If
temperature inside operator's cabin becomes too high, there is a
potential hazard that lighter could explode.
Secure all loose items such as lunch boxes, and other items that
are not a part of equipment.
Operator Station
Inspect condition of seat belt and mounting hardware. Replace
any parts that are worn or damaged. Do not use a seat belt
extension on a retractable seat belt.
Adjust seat so full pedal travel can be achieved with operator's
back against back of seat.
Keep all windows and doors closed on machine.
Adjust operator's seat to a position where it is easy to perform
operations, and check that there is no damage or excessive
wear to seat belt or mounting clamps.
Adjust and clean mirrors so area to rear of machine can be seen
clearly from operator's seat.
When standing up from operator's seat, always place safety lock
lever securely in "LOCK" position. If you accidentally move work
equipment levers when they are not locked, the machine could
suddenly move and cause damage, death or serious injury.

1-1-24
Seat Belt
Check seat belt daily for correct function.
Inspect seat belt system more often if machine is exposed to
severe environmental conditions or applications. Conduct the
following inspections and replace seat belt system as
necessary:
1. Check webbing. If system is equipped with a retractor, pull
webbing completely out and inspect full length of webbing.
Look for cuts, wear, fraying, dirt and stiffness.
2. Check buckle and latch for correct operation.
3. Make sure latch plate is not excessively worn, deformed or
buckle is not damaged or casing is broken.
4. Check retractor web storage device (if equipped) by
extending webbing and checking that it spools out and
retracts correctly.
5. Check webbing in areas exposed to ultraviolet (UV) rays
from sun or extreme dust or dirt. If original color of webbing
in these areas is extremely faded and/or webbing is
packed with dirt, webbing strength may be reduced.
NOTE: Contact your DOOSAN distributor for seat belt
system replacement parts.
WARNING
Failure to properly inspect and maintain seat belt and
seat belt system can cause lack of operator restraint
and can result in death or serious injury.
Before fastening seat belt, check that there is no
problem in belt mounting bracket. If it is worn or
damaged, replace seat belt. Fasten seat belt so it is not
twisted.
Always wear seat belt when operating machine.

1-1-25
Visibility Information
A rear view camera (if equipped) and mirrors provide the
operator with additional means to see the work area.
NOTE: These devices may vary from one region to another,
depending upon local and regional regulations. If a
machine is moved or sold into another region or
marketplace, it is the owner's responsibility to make
sure it complies with all applicable regulations.
WARNING
Failure to check for and clear people from the surrounding
area of a machine can result in death or serious injury. The
operator should make sure that visual aids (mirrors and
camera(s)) are in proper working condition.
Your machine may be equipped with visual aids such as mirrors

or a rear view camera. Even with these aids, there still may be
areas around the machine which cannot be seen from the
operator's seat. Always keep personnel and bystanders out of
the work area. Be careful when operating and always look in
direction of travel.
Adjust visual aids for best visibility around machine.
When swinging work equipment or backing up, press camera
button (if equipped) to change display mode on display monitor
so you can check rear and side of machine.
Before moving machine, look around work site and use mirrors
and display monitor to confirm that no one is in the work area.
While operating or traveling in places with poor visibility it may
be impossible to confirm condition of work site. Inspect and
remove any obstacles around the machine that could be
damaged and keep other personnel out of the work area.
Inspect equipment and repair immediately if there are problems
with visual aids. If machine cannot be fixed immediately, DO
NOT use the machine. Contact your DOOSAN distributor and
arrange for repairs.
Work Site Rules

• If visibility cannot be sufficiently assured, use a flagman.
The operator should pay careful attention to signals and
follow instructions from flagman.
• Signals should only be given by one flagman.
• When working in dark places, turn "ON" work lights and
front lights on the machine. Set up additional lighting in
area.
• Stop operations if there is poor visibility, such as fog, snow,
rain, or sandstorms.

1-1-26
• Check mirrors and rear view camera (if equipped) on
machine before starting operations. Clean off any dirt and
adjust view for good visibility.
When operating or traveling during poor visibility conditions,
follow the preceding work site rules.
It may not be possible to adjust all visual aids to see all the way
around the machine. Therefore, additional precautions such as
flagman, barricades, etc., must be taken to keep other personnel
out of the work area.
Boost Starting or Charging Engine

Batteries
Follow these instructions to prevent an explosion or fire when
connecting booster cables to batteries:
• Turn "OFF" all electric equipment before connecting leads
to battery. This includes electric switches on battery
charger or battery booster equipment.
• When boost starting from another machine or vehicle do
not allow two machines to touch. Wear safety goggles and
gloves while battery connections are made.
• 24 volt battery units consisting of two series connected 12
volt batteries have a cable connecting one positive (+)
terminal on one of the 12 volt batteries to a negative (-)
terminal on the other battery. Booster or charger cable
connections must be made between the nonseries
connected positive (+) terminals and between the negative
(-) terminal of the booster battery and metal frame of the
machine being boosted or charged. The final booster cable
connection, at metal frame of the machine being charged
or boost started, must be as far away from the batteries as
possible. Refer to “Starting Engine With a Booster Cable”
on page 3-12, for proper procedure in this manual.
• Connect positive (+) cable first when installing cables and
disconnect negative (-) cable first when removing them.

1-1-27
Starting Engine
Only operate the machine from the operator's seat with your
seat belt fastened.
Only operate controls while engine is running.
Check for proper operation of all controls and all protective
devices while you operate the machine slowly in an open area.
• Check operation of work equipment, travel system and
swing system.
• Check for any problem with machine. Check for unusual
sounds, vibration, heat, odor, or improper readings from
gauges. Check for any oil or fuel leaks.
• If any problem is found, stop operation and perform repairs
immediately.
Do not use cellular telephones inside operator's cabin when
driving or operating the machine.
Figure 24
When operating the machine, do not extend your hands or head
out of window.
The boom and arm linkage can allow work tool or attachment to
contact lower structure or cabin. Be aware of position of work
tool.
• Do not attempt to start engine by short-circuiting engine
starting circuit. This can result in death or serious injury, or
fire.
• When starting engine, sound horn as a warning to alert
personnel in the work area.
If there is a warning tag or "DO NOT OPERATE" tag hanging
from work levers (joysticks) or travel control levers, do not start
engine or move levers.
• Prevent personnel from walking or standing under raised
boom, unless it is properly supported.
NOTE: When starting engine in cold temperatures, "white
engine exhaust smoke" from the tail pipe can occur
until engine reaches normal operating temperatures.
Also, a white residue, because of water vapor inside
engine, can form at the engine oil fill location. These
conditions will not affect engine performance or
damage the engine or other exhaust system
components.

1-1-28
Swinging or Traveling
As a machine operator, you should know and follow local, state
and federal laws and regulations when operating on public roads
or highways.
It is important to keep in mind that the machine, in comparison
with the rest of traffic, is a slow moving and wide vehicle which
can cause traffic delays. Pay attention to traffic behind you and
allow traffic to pass you.
Before operating the machine or work equipment, always
observe the following precautions to prevent death or serious
injury.
• Check all tires to make sure that they are properly inflated
and are not damaged.
• Make sure that all excess mud, stones, etc. has been
removed from the tires.
• Fully raise and secure all outriggers and the dozer blade.
NOTE: Be sure to "LOCK" the outriggers when
WE1400890
traveling.
Figure 25
• Make sure that upper structure is facing forwards with
dozer blade in front.
• Store the front attachment in the transport position and set
the function lock in the "TRAVEL" position.
• Set the ram cylinder toggle switch in the "UNLOCK"
position.
• Before moving the machine, make sure that swing lock pin
has engaged. This will prevent the machine from
accidentally rotating during traveling.
• When changing travel direction from forward to reverse or
from reverse to forward, reduce speed and stop machine
before changing travel direction.
• Sound horn to alert people in area.
• Check that there is no one in area around machine. There
are restricted visibility areas behind machine so, if
necessary, swing upper structure slowly to check that there
is no one behind machine before traveling in reverse.
• Before moving the machine, make sure that swing lock pin
is "ENGAGED". This will prevent the upper structure from
accidentally rotating while traveling.
• When operating in areas with poor visibility, designate a
flagman to direct work site traffic.
• Keep unauthorized personnel away from turning radius or
travel path of the machine.

1-1-29
Be sure to observe above precautions even if a travel alarm or
mirrors are installed.
• Check that travel alarm works properly and that mirrors are
clean, not damaged and properly adjusted.
• Always latch door and windows of operator's cabin in
position (open or closed).
• On work sites where there is a hazard of flying or falling
objects, or of objects entering operator's cabin, check that
door and windows are securely closed. Install additional
guards, if work site application requires them.
Never turn starter switch to "O" (OFF) position when traveling.
This can lead to a loss of steering control. Travel Position
Do not operate attachments while traveling.

Do not change selected travel mode (FAST/SLOW) while
traveling.
Never travel over obstacles or excessive slopes that will cause
machine to tilt severely. Avoid any slope or obstacle that can 30 - 50 cm (12 - 20 in.)
cause machine to tilt 10° or more to right or left, or 30° or more
from front to rear.
Do not operate steering controls suddenly. Work equipment can
hit ground and this can damage machine or structures in area.
When traveling on rough ground, travel at low speed, and avoid
sudden changes in direction.
Always operate within permissible water depth. Permissible WE1400012
water depth is up to bottom of axle housing. Figure 26
When passing over bridges or structures on private land, check

that structure is strong enough to support weight of machine.
Before traveling on public roads, check with appropriate
authorities and follow their instructions.
Never exceed maximum permitted load for bridges.
Always operate machine with dozer blade to front under cabin
and outriggers to rear.
Know permitted ground pressure. Ground pressure of the
machine may change depending on attachment and load.
Keep height and length of attachment in mind.

1-1-30
Lifting and Digging
When traveling on public roads or digging:
• Keep loads secure so they do not fall off bucket or
attachment while operating.
• Do not exceed maximum rated load for the machine.
Machine operation and stability will be affected when
center of gravity changes, caused by extended loads and
use of different attachments.
Always check the following before lifting loads or digging:
• Condition of ground support.
• Need for use of shoring equipment.
• Excavator configuration and attachments.
• Weight of load, lifting height and swing radius.
• Proper and secure rigging of load.
• Proper handling of suspended load.
• Need for additional barricades or other means to keep
bystanders away.
Always look at the load when swinging and keep bystanders
away. Keep load close to the machine for better stability before
traveling any distances or swinging load.
NOTE: Lifting capacity decreases as load is moved further
from the machine.
Lower outriggers and raise rear tires slightly off the ground for
better stability before digging or lifting loads.
NOTE: All lift charts are shown with the outriggers "UP" and
the dozer blade "UP".
WARNING
• Always lower outriggers so rear tires are slightly raised. WE1400013
Figure 27
• Do not suddenly lower, swing or stop work equipment.
Operate controls smoothly.
• Do not move bucket (or work tool) over other
personnel or work equipment. A load could fall or
attachment could hit other personnel or equipment
resulting in death or serious injury or property
damage.
• Keep bystanders away.
• Do not suddenly lower, swing or stop work equipment.
Operate controls smoothly.
• To prevent tipping or rollover when handling heavy loads,
the ram lock switch must be in the "LOCKED" position.

1-1-31
Operation on Slopes
If the machine has to be used on a slope, pile soil to make a
platform that will keep the machine as horizontal as possible.
Improper traveling on steep slopes could result in machine
0 cm
tipping, rollover or sliding down the slope. Always fasten your 20 ~ 3
seat belt.
When possible, operate machine up slopes and down slopes.
Avoid operating machine across slope.
On hills, banks or slopes, carry bucket approximately 20 ~ 30 cm
(8 - 12 in) above ground. In case of an emergency, quickly lower
bucket or work tool to ground to help stop machine.
Do not travel on grass, fallen leaves, or wet steel plates. Even
slight slopes can cause machine to slide down a slope. Travel at
low speed and make sure that the machine is always traveling 20 ~
30 c
directly up or down slope. m
Do not change travel direction on a slope. This could result in

tipping or sliding sideways of machine.
Improper operation when working on slopes can cause a tip
over. Use caution when swinging or operating work equipment
on slopes.
Do not swing work equipment from uphill side to downhill side
when bucket is loaded. This could cause machine to tip or
rollover.
In addition, lower bucket as far as possible, keep it pulled into
front, and keep swing speed as slow as possible. WE1400015
Figure 28
If the machine begins to slide down on a grade, immediately

dump load and turn the machine downhill.
Be careful to avoid any ground condition which could cause the
machine to tip. Tipping can occur when you work on hills, on
banks, or on slopes. Tipping can also occur when you cross
ditches, ridges, or travel over unexpected obstructions.
Keep the machine under control. Do not overload the machine
beyond capacity.
• When traveling up a steep slope, extend work equipment
to front to improve balance, keep work equipment WE1400014
approximately 20 ~ 30 cm (8 ~ 12 in) above ground, and Figure 29
travel at low speed.
• Do not turn on slopes or travel across slopes. Always go
down to a flat place to change position of the machine,
then travel backup the slope again.

1-1-32
Towing
To prevent death or serious injury when towing, always do the
following:
• Follow the instruction given in this manual.
• Use a wire rope of sufficient strength for towing.
• In the event of slipping into swampy ground or towing
heavy objects, use a wire rope to tow the machine as
shown in the illustration.
• Put wood blocks between the wire rope and the machine to
protect the machine and wire rope from damage.
• Only use the towing hole for light objects.
• Be sure to use shackles. Keep the cable horizontal,
straight, and parallel to the tires.
• Select the "LOW" travel mode. Slowly drive the machine
when towing.
• When performing preparation work for towing with two or
more personnel, determine signals to use and correctly
follow these signals.
FG022282
• Always attach wire rope onto left and right hooks and
Figure 30
secure in position.
• If engine on problem machine will not start or there is a
failure in brake system, always contact your DOOSAN
distributor.
• Never go between towing machine and towed machine
during towing operation.
• Do not perform towing on steep slopes, so select a place
where slope is gradual. If there is no place where slope is
gradual, perform operations to reduce angle of slope
before starting towing operation.
• When towing a machine, always use a wire rope with a
sufficient towing capacity.
• Do not use a wire rope that is kinked or frayed, or a wire
rope with any loss of diameter. Wear leather gloves when
handling a wire rope.
• Do not use lightweight towing hook for towing another
machine.
• Make sure that towing eyes and towing devices are
adequate for towing loads.
• Only connect wire rope to a drawbar or to a hitch.
• Operate the machine slowly and be careful not to apply
any sudden load to wire rope.

1-1-33
Attachment
Never let anyone ride on any work attachment, such as bucket,
crusher, grapple, or clamshell (grab bucket). This creates a falling
and crushing hazard, and can result in death or serious injury.
The clamshell, grapple, or magnet can swing in all directions.
Move work levers (joysticks) in a continuous motion. Failure to
move work levers (joysticks) in a continuous motion can cause
clamshell, grapple, or magnet to swing into cabin or into a
person in work area. This can result in death or serious injury.
EX1400133
• When using a fork or grapple, do not attempt to pick up an
Figure 31
object with its tips. This could damage the machine or cause
personal injury, if picked-up object slips off attachment.
• Do not use impact force of work equipment for demolition
work. This could damage work equipment, cause broken
materials to fly off or tipping. This could result in death or
serious injury.
• Do not use work equipment or swing mechanism to pull
load in any direction. This could cause the work equipment
to move suddenly if the load releases and can result in
death or serious injury.
Equipment Lowering with Engine Stopped

Before lowering any equipment with the engine stopped, clear
the area around the equipment of all personnel and bystanders.
The procedure to use will vary with the type of equipment to be
lowered. Keep in mind most systems use a high-pressure fluid
or air to raise or lower equipment. The procedure will cause
high-pressure air, or hydraulic pressure, or some other media to
be released to lower the equipment.
Engine Stop
Turn engine starter switch to "O" (OFF) position and remove
engine starter switch key.
Before lowering any equipment with engine stopped, clear area
around equipment of all personnel and bystanders. This
procedure will cause high-pressure air or hydraulic pressure to
be released to lower equipment.
Do not stop engine immediately after the machine has been
operated under load. This can cause overheating and
accelerated wear of engine components.
After the machine is parked, allow engine to run for five minutes
before stopping the engine. This allows hot areas of engine to
cool gradually.
• Do not leave operator's seat when there is a raised load.

1-1-34
Parking Machine
Avoid making sudden stops, or parking machine wherever it
happens to be at end of workday. Park machine on firm and
level ground away from traffic and away from high walls,
drop-offs and any area of potential water accumulation or runoff.
If parking on inclines is unavoidable, block tires tracks to prevent It digs
movement. Lower bucket or other working attachment into ground.
completely to ground, or to an overnight support saddle to Block
prevent unintended or accidental movement. Lower dozer blade
to ground, if equipped.
NOTE: Do not lower outriggers when parking. Make sure that
outriggers are "LOCKED" in place.
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that
passing traffic can see machine clearly. Park machine so Unlock
machine, flags, signs and fences do not obstruct traffic.
After front attachment has been lowered to an overnight storage
position and all switches and operating controls are in "OFF" Lock WE1400009
position, safety lock lever must be moved to "LOCK" position.
This will disable all pilot control functions. Figure 32
Always close door of operator's cabin and lock all equipment to

prevent any unauthorized person from operating the machine.
The hydraulic system remains pressurized, provided
accumulator, is charged even when engine is not running.
Accumulator pressure should decrease in a short time
(approximately one minute). While hydraulic system maintains a
charge, hydraulic work tools and machine controls remain
functional.
Machine movement will occur if any controls are moved. This
can result in death or serious injury. WE1400010
Always move hydraulic lockout control to "LOCK" position before Figure 33
stopping off engine or immediately after engine stops running.

1-1-35
Service Brake
WARNING
• Before excavating, apply parking brake and depress
the service brake pedal and "ENGAGE" the latch
mechanism to lock the service brake in the applied
position.
• "LOWER" the dozer blade and outriggers to the
ground before working.
• When finishing work or parking the machine always
"RELEASE" the service brake pedal to prevent
damage caused by overheating.
• Before starting work, always check the condition of
the service brakes. Service as necessary.

1-1-36
Preservation/Storing Machine
Perform the following if storing excavator for more than one
month.
Conditions Maintenance Required

Cleaning Pressure wash lower structure and axle assemblies. Inspect for damage or
loose or missing parts.
Lubrication Perform all daily lubrication procedures.
Apply a coating of light oil to exposed plated metal surfaces, such as hydraulic
cylinder rods, etc.
Apply a coating of light oil to all control linkages and control cylinders (control
valve spools, etc.)
Battery Turn "OFF" the battery disconnect switch.
Cooling System Inspect coolant recovery tank to make sure that antifreeze level in system is at
correct level.
Every 90 days, use a hydrometer to measure protection level of coolant. Refer to
“Antifreeze Concentration Tables” on page 4-105, to determine amount of
protection cooling system requires. Add coolant as required.
Hydraulic System Once a month, start engine and follow procedures in “Hydraulic System
Warm-up” on page 3-13, listed in this manual.
1. Complete the preceding steps.

2. Wash machine and touch up paint finish to avoid rusting.
3. Treat exposed parts with antirust agent, lubricate machine
thoroughly and apply grease to unpainted surfaces like
lifting and tilting cylinders etc.
4. Fill fuel tank and hydraulic oil tank to "FULL" marks.
5. Cover exhaust pipe (parking outside).
6. Make sure that coolant is at proper concentration for
expected lowest temperatures.
7. Park machine on level, firm ground where there is no risk
of freezing, landslide or flooding. Avoid parking machine on
a slope.
Keep in mind that theft and burglary risk can be minimized
by:
• Removing starter key when the machine is left
unattended.
• Locking doors and covers after working hours.
• Turning "OFF" electrical power with battery
disconnect switch.
• Park machine where risk of theft, burglary and
damage is minimized.
• Removing valuables from cabin such as cellular
phone, computer, radio and bags.
See “Long Term Storage” on page 3-83, for more information.

1-1-37
Check After Long-term Parking
• All oil and fluid levels.
• Tension of all belts.
• Air pressure.
• Air cleaner.
• Batteries and electrical connections.
• Lubricate all greasing points.
• Wipe off grease from piston rods.
• Inspect for signs of nests (i.e. birds, rodents, etc.)

1-1-38
MAINTENANCE
Improper operation and maintenance can result in death or
serious injury. Read manual and safety decals before operating
or maintaining the machine. Follow all instructions and safety
messages.
WARNING
Follow instructions before operating or servicing machine.
Read and understand the Operation & Maintenance Manual
and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and
failure to follow instructions can result in death or serious
injury.
• Never service DOOSAN equipment without instructions.

• Always lower bucket and blade to ground before doing any
maintenance.
• Use correct procedure to lift and support excavator.
• Cleaning and maintenance are required daily.
• Welding or grinding painted parts must be done in well
ventilated areas.
• Wear a dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Vent exhaust to outside when engine must be running for
service.
• Exhaust system must be tightly sealed. Exhaust fumes are
hazardous and can cause death or serious injury.
• Stop and allow engine to cool and clean engine of
flammable materials before checking fluids.
• Never service or adjust machine with engine running
unless instructed to do so in this manual.
• Avoid contact with leaking hydraulic fluid or diesel fuel
under pressure. It can penetrate skin or eyes.
• Never fill fuel tank while engine running, while smoking, or
when near open flame.
• Keep body, jewelry and clothing away from moving parts,
electrical contact, hot parts and exhaust.
• Wear eye protection to guard from battery acid,
compressed springs, fluids under pressure and flying
debris when engines are running or tools are used. Use
eye protection approved for welding.

1-1-39
• Lead-acid batteries produce flammable and explosive
gases.
• Keep arcs, sparks, flames and lighted tobacco away from
batteries.
• Batteries contain acid which burns eyes or skin on contact.
• Wear protective clothing. If acid contacts body, flush well
with water. For eye contact flush well and get immediate
medical attention from a physician familiar with this injury.
• The maintenance procedures which are given in this
manual can be performed by the owner or operator without
any specific technical training. Maintenance procedures
which are not in this manual must be performed ONLY BY
QUALIFIED SERVICE PERSONNEL. Always use genuine
DOOSAN replacement parts.
• Only authorized personnel should service and repair the
machine. Do not allow unauthorized personnel into work
area.
• Lower work equipment and stop engine before performing
maintenance.
• Park machine on firm and level ground.
• Turn starter switch to "ON' position and keep safety lock
lever in "UNLOCK" position. Cycle work levers (joysticks)
back and forth, left and right at full stroke 2 to 3 times to
eliminate remaining internal pressure in hydraulic circuit.
Then move safety lock lever to "LOCK" position.
• Check that battery relay is "OFF" and main power is shut
off. (Wait for approximately one minute after turning "OFF"
engine starter switch key and press horn switch. If horn
does not sound, the main power is shut off.)
• Put blocks fore and aft of each tire to prevent the machine
from moving.
• To prevent injury, do not perform maintenance with engine
running. If maintenance must be done with engine running,
perform maintenance with at least two workers and do the
following:
– One worker must always sit in the operator's seat and
be ready to stop engine at any time. All workers must
maintain contact with other workers.
– When maintenance operations are near fan, fan belt,
or other rotating parts, there is a potential hazard of
being caught in rotating parts. Keep hands and tools
away.
• Never drop or insert tools or other objects into rotating fan
or fan belt. Parts can break off and hit someone.
• Do not touch any control levers or control pedals. If any
control levers or control pedals must be operated, always
give a signal to other workers and instruct them to move
away.

1-1-40
• When performing maintenance of engine and you are
exposed to engine noise for long periods of time, wear
hearing protection while working.
• If noise from the machine is too loud, it can cause
temporary or permanent hearing problems.
• Do not smoke when you service an air conditioner or if
refrigerant gas is present.
• Inhaling fumes either from a flame or gas from or a
cigarette that has contacted air conditioner refrigerant can
cause death or serious injury.
• Never put maintenance fluids into glass containers.
Drain all liquids into a suitable containers.
• Unless instructed otherwise, perform maintenance with
equipment in servicing position. Refer to this manual for
procedure for placing equipment in servicing position.

1-1-41
Warning Tag
Alert others that service or maintenance is being performed by
attaching a "DO NOT OPERATE" warning tag to the operator's
cabin controls – and other machine areas, if required. Use of a
chain or cable to keep the safety lock lever in the fully lowered
"LOCK" position, complies with OSHA's lockout requirements.
"DO NOT OPERATE" warning tags, are available from your
DOOSAN distributor.
• Always attach "DO NOT OPERATE" warning tag to work
equipment control lever in the operator's cabin to alert EX1301177
others that you are performing service or maintenance on Figure 34
the machine. Attach additional warning tags on the
machine, if necessary.
Keep warning tags in tool box while it is not used. If there is
not tool box or in the owner manual storage pocket.
• If any other person starts engine, and operates control
levers or control pedals while you are performing service or
maintenance, it can result in death or serious injury.
Attach a "DO NOT OPERATE" warning tag to starter switch or to
controls before servicing or repairing equipment.
Warning tags are available from your DOOSAN distributor.
Cleaning
Clean machine before performing inspection and maintenance.
If inspection and maintenance are done when machine is dirty, it
will become more difficult to locate problems, and you could slip
on steps and work platform areas and injure yourself.
When washing machine, do the following:
• Wear shoes with nonslip soles to prevent slipping and
EX1400134
falling.
Figure 35
• Wear safety goggles and protective clothing when washing
machine with high-pressure steam or water.
• Do not spray water directly on electrical components
(sensors, connectors). If water gets into electrical system,
it can cause operation problems.
• Pick up any tools or hammers that are laying in workplace.
Wipe up any grease or oil to prevent slippery substances,
that can cause tripping or slipping.
• When cleaning cabin top window which is made of
polycarbonate material, use tap water. Avoid use of
organic solvents for cleaning, such as benzene, toluene or
methanol. These solvents can cause a chemical reaction
that will dissolve and damage the window.

1-1-42
Proper Tools and Clothing
Only use tools that are intended for the type of service to be
done. Metal pieces from low quality or damaged tools, such as
chisels or hammers, can break off and hit a service person in the
eyes or face causing serious injury.
HDO1037L
Figure 36
Disassembling Precautions
When using a hammer to remove pins, pins can fly out or metal
particles may break off. Always do the following:
• Hitting hard metal pins, bucket teeth, cutting edges or
bearings with a hammer, can cause metal pieces to break
or fly off resulting in serious injury. Always wear safety
goggles and leather gloves. Keep other personnel away.
Use of Lighting
When checking fuel, oil, battery electrolyte, window washer fluid,
or coolant, always use proper lighting equipment to prevent arcs
or sparks that could cause a fire or explosion resulting in death
or serious injury.
HDO1040L
Figure 37
Fire and Explosion Prevention

Fuels, most lubricants and some coolant mixtures are
flammable. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a fire resulting
in property damage or death or serious injury.
Store all fuels and all lubricants in properly marked and
approved containers and keep away from all unauthorized
personnel.
Store oily rags and other flammable material in a protective
HDO1015I
container.
Figure 38
Tighten all fuel and oil caps.
Do not smoke while you refuel machine or while you are in a
refueling area.

1-1-43
Do not smoke in battery charging areas or in areas that contain
flammable material.
Clean all electrical connections and tighten all electrical
connections. Check electrical wires daily for wires that are loose
or frayed. Tighten all loose, and repair or replace all frayed,
electrical wires before operating machine.
Remove all flammable materials and debris from the engine
compartment, exhaust system components and hydraulic lines.
Burn Prevention
When checking radiator coolant level, stop engine, let engine
and radiator cool down, then check coolant recovery tank. If
coolant level in coolant recovery tank is near upper limit, there is
enough coolant in radiator.
Using gloves, loosen radiator cap slowly to release internal
pressure before removing radiator cap.
If coolant level in coolant recovery tank is below lower limit, add
coolant.
Cooling system conditioner contains alkali which can cause
personal injury. Do not allow alkali to contact skin, eyes, or
mouth.
Allow cooling system components to cool before draining
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact skin.
Vent hydraulic tank only after engine has been stopped and
hydraulic tank is cool. Using gloves, slowly tilt hydraulic tank air
breather to relieve pressure.
Relieve all pressure in hydraulic oil system, in fuel system, or in
cooling system before disconnecting any lines, hoses, fittings, or
related components.
Batteries give off flammable fumes that can explode and start a HAAE1980
fire. Figure 39
Do not smoke while you are checking battery electrolyte level.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact skin or eyes.
Always wear safety goggles and face protection when working
with batteries.

1-1-44
Rubber That Contains Fluorides
Observe extra great care when it is suspected that you may
have to handle rubber that contains fluorides.
Certain seals which have to withstand high operating
temperatures (e.g. in engines, transmissions, axles, hydraulic
motors and pumps) may be made from rubber that contains
fluorides, which, when exposed to high heat (fire), forms
hydrogen fluoride and hydrofluoric acid. This acid is very
corrosive and cannot be rinsed or washed off from the skin. It
causes very severe burns which take a long time to heal.
It usually means that damaged tissue must be surgically
removed. Several hours may pass after contact with the acid,
before any symptoms appear and therefore one is not given any
immediate warning. The acid may remain on the machine parts
for several years after a fire.
If swelling, redness or a stinging feeling appears and one
suspects that cause may be contact with heated rubber that
contains fluorides, contact a medical doctor immediately. If a
machine, or part of a machine, has been exposed to fire or
severe heat, it must be handled by specially trained personnel.
In all handling of machines after a fire, thick rubber gloves and
protective goggles must be used.
The area around a part which has been very hot and which may
be made of rubber that contains fluorides must be
decontaminated by thorough and ample washing with limewater
(a solution or suspension of calcium hydroxide, i.e. slaked lime
in water). After the work has been completed, the gloves must
be washed in limewater and then discarded.

1-1-45
Rubber and Plastics
Polymer materials when heated, can form compounds that
create a health hazard and can harm the environment.
Scrapped rubber and plastic must never be burned. Extra
precautions must be taken when servicing machines that have
been in a fire or exposed to extreme heat.
If gas cutting or welding is to be done near such materials, the
following safety instructions must be followed:
• Protect the material from heat.
• Use protective gloves, protective goggles and an approved
respirator.
Waste Hazardous to the Environment

Painted parts or parts made of plastic or rubber which are to be
scrapped must never be burned, but must be taken care of by an
approved refuse handling plant.
Batteries, plastic objects and anything else which is suspected
of being dangerous to the environment must be taken care of in
an environmentally safe way.
Check List After Fire

When handling a machine which has been damaged by fire
or been exposed to intense heat, the following protective
measures must under all circumstances be followed:
Use thick, gloves made of rubber and wear goggles which are
certain to protect your eyes.
Never touch burned components with your bare hands, as there
is a risk that you may come into contact with melted polymer
materials. First wash thoroughly with plenty of limewater (a
solution or suspension of calcium hydroxide, i.e. slaked lime in
water).
As a precaution, seals (O-rings and other oil seals) should
always be handled as if they were made of rubber that contains
fluorides.
Treat skin, which is suspected of having touched burned rubber
that contains fluorides, with Hydrofluoric Acid Burn Jelly or
something similar. Seek medical advice. Symptom may not
appear until several hours afterwards.
Discard gloves, rags etc. which are suspected of having touched
burned rubber that contains fluorides.

1-1-46
Welding Repairs
When performing welding repairs, perform welding in a properly
equipped place. Repairs must be performed by a qualified
welder. Welding operations, can create potential hazards,
including generation of gas, fire, or electric shock. Never let an
unqualified welder do welding.
A qualified welder must do the following:
• To prevent battery explosion, turn battery disconnect
switch to "OFF" position.
• To prevent generation of gas, remove paint from location
of the weld.
• If hydraulic equipment, piping or component ports close to
them are heated, a flammable gas or mist could result in
an explosion or fire. To prevent this, protect and insulate
components from excessive heat.
• Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before welding on pipes or tubes, or
before flaming cut pipes or tubes, clean them thoroughly
with a nonflammable solvent. Make sure pressure inside
pipes or tubes does not cause a rupture of the component
parts.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover and insulate
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and make sure a fire
extinguisher is available.
Warning for Counterweight and Front

Attachment Removal
WARNING
Removal of the machine counterweight, front attachment or
any other part can affect the stability of the machine. This
could cause unexpected movement, and result in death or
serious injury.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed. Figure 40 WE1400011

1-1-47
Working on Machine
When performing maintenance operations on machine, prevent
tripping and falling by keeping area around your feet clean and
free of objects and debris. Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying around.
• Watch your step when walking.
• Never jump down from machine. When getting on or off
ARO1380L
machine, use steps and handrails, and maintain a
Figure 41
three-point contact (both feet and one hand or both hands
and one foot) to support yourself.
• If job requires it, wear protective clothing.
• To prevent injury from slipping or falling, when working on
hood or covers, never stand or walk on areas except areas
equipped with nonslip pads.
• If it is necessary to work under raised equipment or the
machine, support work equipment and machine securely
with blocks and stands strong enough to support weight of
work equipment and machine.
• Do not work under the machine if lower structure is lifted
off ground and the machine is supported only with work
equipment. If any control levers are moved, or there is
damage to hydraulic system, work equipment or the
machine will suddenly drop causing death or serious injury.
Lock Inspection Covers

When performing maintenance with inspection cover open, use
lock bar to secure cover and prevent accidental lowering of the
cover caused by wind or movement of the machine.

1-1-48
Accumulator
The pilot control system is equipped with an accumulator. For a
short period of time after engine has been stopped, accumulator
will store a pressure charge that allow hydraulic controls to be
activated. Activation of any controls will allow selected functions
to operate under force of gravity.
When performing maintenance on pilot control system, release
hydraulic pressure in system as described in “Handling of
Accumulator” on page 4-109.
The accumulator is charged with high-pressure nitrogen gas. If it
is improperly handled it can explode causing death or serious
injury. Always observe the following precautions:
• Do not drill or punch holes in accumulator or expose it to
any flames, fire or external heat source.
• Do not weld on accumulator.
EX1400135
• When performing disassembly or maintenance of Figure 42
accumulator, or when disposing of accumulator, charged
nitrogen gas must be properly released. Contact your
DOOSAN distributor for assistance.
• Wear safety goggles and leather gloves when working on
an accumulator. Hydraulic oil under pressure can
penetrate skin and result in death or serious injury. If fluid
enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Compressed Air
• When cleaning filters, radiator or other components with
compressed air, there is a hazard of flying particles that
can result in serious injury.
• Always wear safety goggles, dust mask, leather gloves,
and other protective devices.
Supports and Blocking for Work

Equipment
Do not allow weight or equipment loads to remain suspended
and unsupported.
Lower work group to ground before leaving operator's seat.
Do not use hollow, cracked or unsteady wobbling supports.
Do not work under any equipment supported only by a lifting
jack.
HDO1042L
Figure 43

1-1-49
High-pressure Lines, Tubes and Hoses
When inspecting or replacing high-pressure piping or hoses,
check to verify that pressure has been released from circuit.
Failure to release pressure can result in death or serious injury.
Release pressure as described in “Handling of Accumulator” on
page 4-109.
Always do the following:
• Wear eye protection and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized
components can be difficult to see but has enough force to
pierce skin and can result in death or serious injury. Always
use a piece of wood or cardboard to check for suspected
hydraulic leaks. Never use your hands or expose your
fingers. Wear safety goggles.
• Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install lines, tubes or hoses that
are bent or damaged.
• Make sure that all clamps, guards and heat shields are
correctly installed to prevent vibration, rubbing against
other parts, and excessive heat during operation.
EX1400129
• Replace hose or components if any of the following
problems are found: Figure 44
– Damage or leakage from hose end fitting.

– Wear, damage, cutting of hose covering, or wire
braiding is exposed on any hose.
– Cover portion is swollen in any section.
– The hose is twisted or crushed.
– Foreign material is embedded in hose covering.
– Hose end is deformed.
– Connection fittings are damaged or leaking.
NOTE: Refer to “Hose In-service Lifetime Limit
(European Standard ISO 8331 and
EN982 CEN)” on page 4-87, for additional
European regulations.
High-pressure is generated inside engine fuel lines when engine
is running. Before performing inspection or maintenance of fuel
line system, wait for at least thirty seconds after stopping engine
to let internal pressure drop and tip breather cap up to release
residual pressure.
Oil or fuel leaks from high-pressure hoses can cause fire or
improper operation, which can result in death or serious injury. If
any loose bolts are found, stop work and tighten to specified
torque. If any damaged hoses are found, stop operations
immediately and contact your DOOSAN distributor for
replacement parts.

1-1-50
Battery
Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and generates
hydrogen gas. Hydrogen gas is highly explosive, and improper
handling can cause death or serious injury, or fire. Do not allow
electrolyte to contact skin or eyes. Always wear safety goggles
and protective clothing when servicing batteries. Wash hands
after touching batteries and connectors. Use of acid-resistant
gloves is recommended. Always observe the following
precautions.
• Do not smoke or bring any flame near battery.
• When working with batteries, Always wear safety goggles,
protective clothing, and acid-resistant gloves.
• If you spill battery electrolyte on yourself or your clothes,
immediately flush area with water.
• If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and get
immediate medical attention from a physician familiar with
this injury.
• If you accidentally drink battery electrolyte, call a poison
prevention center immediately and get immediate medical
attention from a physician familiar with this injury.
• When cleaning top surface of battery, wipe it with a clean,
damp cloth. Never use gasoline, thinner, or any other EX1400136
organic solvent or detergent. Figure 45
• Tighten battery caps.
• If battery electrolyte is frozen, do not charge battery or start
engine with power from another source. This could cause
the battery to explode and start a fire.
• When charging battery or starting with power from another
source, let battery electrolyte thaw and check that there is
no leakage of battery electrolyte before starting operation.
• Always remove battery from machine before charging.
• Do not use or charge battery if battery electrolyte level is
below "LOW LEVEL" line. This can cause an explosion.
Periodically check battery electrolyte level and add distilled
water to bring electrolyte level to "FULL LEVEL" line.
• Before maintaining or working with batteries, turn starter
switch to "O" (OFF) position.

1-1-51
Since there is a potential hazard that sparks could be generated,
always do the following:
• Do not let tools, rings or other metal objects make any
contact between battery terminals. Do not leave tools or
other metal objects lying near battery.
• When disconnecting battery terminals, wait for
approximately one minute after turning engine starter
switch key to "O" (OFF) position, and be sure to disconnect
grounding terminal; negative (-) terminal first. Conversely,
when connecting them, begin with positive (+) terminal and
then grounding (-) terminal, Make sure that all terminals
are connected securely.
• Flammable hydrogen gas is generated when battery is
charged. Remove battery from machine, take it to a well
ventilated place, and remove battery caps, before charging
it.
• After charging, tighten battery caps securely.
• After charging, secure battery back in machine.
When repairing or welding electrical system, wait for
approximately one minute after turning engine starter switch key
"OFF". Then disconnect negative (-) terminal of battery to stop
flow of electricity.

1-1-52
ENVIRONMENT AND
CIRCUMSTANCES
Work Site Areas Requiring Extra Caution

• Do not operate too close to edge of a quay, ramp, etc.
• Do not operate too close to edge of a steep slope or
drop-off. Take care when working in a place where
machine may tip over.
• Do not operate on soft ground or near riverbanks that could
collapse or where ground may not support weight of
excavator.
• Observe changes in ground and traction conditions after a
rain or other changes in weather.
Digging Under an Overhang

Do not dig work face under an overhang. This can cause
overhang to collapse and fall on top of the machine.
• Do not perform overhead demolition work. This can cause
broken objects and debris to fall on top of machine causing
death or serious injury, or property damage.
WE1400031
Figure 46
Deep Digging
Do not perform deep digging under front of machine. The ground
under machine may collapse and cause machine to fall resulting
in death or serious injury.
Working heavy loads on loose, soft or uneven ground, can cause
side load conditions resulting in a tip over and injury. Traveling
without a load or a balanced load may also be hazardous.
Never rely on lift jacks or other inadequate supports when work
is being done. Block tires fore and aft to prevent any movement.
WE1400032
Use machine only for its intended purpose. Using it for other
Figure 47
purposes will cause failures.
• Do not perform demolition work under machine. There is a
hazard that the machine may become unstable and tip
over.
• When working on or from top of buildings or other
structures, check if structure can support weight of
machine and attachment. If a building structure collapses,
this can cause death or serious injury.

1-1-53
Drop-off or Edge
When working at edge of an excavation or near a drop-off, the
machine could tip over, which can result in death or serious
injury. Always fasten your seat belt. Check ground conditions of
work site before operating to prevent the machine from falling or
rollover, and to prevent ground, stockpiles, or banks from
collapsing.
Do not travel too close to edge of a drop-off.
Poor Visibility
For good visibility, always do the following:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up additional
lighting at work site.
• Stop operations when visibility is poor, such as in fog, mist,
snow, and rain. Wait for visibility to improve before starting
operation.
To avoid hitting work equipment and damaging other property,
always do the following:
• When working in tunnels, on bridges, under electrical
wires, or when parking the machine or performing other
operations in places with limited height, be careful not to hit
and damage other equipment or property.
• To prevent hitting objects, operate machine at a slow
speed when working in confined spaces, indoors, or in
crowded areas.
• Do not swing bucket over the top of personnel or over
operator's cabin of dump truck.
Loose or Soft Ground

Do not operate on soft ground or near edge of drop-offs,
overhangs, and deep ditches. The ground can collapse because
of the weight of the machine causing the machine to fall or
rollover.
Check ground conditions before beginning work with the
machine. If ground is soft, reposition the machine before
operating.
The excavated material must not be dumped too close to edge.
How far away from edge of trench excavated material must be
dumped depends on soil type and moisture content. If loose clay
is being excavated, place it at least 5 m (16 ft) away from edge.
If excavated material is dumped too close to edge, its weight can
cause a landslide.
Thawing of frozen ground, rain, traffic, piling and blasting are
other factors which increase risk of landslide. The risk also
increases on sloping ground. If it is not possible to dig a trench
and adequately slope its sides, always install shoring equipment.
Loose ground may easily give way under weight of the machine.

1-1-54
When working on loose or unstable ground, it is important not to
dig too deep and to carefully reposition the machine. Do not
panic and do not raise bucket, if ground should begin to
collapse. Lower work equipment to improve stability of machine.
Never dig under machine, if there is a potential of causing a
landslide.
High-voltage Cables
Do not travel or operate machine near electrical cables or
overhead power lines. There is a hazard of electric shock, which
can cause property damage and result in death or serious injury.
The bucket or other attachment does not have to make physical
contact with power lines for current to cause an electrocution.
Use a spotter and hand signals to stay away from power lines
not clearly visible to operator. On work sites where machine may
operate close to electrical cables, always do the following:
WE1400033
• Remember that electrical voltage determines what the
Figure 48
minimum distance is to stay away from the power line. See
the following table for minimum distances when working
near electrical power lines. Electrical flashover can occur
and damage machine and cause death or serious injury.
Voltage Minimum Distance

6.6 kV 3 m (9' 10")
33.0 kV 4 m (13' 1")
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
• Always contact the power company responsible before

beginning work near high voltage power lines.

1-1-55
Underground Operation
If excavation is in an underground location or in a building, make
sure there is adequate overhead clearance, and adequate
ventilation.
Special equipment and engines may be required in some
countries. Contact your DOOSAN distributor for more
information.
Check that there is sufficient room for machine and load.
Move slowly.
Make sure that authorities or companies responsible for
underground cables, utilities, and electrical lines have been
contacted and that their instructions are followed. Also check
which rules apply to ground personnel regarding exposing
cables, utilities and electrical lines.
Consider all electrical cables as live. WE1400034
Figure 49
Working in Water
IMPORTANT
Do not exceed maximum permissible water depth. The
water level must not reach higher than bottom of the axle
housing.
After working in water, lubricate all lubrication points on lower

structure, which have been underwater so water is removed. 1 WE1400035
Check that no water has entered axles, transmission, Figure 50
driveshafts and other lower structure components.
Working in Contaminated Environment

When working within area which is contaminated or where there
is a health risk, check local regulations and contact your
DOOSAN distributor for assistance with identifying what
additional safety precautions need to be taken.

1-1-56
Operation in Extreme Conditions
Operation In Extreme Cold

In extremely cold weather, avoid sudden travel movements and
stay away from even slight slopes. The machine could slide
down the slope.
Snow accumulation could hide potential hazards and slippery
surfaces.
Warming up engine for a short period may be necessary to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming boom or attachment could cause severe stress in
very cold temperatures. Reducing work cycle rate and workload
may be necessary.
If machine is to be operated in extremely cold weather
temperatures, certain precautions must be taken. The following
paragraphs detail checks to be made to be certain machine is
capable of operating at these temperatures.
1. Preheat the engine before start-up.
• Preheat the engine before start-up. Wait 3 to 4
seconds after preheating until voltage of the battery
return, and then actuate the starter switch.
2. Keep batteries fully charged to prevent freezing. If distilled
water is added to batteries, run engine at least one hour to
mix electrolyte solution.
When temperature drops below -10°C, efficacy of the
battery is reduced accordingly. Insulation of the battery
prevents reduction of efficacy, and supports improvement
of starting power of the starter.
WARNING
Explosion of the battery can cause death or serious
injury. Never attempt to directly heat the battery with
open fire.
3. Keep engine in good mechanical condition for easy starting

and good performance during adverse weather.
4. Use engine oil with proper specifications for expected
temperatures. Refer to “Table of Recommended
Lubricants” on page 4-21, in this manual or Shop Manual
for details.
5. Always keep the fuel tank fully filled after completion of the
operation. Always drain water from the fuel tank before and
after the operation. In addition, check the water separator,
and drain it if required. The fuel filter, if frozen, may
interrupt the flow of fuel. Periodically remove water from
the fuel tank, drain water from the filter, and replace the

1-1-57
filter upon regular basis. To prevent fuel from being
clogged because of formation of wax in fuel, make sure
that wax formation point of fuel is lower than atmospheric
temperature.
WARNING
Explosion of the fuel tank can cause death or serious
injury. Never attempt to directly heat the fuel tank with
open fire.
6. Lubricate entire machine according to “Lubrication and

Service Chart” on page 4-17, in this manual or lubrication
chart on machine.
7. Start engine and allow it to reach normal operating
temperature before operating.
• If mud and ice collects and freezes on any of moving
parts while machine is idle, apply heat to thaw frozen
material before attempting to operate machine.
• Operate hydraulic units with care until they have
reached a temperature which enable them to operate
normally.
• Check all machine controls and functions to be sure
they are operating correctly.
8. An extra outer air filter must be kept in operator's cabin to
replace element that could become iced and cause
restricted airflow to engine.
9. Clean off all mud, snow and ice to prevent freezing. Cover
machine with a tarp if possible, keep ends of tarp from
freezing to ground.
Operation in Extreme Heat

Continuous operation of machine in high temperatures can
cause machine to overheat. Monitor engine and hydraulic
system temperatures and stop machine to let it cool, when
necessary.
1. Make frequent inspections and services of fan and
radiator. Check coolant level in radiator. Check grilles and
radiator fins for accumulation of dirt, debris and insects
which could block cooling passages.
• Formation of scale and rust in cooling system occurs
more rapidly in extremely high temperatures. Change
antifreeze each year to keep corrosion inhibitor at full
strength.
• If necessary, flush cooling system periodically to
keep passages clear. Avoid use of water with a high
alkali content which increases scale and rust
formation.

1-1-58
2. Check level of battery electrolyte daily. Keep electrolyte
above plates to prevent damage to batteries. Use a slightly
weaker electrolyte solution in hot climates. Batteries
self-discharge at a higher rate if left standing for long
periods at high temperatures. If machine is to stand for
several days, remove batteries and store in a cool place.
IMPORTANT
Do not store acid type storage batteries near stacks of
tires. Acid fumes can damage rubber.
3. Service fuel system as directed in “Check Fuel Level” on

page 4-31 and “Check for Leaks in Fuel System” on
page 4-30, of this manual. Check for water content before
filling fuel tank. High temperatures and cooling off cause
condensation in storage drums.
4. Lubricate as specified in “Lubrication and Service Chart”
on page 4-17, in this manual or Lubrication Decal on
machine.
5. Do not park machine in sun for long periods of time. If
possible, park machine under cover to protect it from sun,
dirt and dust.
A. Cover machine if no suitable shelter is available.
Protect engine compartment and hydraulics from dirt
and debris.
B. In hot, damp climates, corrosion will occur on all parts
of machine and will be accelerated during rainy
season. Rust and paint blisters will appear on metal
surfaces and fungus growth on other surfaces.
C. Protect all unfinished, exposed surfaces with a film of
preservative lubricating oil. Protect cables and
terminals with ignition insulation compound.
Apply paint or suitable rust preventive to damaged
surfaces to protect them from rust and corrosion.
Operation In Dusty and Sandy Areas

Operation of machine can cause dust in almost any area.
However, when in predominantly dusty or sandy areas,
additional precautions must be taken.
1. Keep cooling system fins and cooling areas clean. Blow
out with compressed air, if possible, as often as necessary.
WARNING
Wear goggles when using compressed air to prevent
face or eye injury.

1-1-59
2. Use care when servicing fuel system to prevent dust and
sand from entering tank.
3. Service air cleaner at frequent intervals, check air
restriction indicator daily and keep dust cup and dust valve
clean. Prevent dust and sand from entering engine parts
and compartments as much as possible.
4. Lubricate and perform services outlined on current
lubrication chart on machine and “Lubrication and Service
Chart” on page 4-17. Clean all lubrication fittings before
applying lubricant. Sand mixed with lubricant becomes
very abrasive and accelerates wear on parts.
5. Protect machine from dust and sand as much as possible.
Park machine under cover to keep dust and sand from
damaging unit.
Operation in Rainy or Humid Conditions

Operation under rainy or humid conditions is similar to that as in
extreme heat procedures previously listed.
1. Keep all exposed surfaces coated with preservative
lubricating oil. Pay particular attention to damaged or
unpainted surfaces. Cover all paint cracks and chip marks
as soon as possible to prevent corrosive effects.
Operation in Saltwater Areas

Saltwater and saltwater spray is very corrosive. When operating
in saltwater areas, or in or around snow, observe the following
precautions:
1. When exposed to saltwater, dry machine thoroughly and
rinse with freshwater, as soon as possible.
2. Keep all exposed surfaces coated with preservative
lubricating oil. Pay attention to damaged paint surfaces.
3. Keep all painted surfaces in good repair.
4. Lubricate machine as prescribed on lubrication chart on
machine or “Lubrication and Service Chart” on page 4-17,
in this manual. Shorten lubricating intervals for parts
exposed to salt water.
5. Check operating controls to ensure proper functionality
and that they return to "NEUTRAL" when released.

1-1-60
Operation at High Altitudes
Operation instructions at high altitudes are the same as those
provided for extreme cold. Before operating at high altitudes,
engine fuel and air mixture may have to be adjusted according
to appropriate engine manual.
1. Check engine operating temperature for evidence of
overheating. The radiator cap must make a perfect seal to
maintain coolant pressure in cooling system.
• Perform warming-up operation thoroughly. If machine
is not thoroughly warmed up before control levers or
control pedals are operated, reaction of machine will
be slow.
• If battery electrolyte is frozen, do not charge battery
or start engine with a different power source. There is
a potential hazard that could cause a battery
explosion or fire.
• Before charging or starting engine with a different
power source, thaw battery electrolyte and check for
any leakage of electrolyte before starting.
Operation During Electrical Storms

During electrical storms, do not enter or exit machine.
• If you are off machine, keep away from machine until storm
passes.
• If you are in cabin, remain seated with machine stationary
until storm passes. Do not touch controls or anything
metal.
Exhaust Ventilation
Engine exhaust gases can cause unconsciousness, loss of
alertness, judgment and motor control. This can result in death
or serious injury.
Make sure there is adequate ventilation before starting engine in
any enclosed area.
Check for and be aware of any open windows, doors or
ductwork where exhaust may be carried, or blown by wind,
exposing others to hazardous exhaust gases.
ARO1770L
Figure 51
Ventilation for Enclosed Area
If it is necessary to start engine within an enclosed area, or when
handling fuel, flushing oil, or paint; open doors and windows to
ensure that adequate ventilation is provided to prevent gas
poisoning.
Diesel engine exhaust contains products of combustion which
can be harmful to your health.
Always run engine in a well ventilated area. If you are in an
enclosed area, vent exhaust to outside.

1-1-61
Asbestos Information
WARNING
Avoid exposure to dust containing asbestos as it can cause
death or serious injury to the lungs and other organs
(mesothelioma, lung and other cancers, and asbestosis).
Asbestos dust can be HAZARDOUS to your health if it is inhaled.

Materials containing asbestos fiber can be present on work sites.
Breathing air that contains asbestos fiber can ultimately cause
serious or fatal lung damage or diseases such as mesothelioma,
lung and other cancers, and asbestosis. To prevent lung damage
from asbestos fiber, observe the following precautions:
• Use an approved respirator that is approved for use in an
asbestos-laden atmosphere.
• Use water for cleaning to keep down dust.
• Always observe any regulations related to work site and
working environment.
• Avoid brushing or grinding materials that contain asbestos.
• A vacuum cleaner that is equipped with a high efficiency
particulate air filter can also be used.
• Comply with applicable laws and regulations for workplace.
• Stay away from areas that might have asbestos particles in
air.
Silica Dust Information
WARNING
Avoid exposure to dust containing crystalline silica
particles as it can cause serious injury to the lungs
(silicosis).
Cutting or drilling concrete containing sand or rock containing

quartz can result in exposure to silica dust. Do not exceed
Permissible Exposure Limits (PEL) to silica dust as determined
by OSHA or other work site rules, laws and regulations. Use a
respirator, water spray or other means to control dust. Silica dust
can cause lung disease and is known to the state of California to
cause cancer.

1-1-62
Disposal of Hazardous Materials
Physical contact with used motor oil or gear oil could create a
health risk. Wipe oil from your hands promptly and wash off any
remaining residue.
Used motor oil or gear oil is an environmental contaminant and
should only be disposed of at approved collection facilities. To
prevent pollution of environment, always do the following:
• Never dump waste oil in a sewer system, rivers, etc.
• Always put drained oil from your machine in approved, leak FG009156
proof containers. Never drain oil directly onto ground. Figure 52
• Obey appropriate laws and regulations when disposing of
harmful materials such as oil, fuel, solvent, filters, and
batteries.
Improperly disposing of waste can threaten environment.
Potentially harmful fluids must be disposed of according to local
regulations.
Use all cleaning solutions with care. Report all necessary
repairs.
Sound
Sound Level Information: Hearing protection may be needed
when machine is operated with an open operator station for
extended periods or in a noisy environment.
Sound pressure level (LpA) at operator position

(Measurement according to ISO 6396)
Sound power level (LwA) around the machine (Measurement
according to 2000/14/EC with applicable appendices and
measuring method according to ISO 6395)
Refer to Operation & Maintenance Manual.

1-1-63
Vibration
Hands and Arms: The weighted root mean square acceleration
to which hands and arms are subjected, is less than 2.5 m/s2.
Whole Body: The weighted root mean square acceleration to
which whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
Recommendations for Reducing Vibrations:
1. Select proper machine, equipment and attachments for a
particular application.
2. Replace any damaged seat with a genuine DOOSAN seat.
Keep seat properly maintained and adjusted.
• Adjust seat and suspension for weight and size of
operator.
• Inspect and maintain suspension and adjustment
mechanisms for seat regularly.
3. Check that the machine is properly maintained.
4. Operate controls smoothly when; steering, accelerating,
slowing down, loading, or moving attachments.
5. Adjust machine speed and travel path to reduce vibration
level.
• Slow down when traveling over rough terrain or long
distances.
• Avoid obstacles and rough terrain.
6. Keep machine on and maintain designated travel path
when traveling.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Use other machines to maintain the travel path for the
excavator.

1-1-64
1Specifications
Specifications
Edition 1
DX210WA Specifications
2-1-1
MEMO
Specifications DX210WA
2-1-2
Table of Contents
Specifications
General Description ........................................2-1-5
Component Locations.....................................2-1-6
Overall Dimensions ......................................2-1-10
One - Piece Boom ................................................... 2-1-10
Two - Piece Boom ................................................... 2-1-11
Working Range .............................................2-1-12
One - Piece Boom ................................................... 2-1-12
Two - Piece Boom ................................................... 2-1-14
General Specifications..................................2-1-16
Approximate Weight of Workload Materials..2-1-17
Performance Tests .......................................2-1-19
Purpose of Performance Tests................................ 2-1-19
Kinds of Tests.......................................................... 2-1-19
Performance Standards .......................................... 2-1-19
Precautions for Evaluation of Test Data.................. 2-1-19
Definition of "Performance Standard"...................... 2-1-19
Preparation for Performance Tests ..............2-1-20
The Machine............................................................ 2-1-20
Test Area................................................................. 2-1-20
Precautions ............................................................. 2-1-20
Make Precise Measurement.................................... 2-1-20
Operational Performance Standard Table ....2-1-21
Operational Performance Test .....................2-1-23
Hydraulic Cylinder Cycle Time ................................ 2-1-23
Driveshaft Revolution Speed................................... 2-1-25
Swing Speed ........................................................... 2-1-26
Swing Function Drift Check ..................................... 2-1-27
2-1-3
2-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Structure
• The Lower Undercarriage and Chassis Frame
• The Excavator Front-end Attachment
The following illustration identifies main components and their
locations. (See Figure 1 on page -6.)
2-1-5
COMPONENT LOCATIONS
20 21 1 2 3 4
11
10
15
17
18
19
13 5
14 6
12
16 9 8 7
Figure 1 WE1400820
Reference Reference
Description Description
Number Number
1 Cabin 12 Rim
2 Boom Cylinder 13 Wheel (Tire)
3 Boom 14 Front Axle
4 Arm Cylinder 15 Rear Axle
5 Arm 16 Chocking Cylinder
6 Bucket Cylinder 17 Transmission
7 Guide Link 18 Travel Motor
8 Push Link 19 Driveshaft
9 Bucket 20 Counterweight
10 Side Cutter 21 Hood
11 Tooth Point
2-1-6
FR
ON
T 1 2
WE1400821
Figure 2
Reference Reference
Number Number
1 Engine 4 Air Cleaner
2 Radiator 5 Main Pump
3 Precleaner 6 Muffler
2-1-7
FR
ON
T
8
5
10
Figure 3 1 WE1400822
Reference Reference
Number Number
1 Battery Water Separator & Pre Fuel Filter
7
2 Fuel Tank (Fuel Prefilter)
3 Hydraulic Oil Tank 8 Brake Filter
4 Pilot Filter 9 Suction Filter
5 Gear Pump (Brake and Steering) 10 Return Filter
6 Fuel Cap
2-1-8
FR
ON
1 T
WE1400823
Figure 4
Reference Reference
Number Number
1 Main Control Valve 4 Swing Bearing
Solenoid Valve 5 Swing Device
2 (Breaker, Forward, Reverse, Solenoid Valve
Boost, Cruise) 6
(Ram Lock, Inching, Pilot Cutoff)
3 Center Joint
2-1-9
OVERALL DIMENSIONS
One - Piece Boom
I A
E
D
H
G
F
L J K
B
WE1400783
Figure 1
5.6 m (18' 4") Boom

Dimension Description
3.0 m (9' 10") Arm 2.4 m (7' 10") Arm 2.75 m (9') Arm
A Shipping Length 9,400 mm (30' 10") 9,470 mm (31' 8") 9,420 mm (30' 11")
B Shipping Width 2,500 mm (8' 2")
C Shipping Height (Boom) 3,490 mm (11' 5") 3,200 mm (10' 6") 3,200 mm (10' 6")
D Height Over Cab 3,140 mm (10' 4")
Counter Weight Swing
E 2,750 mm (9')
Clearance
F Ground Clearance 350 mm (1' 2")
G Counter Weight Clearance 1,259 mm (4' 2")
H Engine Cover Height 2,485 mm (8' 2")
I Upper Housing Width 2,530 mm (8' 4")
J Wheel Base 2,850 mm (9' 4")
K, L Tread Width 1,914 mm (6' 3")
2-1-10
Two - Piece Boom
I A
E
D
H
G
F
L J K
B
WE1400784
Figure 2
5.4 m (17' 9") Boom

Dimension Description
2.4 m (7' 10") Arm
A Shipping Length 9,210 mm (30' 3")
B Shipping Width 2,500 mm (8' 2")
C Shipping Height (Boom) 3,140 mm (10' 4")
D Height Over Cab 3,140 mm (10' 4")
E Counter Weight Swing Clearance 2,750 mm (9')
F Ground Clearance 350 mm (1' 2")
G Counter Weight Clearance 1,259 mm (4' 2")
H Engine Cover Height 2,485 mm (8' 2")
I Upper Housing Width 2,530 mm (8' 4")
J Wheel Base 2,850 mm (9' 4")
K, L Tread Width 1,914 mm (6' 3")
2-1-11
WORKING RANGE
One - Piece Boom
F
G
D
G.L
L
H J C
K 2,500 mm
A
WE1400340
Figure 3
2-1-12
Boom Type 5.6 m (18' 4")
DIM. Arm Type 3.0 m (9' 10") 2.4 m (7' 10") 2.75 m (9')
Bucket Type (SAE) 0.86 m3 (1.12 yd3)
A Max. Digging Reach 9,985 mm (32' 9") 9,413 mm (30' 11") 9,715 mm (31' 10")
B Max. Digging Reach (Ground) 9,790 mm (32' 1") 9,210 mm (30' 3") 9,518 mm (31' 3")
C Max. Digging Depth 6,240 mm (20' 6") 5,640 mm (18' 6") 5,990 mm (19' 8")
D Max. Loading Height 7,260 mm (23' 10") 6,905 mm (22' 8") 7,035 mm (23' 1")
E Min Swing Radius 3,440 mm (11' 3") 3,385 mm (11' 1") 3,375 mm (11' 1")
F Max. Digging Height 10,040 mm (32' 11") 9,680 mm (31' 9") 9,790 mm (32' 1")
G Max. Bucket Pin Height 8,715 mm (28' 7") 8,360 mm (27' 5") 8,490 mm (27' 10")
H Max. Vertical Wall Depth 5,745 mm (18' 10") 5,050 mm (16' 7") 5,335 mm (17' 6")
I Max. Radius Vertical 6,250 mm (20' 6") 6,175 mm (20' 3") 6,335 mm (20' 9")
J Max. Depth to 2.5 m Line 6,060 mm (19' 11") 5,420 mm (17' 9") 5,795 mm (19')
K Min Radius 2.5 m Line 3,130 mm (10' 3") 3,115 mm (10' 3") 3,125 mm (10' 3")
L Min. Digging Reach 1,065 mm (3' 6") 1,720 mm (5' 8") 880 mm (2' 11")
d Bucket Angle 177°
2-1-13
Two - Piece Boom
F
G
G.L
H J C
K 2,500 mm
A
WE1400341
Figure 4
2-1-14
Boom 5.4 m (17' 9")
DIM. Arm 2.4 m (7' 10")
Bucket (PCSA) 0.86 m3 (1.12 yd3)
A Max. Digging Reach 9,370 mm (30' 9'')
B Max. Digging Reach (Ground) 9,180 mm (30' 1'')
C Max. Digging Depth 5,610 mm (18' 5'')
D Max. Loading Height 7,035 mm (23' 1')
E Min Swing Radius 3,185 mm (10' 5'')
F Max. Digging Height 10,545 mm (34' 7'')
G Max. Bucket Pin Height 9,090 mm (29' 10'')
H Max. Vertical Wall Depth 4,840 mm (15' 11'')
I Max. Radius Vertical 5,050 mm (16' 7'')
J Max. Depth to 2.5 m Line 5,505 mm (18' 1'')
K Min. Radius 2.5 m Line 831 mm (2' 9'')
L Min. Digging Reach -
d Bucket Angle 177°
2-1-15
GENERAL SPECIFICATIONS
Shipping Weight NON-ROPS 20,444 kg (45,071 lb)
ROPS 20,554 kg (45,313 lb)
Includes 10% fuel, 5,600 mm (18' 5") one-piece boom, 3,000 mm (9'10")
arm, 0.86 m3 (1.12 yd3) bucket and front outrigger & rear dozer.
Counterweight 3,800 kg (8,377 lb)
Upper Turntable Weight 7,350 kg (16,203 lb)
Lower (Below Swing Bearing) Weight 6,150 kg (13,558 lb)
Operating Weight NON-ROPS 19,9 tons (43,890 lb) with full fuel tank and operator
ROPS 20,0 tons (44,090 lb) with full fuel tank and operator
Major Component Weights Standard Boom 1,335 kg (2,943 lb)
Boom Cylinder 166 kg (366 lb)
Arm (Standard) 675 kg (1,488 lb)
Arm Cylinder 251 kg (553 lb)
Bucket (Standard) 775 kg (1,709 lb)
Bucket Cylinder 153 kg (337 lb)
Dozer (Standard) 850 kg (1,874 lb) each
Dozer Cylinder 90 kg (198 lb)
Outrigger Cylinder 75 kg (165 lb) each
Digging Forces:
Bucket Cylinder 149 kN or 15,188 kg (33,484 lb) - (with 3,000 mm arm)
Arm Cylinder 99.8 kN or 10,181 kg (22,445 lb) - (with 5,600 mm boom, 3,000 mm arm)
Fuel Tank Capacity 350 L (92.5 U.S. gal.)
Hydraulic System Capacity 300 L (79.2 U.S. gal.)
Bucket Heaped Capacity Range PCSA 0.66 ~ 0.86 m3 (0.86 ~ 1.13 yd3)
NOTE: Refer to the Load Weight, Bucket and Arm Length Compatibility
Table for information on which bucket sizes may be used safely with
which arm length, for load material weights.
Travel Dimensions:
Ground Clearance 350 mm (1' 2")
Wheel Base 2,850 mm (9' 4")
Dozer Blade Width x Height 2,500 mm x 6,200 mm (8' 2" x 2")
Tire Size (Std. Double) 8 x 10.0 - 20 -14PR
Transport Dimensions
Overall Length 9,400 mm (30' 10")
Overall Width 2,500 mm (8' 2")
Overall Height 3,490 mm (11' 5")
Transport Loading Ramp:
15° angle CAUTION: Refer to Transport Maximum Procedure for Safe
Allowable Slope
Shipping Instructions.
2-1-16
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or groundwater; settling
or compaction because of overhead weight and chemical or
industrial processing or changes because of thermal or
chemical transformations could all increase value of
weights listed in table.
Density Density Density Density

1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
401 kg/m3
Charcoal - - -
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size - - -
(729 lb/yd3)
449 kg/m3
Coke, foundry size - - -
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled - - -
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled - - -
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite - - -
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps - - -
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed - - -
(2,943 lb/yd3)
1,506 kg/m3
Cement, portland, DRY granular - - -
(2,583 lb/yd3)
1,362 kg/m3
Cement, portland, DRY clinkers - - -
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed - - -
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose - - -
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed - - -
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy - - -
(2,970 lb/yd3)
Gypsum, calcined, (heated, 961 kg/m3
- - -
powder) (1,620 lb/yd3)
2-1-17
Density Density Density Density
1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
1,522 kg/m3
Gypsum, crushed to 3 inch size - - -
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments - - -
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments - - -
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 - - -
(2,160 lb/yd3)
1,362 kg/m3
Limestone, graded 1-1/2 or 2 - - -
(2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed - - -
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine - - -
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock - - -
(2,160 lb/yd3)
929 kg/m3
Salt - - -
(1,566 lb/yd3)
529 kg/m3
Snow, light density - - -
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose - - -
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed - - -
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken - - -
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken - - -
(891 lb/yd3)
2-1-18
PERFORMANCE TESTS
Use operational performance test procedure to quantitatively
check all system and functions on the machine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational function by
comparing the performance test data with the standard
values.
2. According to the evaluation results, repair, adjust, or
replace parts or components as necessary to restore the
machine’s performance to the desired standard.
3. To economically operate the machine under optimal
conditions.
Kinds of Tests
1. Base machine performance test is to check the operational
performance of each system such as engine, travel, swing,
and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational
performance of each component such as hydraulic pump,
motor, and various kinds of valves.
Performance Standards
"Performance Standard" is shown in tables to evaluate the
performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that test data is correct, but also in
what range the test data is.
2. Be sure to evaluate the test data based on the machine
operation hours, kinds and state of work loads, and
machine maintenance conditions.
The machine performance does not always deteriorate as the
working hours increase. However, the machine performance is
normally considered to reduce in proportion to the increase of
the operation hours. Accordingly, restoring the machine
performance by repair, adjustment, or replacement shall
consider the number of the machine's working hours.
Definition of "Performance Standard"

1. Operation speed values and dimensions of the new machine.
2. Operational performance of new components adjusted to
specifications. Allowable errors will be indicated as
necessary.
2-1-19
PREPARATION FOR PERFORMANCE TESTS
Observe the following rules to perform performance tests
accurately and safety.
The Machine
1. Repair any defects and damage found, such as oil or water
leaks, loose bolts, cracks etc, before starting to test.
Test Area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run straight
more than 20 m (65 ft 7 in), and to make a full swing with
the front attachment extended.
3. If required, rope off the test area and provide signboards to
keep unauthorized personnel away.
Precautions
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate with each
other using these signals, and to follow them without fail.
2. Operate the machine carefully and always give first priority
to safety.
3. While testing, always take care to avoid accidents because
of landslides or contact with high voltage power lines. EX1302009
Always confirm there is sufficient space for full swings. Figure 5
4. Avoid polluting the machine and the ground with leaking

oil. Use oil pans to catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
Make Precise Measurement

1. Accurately calibrate test instruments in advance to obtain
correct data.
2. Perform tests under the exact test conditions prescribed for
each test item.
3. Repeat the same test and confirm that test data obtained
can be produced repeatedly. Use mean values of
measurements if necessary.
2-1-20
OPERATIONAL PERFORMANCE STANDARD TABLE
Measuring Performance
Item Model Unit
Conditions Standard
Power+ Mode rpm 2,200 ±50
Travel Mode
Standard Mode rpm -
Power+ Mode rpm -
Power Mode rpm 1,950 ±25
Work Mode
Standard Mode rpm 1,850 ±25
Engine
Economy Mode rpm 1,750 ±25
Speed
Lifting Mode rpm -
Auto Idle rpm 1,400 ±25
Low Idle rpm - 1,200 ±25
1 Pump Relief rpm above 1,800
Load
2 Pump Relief rpm above 1,800
Relief bar 324 +10
Front *Standard
Relief Power Up bar 343 +10
Relief (at Motor) bar 265 +15
Swing *Standard
Pressure Relief (at Pump) bar 353 +15
Set Max. Flow lpm 205 +10
Relief (in Front of Valve) bar 220 ±25
Option
Relief (at Pump) bar 222 ±25
EPPR Valve Current mA -
Power Mode mA 280 ±15
Travel Mode
Standard Mode mA 280 ±15
Power+ Mode mA -
Power Mode mA 280 ±15
Pump Work Mode
Standard Mode mA 310 ±15
EPPR v/v
Economy Mode mA 340 ±15
Lifting Mode mA -
Auto Idle mA 650 ±15
Low Idle mA 650 ±15
Up sec 3.3 ±0.4
Boom
Down sec 2.2 ±0.3
Crowd sec 3.1 ±0.4
Arm
Dump sec 2.6 ±0.3
Crowd sec 3.6 ±0.3
Bucket *Standard
Front Dump sec 2.1 ±0.3
Speed Up sec -
Arti Boom
Down sec -
Up sec 2.3 ±0.3
Dozer
Down sec 1.9 ±0.3
Up sec 4.6 ±0.5
Outrigger
Down sec 3.8 ±0.4
2-1-21
Measuring Performance
Item Model Unit
Conditions Standard
*Standard, Swing
Swing Swing Speed sec 16.5 ±1.5
Single 3 Revolution
Swing Speed After 360° Swing,
Swing
Swing Coasting mm Empty Bucket, 900(75°) ±20%
Coasting
Bearing Outer Race
Inching rpm 314 ±30
Jack-up 1st Speed rpm 771 ±30
Travel Speed
Speed 2nd Speed rpm 3,090 ±70
2nd (20km/hr) rpm 2,470 ±60
Weight Standard ton 1.3
Travel Posture,
Boom Down mm/5min below 5
Bucket Crowd Posture,
Weight Bucket
Arm Crowd mm/5min (1.5 times of bucket below 5
capacity)
Bucket Dump mm/5min No settlement when below 20
Cylinder Lock V/V is applied
Front Load Travel Posture,
Bucket Crowd Posture,
Arm Dump mm/5min Weight Bucket below 20
(1.5 times bucket
capacity)
Dozer mm/5min below 5
Outrigger mm/5min below 5
2-1-22
OPERATIONAL PERFORMANCE TEST
Hydraulic Cylinder Cycle Time
Summary
1. Check the overall operational performance of the front
attachment hydraulic system (between the hydraulic
pumps and each cylinder) by measuring the cycle time of
the boom, arm, bucket, and bucket dump (open/close)
cylinders with the empty bucket.
2. Bucket must be empty.
Preparation
1. Maintain the hydraulic oil temperature at 50 ±5 °C
(122 ±41 °F).
Engine Power Mode Auto-idle

Work Mode
Control Dial Switch Switch
Power Plus Digging
High Idle OFF
Mode Mode
2. Position the front attachment as described in the following.

Then, measure the operating time until cylinder reaches
the stroke end by fully moving the control lever.
A. Boom cylinder
1) Boom up speed
Rapidly operate the bucket from the ground,
and measure the time it takes for the boom to
reach the end point.
2) Boom down speed
Rapidly operate the bucket with the boom
reached the end point, and measure the time it
takes for the bucket to reach the ground. WE1400777
3) Measuring available displacement of the Figure 6
cylinder: Measure and record the extension of
the cylinder rod from when the bucket is resting
on the ground to when the boom cylinder is
extended to its maximum length.
2-1-23
B. Arm cylinder
1) Arm crowd speed
Rapidly operate the arm while kept fully dumped
(extended), and measure the time it takes for
the arm to fold fully.
2) Arm dump speed
Rapidly operate the arm maintained in the fully
folded position, and measure the time it takes 0.5 m
for the arm to extend fully. WE1400778
cylinder: Measure and record the extension
length of the cylinder rod from the point at which
the arm cylinder is fully extended (crowded) to
the point at which the arm cylinder is fully folded
(dumped).
C. Bucket cylinder
1) Bucket crowd speed
Rapidly operate the bucket while fully dumped
(extended), and measure the time it takes for
the bucket to fold fully.
2) Bucket dump speed
Rapidly operate the bucket while fully folded,
and measure the time it takes for the bucket to
extend fully. 1m
WE1400779
cylinder: Measure and record the extension
length of the cylinder rod from the point at which
the bucket cylinder is fully extended (crowded)
to the point at which the bucket cylinder is fully
folded (dumped).
NOTE: Jack up the dozer of the wheel-type excavator and
mini-excavator pointing forward, and measure the
time taken to jack it up and to jack it back down.
Measure and record the operating time of the boom
swing (option) of the mini-excavator from right to left,
or from left to right.
NOTE: Record the details of any abnormal noise heard
during measurement, or any abnormal conditions
observed during operation, on a blank measurement
record sheet.
2-1-24
Driveshaft Revolution Speed
Summary
Measure the drive shaft revolution cycle time with jack up
condition.
Preparation
1. Position the front attachment as described in Figure 9.
2. Jack up the machine with dozer and outrigger.
CAUTION
AVOID INJURY
Position the machine on firm and level ground not to
be tilted.
WE1400816
Figure 9
3. Prepare a tachometer to measure driveshaft revolution.

(Figure 10)
Measurement
1. Set the machine to correspond with measuring conditions.
2. Measure conditions are as below.
Travel Mode Power Mode Engine Idle Travel Switch

ON ON High Idle 1st
WE1400817
ON ON High Idle 2nd
ON ON High Idle 3rd Figure 10
ON ON High Idle 3rd (20 km/h)
3. Start engine and accelerate with accelerator pedal to

operate drive shaft.
4. Measure the revolution of drive shaft by tachnometer.
5. Perform the measurement three times and calculate the
average values.
NOTE: Record the details of any abnormal noise heard
during measurement, or any abnormal conditions
observed during operation, on a blank measurement
record sheet.
WE1400818
Figure 11
2-1-25
Swing Speed
Summary
Measure the time required to swing three complete turns.
Preparation
1. Check the lubrication of the swing gear and swing bearing.
2. Place the machine on flat, solid ground with ample space
lor swinging. Do not conduct this test on slopes.
3. With the bucket empty, position the front attachment as
follows.
With the arm cylinder fully retracted, and the bucket The height as the
cylinder fully extended, raise the boom so bucket pin boom foot pin height.
height is flush with the boom foot pin height.
WE1400780
NOTE: In case of no place to be measured, measure Figure 12
with the boom raised and the arm rolled-in.
4. Maintain the hydraulic oil temperature at 50 ±5°C
(122 ±41°F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area
before starting the measurement.
Measurement
1. Measurement conditions are as below.

Work Mode
Power Plus Digging
High Idle OFF
Mode Mode
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction. (Record the stopwatch measurement to the
second decimal place.)
4. Operate swing control lever fully in the opposite direction
and measure the time required for 3 turns.
average values.
Evaluation
Refer to “Operational Performance Standard Table” on page -21.
2-1-26
Swing Function Drift Check
Summary
Measure the swing drift on the bearing outer circumference
when stopping after a 360° full-speed swing.
Preparation
1. Check the lubrication of the swing gear and swing bearing.
2. Place the machine on flat, solid ground with ample space
for swinging. Do not conduct this test on a slope.
3. With the bucket empty, position the front attachment as
follow.
With the arm cylinder fully retracted, and the bucket
cylinder fully extended, raise the boom so bucket pin
height is flush with the boom foot pin height. Two Matching Marks
WE1400781
4. Put the matching marks on the swing bearing and on the
Figure 13
track frame by using a tape, as illustrated.
5. Swing the upper structure 360°.
6. Maintain the hydraulic oil temperature at 50 ±5°C
(122 ±41°F).
CAUTION
AVOID INJURY
Prevent personal injury. Always make sure that area is
clear and that co-workers are out of the swing area WE1400782
before starting the measurement. Figure 14
Measurement Measure Difference

Between Marks
1. Measurement conditions are as below.

Work Mode
Power Plus Digging
High Idle OFF
Mode Mode
Mark on Track Frame
2. Operate swing control lever fully and return it to the neutral
position when the mark on upper structure aligns with that Mark on Swing Bearing
on track frame after swinging 360°. EX1301774
Figure 15
3. Measure the time distance between the two marks.
4. Align the marks again, swing 360°, and then test in the
opposite direction.
average values.
Evaluation
Refer to “Operational Performance Standard Table” on page -21.
2-1-27
2-1-28
1General Maintenance
General
Maintenance
Instructions
Edition 1
DX210WA General Maintenance Instructions

3-1-1
MEMO
General Maintenance Instructions DX210WA

3-1-2
Table of Contents
General Maintenance Instructions

Safety Instructions ........................................ 3-1-5
Welding Precautions and Instructions .......... 3-1-6
Hydraulic System - General Precautions...... 3-1-7
Maintenance Service and Repair Procedure 3-1-9
General Precautions................................................ 3-1-9
Hydraulic System Cleanliness and Oil Leaks 3-1-10
Maintenance Precautions for Hydraulic System
Service .................................................................. 3-1-10
Oil Leakage Precautions ....................................... 3-1-11
Cleaning and Inspection ............................. 3-1-12
General Instructions .............................................. 3-1-12
Bearing Inspection................................................. 3-1-13

3-1-3
3-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

3-1-5
WELDING PRECAUTIONS AND
INSTRUCTIONS
WARNING
To avoid accidents, personal injury and the possibility of
causing damage to the machine or to components, welding
must only be performed by properly trained and qualified
personnel, who possess the correct certification (when
required) for the specific welding fabrication or specialized
repair being performed.
WARNING
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat-treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could result.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, upper structure, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
WARNING
Always perform welding procedures with proper safety
equipment and adequate ventilation in a dry work area.
Keep a fire extinguisher near and wear personal protective
equipment.

3-1-6
WARNING
Observe the following safety instructions:
1. Use adequate safety shielding and keep away from
fuel and oil tanks, batteries, hydraulic piping lines or
other fire hazards when welding.
2. Never weld when the engine is running. Battery cables
must be disconnected before the welding procedure is
started.
3. Never weld on a wet or damp surface. The presence of
moisture causes hydrogen embrittlement and
structural weakening of the weld.
4. If welding procedures are being performed near
cylinder rods, operator's cabin window areas or any
other assemblies could be damaged by weld spatters.
Use adequate shielding protection in front of the
assembly.
5. During welding equipment setup, always attach
ground cables directly to the area or component being
welded to prevent arcing through bearings, bushings,
or spacers.
6. Always use correct welding rods for the type of weld
being performed and observe recommended
precautions and time constraints. AWS Class E7018
welding rods for low alloy to medium carbon steel
must be used within two hours after removal from a
freshly opened container. Class E11018G welding rods
for T-1 and other higher strength steel must be used
within 1/2 hour of removal from a freshly opened
container.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high-speed, with
extremely precise tolerances between moving parts (e.g. pistons
and cylinders, or shoes and swash plates), can be severely
damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil because of neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage or improper
operation.

3-1-7
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
circuits are in neutral, or "OFF". That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part
shows no trace of factory prelube or has been contaminated by
dirt or by questionable oils, flushing and prefilling with clean
hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from
any part of the hydraulic system could be an indication of air in
the system (and many other types of problems). As a general
precaution (and to help lessen the risk of potential long-term
damage), allow the engine to run at no-load idle speed
immediately after initial start-up. Hydraulic fluid will circulate,
releasing any air that may have been trapped in the system
before load demands are imposed.
Before starting the machine, a daily walk-around safety
inspection, including a quick visual inspection for any exterior
evidence of leaking hydraulic fluid, can help extend the service
life of system components.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy workloads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.

3-1-8
MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other maintenance service or repair is being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in subfreezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap must be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filters are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced
because of a mechanical problem inside the pump.
However, pressure loss could also be because of
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove tank return drain line from the top
part of the swing motor, both travel motors and each main pump.
If there is air in any one of the drain lines, carefully prefill the
assembly before bolting together the drain line piping
connections. Run the system at low rpm.

3-1-9
HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
Maintenance Precautions for Hydraulic

System Service
Whenever maintenance, repairs or any other troubleshooting or
service is being performed, it's important to remember that
hydraulic system - including both the interior and exterior
surfaces of assemblies, and every drop of operating fluid - must
be protected from contamination.
Dust and other foreign contaminants are major contributors to
premature wear in hydraulic circuits. The narrow tolerances,
rapidly moving parts and high operating pressures of the system
require that fluid be kept as clean as possible. The performance
and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper
precautions are not observed:
• Use a noncombustible, evaporative type, low residue
solvent and thoroughly clean exterior surfaces of
assemblies before any part of the circuit is opened or
disassembled.
NOTE: It's just as important to clean the cap and
reservoir top before routine fluid changes or
quick checks as it is before major repairs.
(Accumulated dirt attracts moisture, oil and
other fluids - and more dirt.)
• Keep dismantled parts covered during disassembly. Use
clean caps, plugs or tape to protect the disconnected
openings of flanges, manifolds and piping.
• Do not allow cleaning solvents or other fluids to mix with
the oil in the system. Use clean oil to flush any traces of
solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system, flush
and replace all fluid in the system and troubleshoot the
circuit to identify the source of contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.

3-1-10
Oil Leakage Precautions
Oil that is visibly seeping from joints or seals should always
serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew
that air, water and dirt have an open, free passageway through
which to enter the circuit. Corrosive salt air, freezing and thawing
condensation cycles and working environments that are full of
fine dust are especially hazardous. Clogging of valve spools or
external piping (especially pilot circuit piping) can gradually
diminish or suddenly put a stop to normal hydraulic function. You
can prevent having to make these types of repairs by the
following recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic
assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking
alignment and flatness. Clean and repair corrosion or any
other damage.
3. Follow bolt torque recommendations and all other
assembly requirements.
NOTE: Grease lip seals before assembly.
Figure 1

3-1-11
CLEANING AND INSPECTION
General Instructions
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close installed parts such as thrust bearing,
matched parts, etc.
WARNING
Do not inhale vapors or allow solvent type cleaners to
contact skin. Keep solvent away from open flame, arcs or
sparks or other sources of ignition that could start a fire.
1. Clean all metal parts thoroughly using a suitable cleaning

fluid. It is recommended that parts be immersed in cleaning
fluid and moved up and down slowly until all oils,
lubricants, and/or foreign materials are dissolved and parts
are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable
cleaning fluid for a minute or two, then remove bearings
from cleaning fluid and strike flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in
cleaning fluid to flush out particles. Repeat above
operation until bearings are thoroughly clean. To dry
bearings, use moisture-free compressed air. Be careful to
direct airstream across bearing to avoid spinning bearings
that are not lubricated. DO NOT SPIN BEARINGS WHEN
DRYING; bearings may be rotated slowly by hand to
facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without replacing
mating cup or cone at the same time. After inspection, dip
bearings in lightweight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place;
inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are
found, replace bearings. Also, inspect defective bearing
housing and/or shaft for grooved, galled or burred
conditions that indicate bearing has been turning in its
housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing
rings, gaskets and retaining rings when unit is
disassembled than waiting for premature failures; refer to
latest Micro Fiche and/or Parts Book for replacement items.

3-1-12
Be careful when installing sealing members, to avoid
cutting or scratching. Curling under of any seal lip will
seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter of metal casing and on oil seals to
assure an oil tight install into retainer. Use extreme care
not to get Loctite on lips of oil seals. If this happens, that
portion of the seal will become brittle and allow leakage.
When replacing lip type seals, make sure spring loaded
side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking
for cracks that are not visible. Examine teeth on all gears
carefully for wear, pitting, chipping, nicks, cracks or scores.
Replace all gears showing cracks or spots where
case-hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to
make certain they have not been sprung, bent, or no
twisted splines, and that shafts are true.
NOTE: Spline wear is not considered detrimental
except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and
wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and
machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth.
Remove foreign material. Replace any parts that are
deeply grooved or scratched which would affect their
operation.
Bearing Inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty,
soak the bearing assembly in a light solution and move the
bearing around until all lubricants and/or foreign materials are
dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check for roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.

3-1-13
After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate the bearing
has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for
cracks that are not visible.
The following illustrations will aid in identifying and diagnosing
some of the bearing related problems.
NOTE: The illustrations will only show tapered roller
bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles
and types of bearings.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage because of improper handling or tool usage.
Figure 3

3-1-14
Replace bearing.
Figure 4
Galling
Metal smears on roller ends because of overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Abrasive Step Wear

Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts and housings,
check seals and bearings and replace if leaking, rough or noisy.
Figure 6

3-1-15
Etching
Bearing surfaces appear gray or grayish black in color with
related etching away of material usually at roller spacing.
Replace bearings - check seals and check for proper lubrication.
Figure 7
Misalignment
Outer race misalignment because of foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9

3-1-16
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12

3-1-17
Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Cracked Inner Race

Race cracked because of improper installation, cocking or poor
bearing seat.
Replace all parts and housings, check seals and bearings and
replace if leaking.
Figure 14
Smears
Smearing of metal because of slippage caused by poor
installation, lubrication, overheating, overloads or handling
damage.
Replace bearings, clean related parts and check for proper
installation and lubrication.
Replace shaft if damaged.
Figure 15

3-1-18
Frettage
Corrosion set up by small relative movement of parts with no
lubrication.
Replace bearing. Clean all related parts. Check seals and check
for proper lubrication.
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if overheating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
If the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18

3-1-19
3-1-20
Standard
Torques
Edition 1
DX210WA Standard Torques

3-2-1
MEMO
Standard Torques DX210WA

3-2-2
Table of Contents
Standard Torques
Safety Instructions ......................................... 3-2-5
Torque Values for Standard Metric Fasteners3-2-6
Torque Values for Standard U.S. Fasteners . 3-2-7
Type 8 Phosphate Coated Hardware ............ 3-2-9
Torque Values for Hose Clamps ................. 3-2-10
ORFS Swivel Nut Recommended Torque ... 3-2-10
Torque Values for Split Flanges .................. 3-2-11
Torque Wrench Extension Tools ................. 3-2-12
Torque Multiplication .............................................. 3-2-12
Other Uses for Torque Wrench Extension Tools.... 3-2-13
Tightening Torque Specifications (Metric) .............. 3-2-14

3-2-3
3-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

3-2-5
TORQUE VALUES FOR STANDARD METRIC FASTENERS
NOTE: The units for the torque values are kg.m (ft lb).
Grade
Dia. x Pitch
(mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1.25
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.25
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

3-2-6
TORQUE VALUES FOR STANDARD U.S. FASTENERS
SAE Bolt Head
Type Description
Grade Marking
WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD.

1 1 or 2
Low or Medium Carbon Steel Not Heat-treated.
WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.
WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.
Recommended torque, in foot-pounds, for all Standard

Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30
engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible
materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 When finished jam nuts are used.
0.70 When Molykote, white lead or similar
mixtures are used as lubricants.
0.75 When Parkerized bolts or nuts are used.
0.85 When cadmium plated bolts or nuts and
zinc bolts w/waxed zinc nuts are used.
0.9 When hardened surfaces are used under
the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use
minimum torque values.

3-2-7
The following General Torque Values must be used where
SPECIAL TORQUE VALUES are not given.
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values must be increased
1/3 for nonlubricated (dry) threads.
Heat-treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes on Head) (6 Radial Dashes on Head)
Foot pounds Newton Meter Foot pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less
than what the chart states, it is recommended that
loose bolt and/or nut be replaced with a new one.

3-2-8
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts, nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
Standard Torque ±10%

Nominal Thread Diameter Kilogram.meter Foot pounds
(kg.m) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2" 522.8 3780

3-2-9
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type and Size
Kilogram.meter Inch Pounds Kilogram.meter Inch Pounds
(kg.m) (in lb) (kg.m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- -------
Worm Drive - Under
44 mm (1-3/4 in) Open Diam- 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
eter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- -------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-Tite" 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
ORFS SWIVEL NUT RECOMMENDED TORQUE

Torque (kg.m)
Dash Size Hose I.D. Thread Size
Recommended
4 1/4" 9/16" 2.4 - 2.6
6 3/8" 11/16" 3.3 - 3.9
8 1/2" 13/16" 5.1 - 5.7
12 3/4" 1 3/16" 11.7 - 12.7
16 1" 1 7/16" 15.3 - 17.3
20 1 1/4" 1 11/16" 18.0 - 20.0

3-2-10
TORQUE VALUES FOR SPLIT FLANGES
The following chart provides the tightening torques for split
flange connections used in hydraulic systems. Split flanges and
shoulders should install squarely. Install all bolts, finger tight and
then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or
bolts, which can cause leakage.
Bolt Torque
Flange Bolt
Size (*) Size Kilogram.meter Foot-pounds
(kg.m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose
fitting.
NOTE: Values stated in chart are for Standard Pressure
Series (Code 61) Split Flanges.

3-2-11
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high-grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of
the torque wrench.
• Specialized sockets do not fit the adapter on the front end
(nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the
wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the
torque wrench impossible.
• A unique application requires fabrication of an adapter or
other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T/A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
A = Length of the torque wrench (between the center of the nut

or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque
wrench, and the indicated torque on the dial reads "150 ft lb",
the real force applied to the bolt is 300 ft lb:
AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24

3-2-12
NOTE: The formula assumes there is no added deflection or
"give" in the joint between the extension and torque
wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force
and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly
straight (for example, an extension made to go around an
obstruction, to allow access to a difficult to tighten
fastener), the materials and methods used must be solid
enough to transmit full tightening torque.
Other Uses for Torque Wrench Extension

Tools
Torque wrench extensions are sometimes made up for reasons
other than increasing leverage on a fastener.
For example, a torque wrench and extension can be used to
measure adjustment "tightness" of a linkage or assembly.
Specially fabricated extensions can be used to make very
precise checks of the force required to engage or disengage a
clutch mechanism, release a spring-applied brake assembly, or
"take up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated
checks at regular intervals can help to monitor and maintain
peak operating efficiency. These types of adjustment checks are
especially useful if physical measurements of linkage travel are
difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench,
welding a nut or other adapter on the end of a linkage shaft or
other leverage point will allow turning the shaft or assembly
manually.

3-2-13
Tightening Torque Specifications (Metric)
(For coated threads, prelubricated assemblies.)
IMPORTANT
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically approve a specific manufacturer or
brand name, but the following table of "Loctite"
applications is included for which cross-references to other
manufacturer's products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Threadlocker sealers 222, 242/243,
262, 271, 272, or 277.

3-2-14
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high-grade fasteners
262 Red Remove HOT 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

"No-filler/nonclog" formula for
4 Hours (or 1/2
high-pressure hydraulic systems.
545 Purple Hand tools hour with Locquic
Over application will not restrict or foul
"T" Primer)
system components.
4 Hours (or 1/2
Solvent resistant, higher viscosity
656 White Hand tools hour with Locquic
tapered thread sealer.
"T" Primer)
III. "Loctite" gasket/flange sealer
Product Application Color Notes

Gasket eliminator specifically made
for aluminum flanges/surfaces. For Use Locquic "N" primer for fast (1/2 - 4
518 Red
hydraulic systems to 34,475 kPa hours) setup. Unprimed setup 4 - 24 hours.
(5,000 psi).
Low-pressure/wide-gap gasket
eliminator compound. Fills gaps to Use Locquic "N" primer for faster (1/2 - 4
504 Orange
0.0012 mm (0.030"), cures to rigid hours) setup. Unprimed setup 4 - 24 hours.
seal.
General purpose, fast setup,
flexible-cure gasket eliminator. For Use Locquic "N" primer for faster (1/4 - 2
515 Purple
nonrigid assemblies subject to shock, hours) setup. Unprimed setup 1 - 12 hours.
vibration or deflection.

3-2-15
IV. "Loctite" retaining compounds

For bushings, sleeves, press fit
Use Locquic "N" primer for increased bond
bearings, splines and collars. For
609 Green strength and all cold temperature
gaps to 0.0002 mm (0.005"),
applications.
temperatures to 121°C (250°F).
For high temperatures to 232°C
620 Green Same as 609, above.
(450°F).
For high strength bonds and tight
680 clearance gaps, to 0.00008 mm Green Same as 609, above.
(0.002").
V. "Loctite" Adhesives

Black Max instant adhesive for shock May take 120 hours to reach full cure
380 Black
and vibration-resistant bonds. strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

3-2-16
1Engine
1Upper Structure
1Cabin (Non-Rops)
Edition 1
DX210WA Cabin (Non-Rops)

5-1-1
MEMO
Cabin (Non-Rops) DX210WA

5-1-2
Table of Contents
Cabin (Non-Rops)
Cabin Identification .........................................5-1-5
Removal .........................................................5-1-6
Installation ....................................................5-1-10
Completing work ...........................................5-1-10
Dimensions of Cabin Glass ..........................5-1-11
Removal and Installation of Cabin Glass......5-1-15
Removal of Cabin Glass.......................................... 5-1-15
Installation of Cabin Glass....................................... 5-1-17
Installation of Upper Door Glass ............................. 5-1-22
Installation of Upper Front Glass............................. 5-1-22

5-1-3
5-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
CABIN IDENTIFICATION
The excavator could be equipped with either a ROPS or NON-
ROPS cab.
Figure 1, shows a NON-ROPS cabin (1) and a ROPS cabin (2).
When servicing your cabin use the correct section.
Figure 1
Reference Reference
Number Number
1 Non-Rops Cabin 2 Rops Cabin

5-1-5
REMOVAL
1. Make the machine swing about 25 ~ 30° leftward on the
flat ground as shown in Figure 2 before lowering the bucket
on the ground and then stop engine.
Figure 2 WE1400430
2. Move safety lever to "RELEASED" (UNLOCK) position. O I

(Figure 3)
3. Turn starter switch to "I" (ON) position.
LOCK
WARNING
WARNING
DO NOT OPERATE
AVOID DEATH OR SERIOUS INJURY when performing inspection
or maintenance
If engine must be running while performing 190-00695A
ON OFF
maintenance, always use extreme caution. Always EX1401660
have one person in the cabin at all times. Never leave Figure 3
the cabin with engine running.
4. To relieve pressure from accumulators, fully stroke work

levers in all directions. Movement can occur.
5. Move safety lever to "LOCK" position. (Figure 3)
6. Set parking brake switch to the "I" position. (Figure 4)
O
7. Apply the service brake with full stroke several time to
relieve pressure from accumulate functioning braking.
I
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Attach maintenance warning tag on controls.
Figure 4 FG002178

5-1-6
10. Turn battery disconnect switch to "OFF" position.
OFF
(Figure 5)
ON
Figure 5 EX1401760
11. Remove bolts and washers (1, Figure 5) (6 ea) with under
cover (2) on bottom of main frame.
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) 1
2
• Under cover weight: 7 kg (15.4 ft lb)
WE1400431
Figure 6 Bottom of Main Frame
12. Disconnect washer hose.
Figure 7 Bottom of Cabin WE1400432
13. Remove floor mat from the cabin.
Figure 8 WE1400423

5-1-7
14. Remove cup holder (1, Figure 9).
6 7
Remove front covers (2 and 3, Figure 9) and side covers (4
and 5). 4
Before removing front cover (2, Figure 9) disconnect hour
meter connector.
NOTE: Don't remove monitor panel (6, Figure 9) and
switch panel (7).
1
3 2 5
WE1400448
Figure 9
15. After removing rear mat (1, Figure 10), remove rear center
cover (2), cassette cover(3), rear side covers (4 thru 6) and 4 5
rear cover (7).
3
7 6
2
WE1400449
Figure 10
16. Remove fuse box bracket (1, Figure 11) from left sidewall
without disassembly harness connector.
1
Remove cassette bracket (2, Figure 11) and disconnect
antenna and speaker wire.
Remove EPOS controller (3, Figure 11) without 3
disassembly harness connectors.
2
WE1400450
Figure 11
17. Remove air ducts (1 thru 4, Figure 12) from cabin rear
panel.
Remove across bar (5, Figure 12) between left and right
side of cabin.
2
1 3
4
5
WE1400451
Figure 12

5-1-8
18. Disconnect cabin wiring connectors from main harness.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If cabin is equipped with additional protective
guards over cabin openings, they must be
removed.
WE1400452
Figure 13
19. Remove air ducts (1 thru 6, Figure 14) at the right side of
cabin sequently from the front duct. 6
5
3
1
Figure 14 WE1400453
20. Using a suitable lifting device, attach slings to four lift

points on top of cabin (Figure 15).
• Lifting hole size: M12 x 1.75, depth: 15 mm
• Cabin weight: about 315 kg (695 lb)
Figure 15 WE1400454
21. Remove bolts and washers (1 and 2, Figure 16) (6 ea).
Torque
No.
(mm) N.m kg.m ft lb
1 1
1 19 88.2 9 65.1 3
3
2 17 63.7 6.5 47
3 2 3
22. Remove nuts and washers (3, Figure 16) (4 ea) from cabin 2 1
floor.
• Tool: 24 mm ( )
WE1400455
Figure 16
• Torque: 205.9 N.m (21 kg.m, 151.9 ft lb)

5-1-9
IMPORTANT
Lift cabin approximately 25 ~ 50 mm (1" ~ 2") above
deck. Check that all electrical connections have been
disconnected and all other items unbolted.
Continue lifting with assist crane to remove cabin
shell. Lower shell to a prepared safe blocking support.
Do not rapidly lift operator's cabin: The bottom of
operator's cabin may come into contact with, and
scratch, control stand cover. WE1400456
Figure 17
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
• Cabin weight: 315 kg (695 lb)
2. Lower cabin into position on cabin floor.
WE1400456
Figure 18
3. Install mounting nuts (Figure 19) (4 ea) and washers in four

corners of cabin floor.
• Tool: 24 mm ( )
Perform installation in the reverse order to removal.
WE1400457
Figure 19
COMPLETING WORK
1. Start the engine and run at low idle for about 5 minutes.
2. Perform the machine performance test.

5-1-10
DIMENSIONS OF CABIN GLASS
Front Glass
845
1034.4
6.76
43.2
96 96
854
423.6
427.1
WE1400003
Figure 20
NOTE: Unit: mm (1 mm = 0.039 in)

5-1-11
Left Glass
358.8 353.2 5 280.2 5
0.2
R2
206.3
R7
60
197.6
.2 R1 R3
00
00
R2
828
760.4
761
.5
567.3
554.1
24.5
2- 13 Hole
40
E-mark Position
(100)
0 .2
11 R7
170
R 0.
(100)
2
367.1 194.1 150.8 525.5 93.6
895.8
575.2
43.2 5
Ceramic
R5
118.3
R56
5 Coating
5.
R6 37
R2
329.1
R
65 R1 2-
4
.5 0
681.6
R21
100
412.6
85.5
R2734
2
0. E-mark Position
R3
R85
100
.8
0
94.6
4.9
R9
5
85.1
R2
901.7
EX1401714
Figure 21

5-1-12
Rear Side Glass
100
4-
R7
2
529
778
37.4
311.7 5
Ceramic
R6 Coating
4.2 R1394.3
4.2
R6
28.3
R12
36.9
R799.1
1108
E-mark Position
100
100
0
165
R6
459.2
.2
4
R6
EX1401715
Figure 22

5-1-13
Right Glass
1,023.8 333.8 5
1,199
1,035
1,121
1,533.4
WE1400004
Figure 23

5-1-14
REMOVAL AND INSTALLATION OF CABIN GLASS
Removal of Cabin Glass

Procedures to remove right-hand glass (1, Figure 24), rear left,
glass, lower door glass and rear glass. 1
CAUTION
AVOID INJURY
When removing the broken or cracked glass, the glass EX1401717
shards can cause serious injury. Figure 24
Before removing, use tape to hold the broken or cracked
glass together.
1. Remove resin panel, garnish or etc. around the glass.
Reference
Description
Number
1 Garnish 3
2 Lower Glass of Door

3 Rear Glass 1 4
4 Rear Left-hand Glass 5
2
5 Resin Panel
EX1401718
Figure 25
2. Prick a hole in the adhesive by using an awl (or cutter

knife). 1 2
Reference
Description 3
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive
4
EX1301298
Figure 26

5-1-15
3. Pass a piano wire (1, Figure 27) (or a wire) through the
hole.
EX1301299
Figure 27
4. Wind both ends of the piano wire onto two screwdrivers.

Draw the wire back and forth to cut the adhesive (3, Figure Cabin Outside
28) between cabin (1) and glass (2). 1 2
Remove glass (2, Figure 28) from the cabin (1).

NOTE: Piano wire is easily broken. If a part of the piano
wire turns hot, change the position of the wire
and continue cutting the adhesive.
Cabin Inside 3
EX1301300
Figure 28

5-1-16
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 30), rear, left-
hand glass, lower door glass and rear glass.
1. Cut off the remaining adhesive leaving a layer of old 2
adhesive 1 ~ 2 mm thick (Figure 29). The new adhesive
will bond to the remaining adhesive.
NOTE: Do not damage the cabin paint. Cut off Adhesive
by 1 ~ 2 mm Deep
Reference
Description EX1301302
Number
Figure 29
1 Cabin
2 Knife
EX1401717
Figure 30
2. Clean the remaining adhesive and metal surfaces with a

general purpose adhesive cleaner.
Reference
Description
Number 3
1 Garnish
2 Lower Glass of Door 1 4
3 Rear Glass 5
2
4 Rear Left-hand Glass
5 Resin Panel EX1401718
Figure 31
IMPORTANT
Primer must be shaken for about 1 minute and mix
thoroughly before opening the cap.
After opening primer, apply primer as quickly as
possible and replace the cap immediately after using.
After opening primer, all the contents must be used
within 180 days (or 2 hours with the cap off).

5-1-17
3. Apply the damper on cabin body before applying adhesive.
Damper - Front Upper Glass
A
Length: about 3,600 mm
7
Section A - A
EX1401719
Figure 32
Damper - Rear Glass
787
8
538.1
Section A - A
EX1401720
Figure 33

5-1-18
Damper - Right-hand Glass
A
7
5
Section A - A
EX1401721
Figure 34
Damper - Lower Glass of Door
716
7
94
5
A
324
Section A - A
Figure 35
EX1402138
Damper - Rear Left-hand Glass
7
5
Section A - A
EX1401722
Figure 36

5-1-19
4. Clean the mating edge of new glass by using clean rag and
ethylalcohol.
IMPORTANT
Primer (Sika Primer W06G+P) must be shaken for about
1 minute and mixed thoroughly before opening the cap.
5. Using application brush, apply primer for glass (Sika

Primer W06G+P) to the layer of old adhesive from step 1.
Wait for about 15 minutes to let it dry. 1
(Refer to position to apply primer (2, Figure 37).)
NOTE: The painting primer must be applied evenly to
2
leave no blemishes.
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 37
3 Layer of Old Adhesive on Cabin
6. Cut off the nozzle of adhesive cartridge (Sika Tack-Drive)

into V-shaped by using a knife. (Refer to page -18.)
7. Remove seal of cartridge. Install the V-shaped nozzle.
8. Install the cartridge to the manual caulking gun.
9. Apply adhesive to the adhesive position at cabin side so
bead triangle will be even.
(Refer to position to apply adhesive (3, Figure 37).)

5-1-20
Required
Cut Nozzle Required

End into
V-shaped
Adhesive
Apply Bead Here
Application bead
should form
9 even triangle.
12 Remove Seal
Adhesive Cartridge
Panel
EX1401037
Figure 38

10. The required amount (just for reference) of adhesive and
primer.
Painted Surface or
Glass Surface
Adhesive Surface
Adhesive Sika
Primer Sika Activator Primer Sika Primer
Tack-drive 310 ml
DM-1 250 ml Can 206G+P 30 ml Bottle
Cartridge
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Glass of Door 150 ml 0.50 ml 0.45 ml
Rear Left-hand Glass 250 ml 0.65 ml 0.60 ml
Rear Right-hand Glass 100 ml 1.00 ml 0.90 ml
Rear Glass 210 ml 0.50 ml 0.45 ml

5-1-21
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 39) 1
around sash assembly (1) from the cabin inside for easy
2
removal. Push the sash assembly by hands and remove
sash outside. 3
2. Install glass (3, Figure 39) and glass (4) into the sash 4
grooves.
3. Install the sash assembly, which the glass is installed on,
onto the door from the outside of cabin.
EX1401723
Secure the sash assembly at the inside of cabin by using Figure 39
the garnish.
Installation of Upper Front Glass

1. Stick seal to the lower side of front upper glass by using
Cemedine SIKAFLEX 255 ultrafast.
Stick and secure both right and left ends (the thicker part)
of seal to the glass by using Cemedine SIKAFLEX 255
ultrafast.
Stick the mating surface of seal and the glass by using
Cemedine SIKAFLEX 255 ultrafast so no visible undulation
or boss can be found.
NOTE: Cemedine SIKAFLEX 255 ultrafast Glue-state
adhesive, tubed.
Reference
Description
Number
1 Upper Glass
2 Weather Strip
3 Lower Glass
1
4 Damper 4
2
3
EX1401724
Figure 40

5-1-22
1Cabin (Rops)
Edition 1
DX210WA Cabin (Rops)

5-2-1
MEMO
Cabin (Rops) DX210WA

5-2-2
Table of Contents
Cabin (Rops)
Cabin Identification .........................................5-2-5
Roll Over Protective Structure (ROPS)
When Required by Local Regulations ....................... 5-2-6
Removal .........................................................5-2-8
Installation ....................................................5-2-13
Completing work ...........................................5-2-14
Dimensions of Cabin Glass ..........................5-2-15
Removal and Installation of Cabin Glass......5-2-19
Removal of Cabin Glass.......................................... 5-2-19
Installation of Cabin Glass....................................... 5-2-21
Installation of Upper Door Glass ............................. 5-2-26
Installation of Upper Front Glass............................. 5-2-26

5-2-3
5-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
CABIN IDENTIFICATION
The excavator could be equipped with either a ROPS or NON-
ROPS cab.
Figure 1, shows a NON-ROPS cabin (1) and a ROPS cabin (2).
When servicing your cabin use the correct section.
Figure 1
Reference Reference
Number Number
1 Non-Rops Cabin 2 Rops Cabin

5-2-5
Roll Over Protective Structure (ROPS)
When Required by Local Regulations
Global markets may or may not require a Roll Over Protective
Structure (ROPS). Always comply with all regional and
governmental regulations that apply to your market. The
following information is for a ROPS cabin.
General ROPS Guidelines for ROPS Certified Cabins

The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and operator may
suffer serious injury or death. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and carry out operations
without it.
• Never modify the operator’s cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer serious injury or death.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.

5-2-6
ROPS Certification
This DOOSAN excavator has an operator’s cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 2) is found on the left side
of the cabin on most models. It may vary slightly in its location
on some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware
if damaged. See your DOOSAN dealer for parts. EX1300529
Figure 2 Left Side of Rops Cabin (Inside)
ROPS − Roll-over Protective Structure complies with
ISO 12117-2:2008, EN13531:2001.
WARNING
Never modify the operator cabin by welding, grinding,
DOOSAN. Changes to the cabin can cause loss of operator
protection from rollover and falling objects, and result in
serious injury or death.

5-2-7
REMOVAL
1. Make the machine swing about 25 ~ 30° leftward on the
flat ground as shown in Figure 3 before lowering the bucket
WE1400430
Figure 3

(Figure 4)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF
4. To relieve pressure from accumulators, fully stroke work

levers in all directions. Movement can occur.
7. Apply the service brake with full stroke several time to O
relieve pressure from accumulate functioning braking.
8. Turn key to "O" (OFF) position and remove from starter I
switch.
WE1400464
Figure 5

5-2-8
OFF
(Figure 6)
ON
Figure 6 EX1401760
11. Remove bolts and washers (1, Figure 6) (6 ea) with under
• Tool: 19 mm ( )
2
• Under cover weight: 7 kg (15.4 ft lb)
WE1400431
12. Disconnect washer hose.
Figure 8 Bottom of Cabin WE1400432
WE1400463
Figure 9

5-2-9
14. Remove cover (1, Figure 10), bolt and washer (2) with
safety lever assembly (3) from control stand.
• Tool: 4 mm ( )
1
3 2
EX1403564
Figure 10
15. Remove duct covers (1 and 2, Figure 11).
1 2
Figure 11 WE1400435
16. Disconnect wiper, monitor, sun sensor and hour meter

connectors.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If cabin is equipped with additional protective
guards over cabin openings, they must be
removed.
WE1400436
Figure 12
17. Remove air ducts (1 thru 6, Figure 13) on right-hand side

of operator's cabin. 5
3
4
1
Figure 13 WE1400437

5-2-10
18. Remove glove box pad (1, Figure 14), and two bolts under
pad. 4
Remove caps and bolts (2, Figure 14) (3 ea) from top of
rear cover.
1 2
Remove bolts (3, Figure 14) (2 ea) from bottom of rubber
mounts in rear cover.
Remove rear cover (4, Figure 14).
3
WE1400438
Figure 14
19. Remove air ducts (1 thru 3, Figure 15) and atmospheric air
duct (4).
2 4
3
WE1400439
Figure 15
20. Remove all bolts (1, Figure 16) (17 ea) with brackets (2
thru 4) from body of operator cabin.
• Tool: 13 mm ( ) 2
3
1
4
WE1400440
Figure 16
21. Disconnect connectors of interior lights, speakers and

antenna.

5-2-11
WE1400441
Figure 17
22. Using a suitable lifting device, attach slings to four lift

points on top of cabin (Figure 18)
• Lifting hole size: M12 x 1.75, depth: 15 mm
• Cabin weight: about 485 kg (1,069 lb)
WE1400442
Figure 18
23. Remove bolts and washers (1, Figure 19) (11 ea).
• Tool: 19 mm ( )
• Torque: 88.3 N.m (9 kg.m, 65.1 ft lb) 1 1
2
24. Remove nuts and washers (2) (4 ea) from cabin floor. 2
1 1
• Tool: 24 mm ( ) 2 1 2
1 1
WE1400443
Figure 19

5-2-12
25. Remove bolts which is fixing the plate to prevent loosening
of ROPS bolt (1, Figure 20).
• Tool: 19 mm ( ) 2
26. Remove ROPS bolt (2, Figure 20).
• Tool: 60 mm ( )
1
• Torque: 127.5 N.m (13 kg.m, 94 ft lb)
WE1400444
Figure 20
IMPORTANT
Lift cabin approximately 25 ~ 50 mm (1" ~ 2") above
deck. Check that all electrical connections have been
disconnected and all other items unbolted.
Continue lifting with assist crane to remove cabin
shell. Lower shell to a prepared safe blocking support.
Do not rapidly lift operator's cabin: The bottom of
operator's cabin may come into contact with, and
WE1400445
scratch, control stand cover. Figure 21
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
• Cabin weight: 485 kg (1,069 lb)
2. Lower cabin into position on cabin floor.
WE1400445
Figure 22

5-2-13
3. Install mounting nuts (Figure 23) (4 ea) and washers in four
corners of cabin floor.
• Tool: 24 mm ( )
Perform installation in the reverse order to removal.
WE1400446
Figure 23
COMPLETING WORK

5-2-14
DIMENSIONS OF CABIN GLASS
Front Glass
816 7
993
86.5
40
824
454.5
27.6
169.6
7
58.3 707.4
EX1301291
Figure 24

5-2-15
Left Glass
399.5 5 270.7 5
786.4
410.6 402.3
437.5 131.6
850.2 5
210.7
367
468.8
436.1
642.3
722.8
871.7
EX1301292
Figure 25

5-2-16
Rear Side Glass
786.7 5
601.2
391.1 5
1026.2
958.2
258.2
452.9
EX1301293
Figure 26

5-2-17
Right Glass
1330.8 5
83.2
527.5
957.1
1407.6
505.1
419.7
306.6
97.9
30.8
918.7 207.9 163.3
1534.8
EX1301294
Figure 27

5-2-18
REMOVAL AND INSTALLATION OF CABIN GLASS
Removal of Cabin Glass

Procedures to remove right-hand glass (1, Figure 28), rear left,
glass, lower door glass and rear glass. 1
CAUTION
AVOID INJURY
When removing the broken or cracked glass, the glass EX1301295
shards can cause serious injury.
Figure 28
Before removing, use tape to hold the broken or cracked
glass together.
1. Remove resin panel, garnish or etc. around the glass.
Reference
Description
Number
3
1 Garnish
2 Lower Glass of Door
3 Rear Glass 1 4
2
5 Resin Panel
EX1301296
Figure 29
2. Prick a hole in the adhesive by using an awl (or cutter

knife). 1 2
Reference
Description 3
Number
1 Cabin
2 Cabin Glass
3 Awl
4 Adhesive
4
EX1301298
Figure 30

5-2-19
3. Pass a piano wire (1, Figure 31) (or a wire) through the
hole.
EX1301299
Figure 31
4. Wind both ends of the piano wire onto two screwdrivers.

Draw the wire back and forth to cut the adhesive (3, Figure Cabin Outside
32) between cabin (1) and glass (2). 1 2
Remove glass (2, Figure 32) from the cabin (1).

NOTE: Piano wire is easily broken. If a part of the piano
wire turns hot, change the position of the wire
and continue cutting the adhesive.
Cabin Inside 3
EX1301300
Figure 32

5-2-20
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 34), rear, left-
hand glass, lower door glass and rear glass.
1. Cut off the remaining adhesive leaving a layer of old 2
adhesive 1 ~ 2 mm thick (Figure 33). The new adhesive
will bond to the remaining adhesive.
NOTE: Do not damage the cabin paint. Cut off Adhesive
by 1 ~ 2 mm Deep
Reference
Description EX1301302
Number
Figure 33
1 Cabin
2 Knife
EX1301295
Figure 34
2. Clean the remaining adhesive and metal surfaces with a

general purpose adhesive cleaner.
Reference
Description 3
Number
1 Garnish
2 Lower Glass of Door 1 4
3 Rear Glass
5
5 Resin Panel EX1301296

Figure 35
IMPORTANT
Primer must be shaken for about 1 minute and mix
thoroughly before opening the cap.

5-2-21
3. Apply the damper on cabin body before applying adhesive.
Damper - Front Upper Glass
787
Adhesive Sides 5
975
5
A
Section A - A
EX1301354
Figure 36
Damper - Rear Glass
758
Adhesive Sides 5
573
A
Section A - A
EX1301355
Figure 37

5-2-22
Damper - Right-hand Glass
1,492
A
Adhesive Sides 5
1,376
7
Section A - A
EX1301356
Figure 38
Damper - Lower Glass of Door
800
7
184
329
A
Adhesive Sides
429
5
606 Section A - A
685
EX1301357
Figure 39
Damper - Rear Left-hand Glass
A
Adhesive Sides
5
Section A - A
EX1301358
Figure 40

5-2-23
4. Clean the mating edge of new glass by using clean rag and
ethylalcohol.
IMPORTANT
Primer (Sika Primer W06G+P) must be shaken for about
1 minute and mixed thoroughly before opening the cap.
5. Using application brush, apply primer for glass (Sika

Primer W06G+P) to the layer of old adhesive from step 1.
Wait for about 15 minutes to let it dry. 1
(Refer to position to apply primer (2, Figure 41).)
NOTE: The painting primer must be applied evenly to
2
leave no blemishes.
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 41
3 Layer of Old Adhesive on Cabin
6. Cut off the nozzle of adhesive cartridge (Sika Tack-Drive)

into V-shaped by using a knife. (Refer to page -22.)
7. Remove seal of cartridge. Install the V-shaped nozzle.
8. Install the cartridge to the manual caulking gun.
9. Apply adhesive to the adhesive position at cabin side so
bead triangle will be even.
(Refer to position to apply adhesive (3, Figure 41).)

5-2-24
Required
Cut Nozzle Required

End into
V-shaped
Adhesive
Apply Bead Here
Application bead
should form
9 even triangle.
12 Remove Seal
Adhesive Cartridge
Panel
EX1401037
Figure 42

10. The required amount (just for reference) of adhesive and
primer.
Painted Surface or
Glass Surface
Adhesive Surface
Adhesive Sika
Primer Sika Activator Primer Sika Primer
Tack-drive 310 ml
DM-1 250 ml Can 206G+P 30 ml Bottle
Cartridge
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Glass of Door 150 ml 0.50 ml 0.45 ml
Rear Left-hand Glass 250 ml 0.65 ml 0.60 ml
Rear Right-hand Glass 100 ml 1.00 ml 0.90 ml
Rear Glass 210 ml 0.50 ml 0.45 ml

5-2-25
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 43) 1
around sash assembly (1) from the cabin inside for easy
2
removal. Push the sash assembly by hands and remove
sash outside. 3
2. Install glass (3, Figure 43) and glass (4) into the sash 4
grooves.
3. Install the sash assembly, which the glass is installed on,
onto the door from the outside of cabin.
EX1301297
Secure the sash assembly at the inside of cabin by using Figure 43
the garnish.
Installation of Upper Front Glass

1. Stick seal to the lower side of front upper glass by using
Cemedine SIKAFLEX 255 ultrafast.
Stick and secure both right and left ends (the thicker part)
of seal to the glass by using Cemedine SIKAFLEX 255
ultrafast.
Stick the mating surface of seal and the glass by using
Cemedine SIKAFLEX 255 ultrafast so no visible undulation
or boss can be found.
NOTE: Cemedine SIKAFLEX 255 ultrafast Glue-state
adhesive, tubed.
Reference
Description
Number
1 Upper Glass
2 Seal
3 Lower Glass
4 Damper 1
Apply Silicone after 4
Fixing 2 (Seal)
Fill with Sealant

2
3
EX1301304
Figure 44

5-2-26
1Counterweight
Edition 1
DX210WA Counterweight
5-3-1
MEMO
Counterweight DX210WA
5-3-2
Table of Contents
Counterweight
General ...........................................................5-3-6
Warning for Counterweight and Front Attachment
Removal .................................................................... 5-3-6
Removal .........................................................5-3-8
Installation ......................................................5-3-9
5-3-3
5-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
5-3-5
GENERAL
Warning for Counterweight and Front

Attachment Removal
WARNING
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment (boom and arm) or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
WE1400011
Figure 1
front attachment has been removed.
Before any attempt is made to begin removal or installation of

the counterweight, the excavator must be parked on a firm and
level supporting surface, with no sloping surfaces or soft or
muddy ground in the area where the assist lift crane will be
working. Position all accessories in the overnight storage
position.
WARNING
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when
removal or installation lifts are being made. Lifting slings,
shackles and all other hardware must be rigged safely. An
assist crane that is rated above weight capacity is required.
• Weight
– Standrad: 3,400 kg (7,496 lb)
– Option: 3,800 kg (8,378 lb)
5-3-6
Responsibility must be assigned to one person to be in charge
of the lifting crew, and to verify that required safe lifting
precautions have been taken before each part of this procedure
has been started.
All members of the working crew should know and understand
the signals that will be used between the lifting leader, the assist
crane operator and the remainder of the work crew.
WARNING
If the upper structure deck has been unbalanced by
removal of weight from one end only, traveling with the
excavator, swinging the turntable, movement over bumps
or sloping and uneven surfaces could cause loss of control
resulting in tipping or rollover.
To maintain stability the counterweight must be removed only

when the front attachment is taken off the machine.
90 ~ 110
15
WE1400142
Figure 2
When loading an excavator (either track or wheeled type) on a

trailer for transport after the front attachment has been removed,
always go backwards up the loading ramp with the
counterweight uphill (Figure 3).
15
WE1400143
Figure 3
5-3-7
REMOVAL
O I
WARNING
LOCK
Death or serious injury can occur from a counterweight
falling during removal or installation. Do not allow WARNING
personnel under or around the counterweight during DO NOT OPERATE
removal or installation.
when performing inspection
or maintenance
190-00695A
ON OFF
Use certified cables and shackles of adequate load rating.
EX1401660
Improper lifting can allow the load to shift and cause death
Figure 4
or serious injury.
1. Park on firm and level ground.

2. Lower front attachment (bucket) to ground.
3. Stop engine.
4. Move safety lever to "UNLOCK" position.
WARNING
If engine must be running while performing
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.
6. Fully stroke work levers (joysticks) in all directions to

relieve any pressure from accumulators.
7. Move safety lever to "LOCK" position.
9. Apply the service brake with full stroke several time to O
relieve pressure from accumulator functioning braking.
10. Turn key to "O" (OFF) position and remove from starter switch. I
13. Make sure all electrical and other items are disconnected.
FG002178
Figure 5
5-3-8
14. Remove two caps (1, Figure 6) from counterweight (2). 3
1
15. Install two lifting eyes in lifting holes (3, Figure 6).
• Lifting eye size: M48 x 5.0 3
16. Using a suitable lifting device capable of handling a heavy

load, partially support counterweight (2, Figure 6) before
loosening four bolts (4). Stop lifting with assist crane as
2
soon as lifting slings are taut.
17. Remove four bolts (4, Figure 6), spacer (5) and shims (7
and 8) from counterweight (2).
• Tool: 46 mm ( )
NOTE: Heat bolts, if necessary, to free them.
8
18. When bolts (4, Figure 6) and shims (7 and 8) have been
7
removed, lift counterweight (2) a very short distance above 8
support frame (6) and stop. Check slings and make sure 7
counterweight is being supported evenly. 6
6 5
5
4
4 WE1400172
Figure 6
INSTALLATION 1
3
1. Using suitable lifting device capable of handling a heavy

load, raise counterweight (2, Figure 7) into position just 3
above support frame (6) leaving counterweight suspended.
Verify that counterweight is level and even.
NOTE: Leave counterweight (2, Figure 7) suspended 2
3 mm (0.12") above support frame (6) until all
four mounting bolts (4) are started in
counterweight mounting holes.
2. Slide spacer (5, Figure 7) onto bolts (4). Apply Loctite #242
to mounting bolt threads.
3. Install four bolts (4, Figure 7) with shims (7 and 8) into 8
counterweight until washers contact support frame. Fully
7
lower counterweight onto support frame and finish 8
tightening bolts. 7
6
• Tool: 46 mm ( )
• Torque: 1,471 N.m (150 kg.m, 1,085 ft lb) 6 5
4. Remove lifting device and lifting eyes from counterweight 5
lifting holes (3, Figure 7). 4
4 WE1400172
5. Install two caps (1, Figure 7) in lifting holes (3).
Figure 7
6. Turn battery disconnect switch to "ON" position.
5-3-9
5-3-10
1Hydraulic Oil Tank
Edition 1
DX210WA Hydraulic Oil Tank

5-4-1
MEMO
Hydraulic Oil Tank DX210WA

5-4-2
Table of Contents
Hydraulic Oil Tank

General ...........................................................5-4-5
Specification .............................................................. 5-4-5
Parts List ................................................................... 5-4-6
Air Breather ............................................................... 5-4-8
Removal .........................................................5-4-9
Installation ....................................................5-4-16
Completing Work ..........................................5-4-17

5-4-3
5-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Volume (Full) 205 L (54.2 U.S. gal)
Optimum Volume 122 L (32.2 U.S. gal)
Tank Size 521 x 652 x 872
Tank Weight about 143 kg (315 lb) (Empty)
Size 10 μm, 1.3 m2 (ø150 x 450)
Operation Pressure 0 ~ 15 bar (0 ~ 15 kg/cm2, 0 ~ 217.6 psi)
Return Filter (5, Figure 1)
Bypass Valve Setting 15 bar (1.5 kg/cm2) at 40 L/min
Flow Rate 600 L/min (158.5 U.S. gpm)
Filter 10 μm, 590 cm2
Air Breather (14, Figure 1)
Cracking Pressure 0.39 ~ 0.49 bar (0.04 ~ 0.05 kg/cm2, 0.57 ~ 0.71 psi)
Size 80 mesh, 2,958 cm2 (ø150 x 142)
Suction Filter (10, Figure 1)
Flow Rate 750 L/min (198 U.S. gpm)
Pressure Switch Actuation Pressure 1.5 bar (1.5 kg/cm2, 21.8 psi)
(101, Figure 1) Rating 4 A Resistance at 24 V DC Max.

5-4-5
Parts List
29
14B 14
FR
32
ON
14A T
32
2 7
8
3 12
4
11
6
22
15
10
5 30
13
101
21
26
25
27
27
28
28 16
20
19 9
18
17
WE1400173
Figure 1

5-4-6
Reference Reference
Number Number
1 Tank, Oil 15 Nut
2 Cover 16 O-ring
3 O-ring 17 Bolt M10 x 1.5 x 25
4 Spring 18 Washer, Spring
5 Element; Return Filter 19 Plug
6 Valve; By-pass 20 O-ring
7 Cover 21 Sensor; Hyd Oil Temp
8 O-ring 22 Strainer; By-pass
9 Pipe; Suction 25 Shim
10 Filter; Suction 26 Shim
11 Rod 27 Spacer
12 Spring; Compress 28 Bolt
13 Gauge; Level 29 Bolt
14 Breather, Air 30 Bolt M12 x 1.75 x 16
14A Gasket 32 Bolt; Set
14B Element; Air Breather 101 Pressure Switch

5-4-7
Air Breather
1. Structure of air breather
0.45 k 0.05 k 2
5
EX1301764
Figure 2
Reference Reference
Number Number
1 Housing 4 Flange
2 Element 5 Gasket
3 Body
2. Pressure release
Pulling the breather cap upward, the check valve 0.46 kg/cm2
(0.45 bar) opens, and the air is discharged to the atmosphere
from the top of the hydraulic oil tank.

5-4-8
REMOVAL
WARNING
Contact with hydraulic fluid can harm your health. (e.g. eye
injuries, skin damage or poisoning, if inhaled).
• While performing removal and installation, wear safety
gloves, safety glasses and suitable working clothes.
• If hydraulic fluid should come into contact with your
eyes or penetrate your skin, consult a doctor
immediately.
WARNING
FIRE CAN CAUSE SERIOUS INJURY OR DEATH
Hydraulic fluid is highly flammable.
• Keep open flames and ignition sources away from the
workplace.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants, grease,
etc. must be disposed of in an environmentally safe
manner. Some regulations require that certain spills and
leaks on the ground must be cleaned in a specific manner.
See local, state and federal regulations for the correct
disposal.
1. Make the machine swing about 150° rightward on the flat

ground.
2. Front position: Extend the arm and dump the bucket until
both cylinders are fully retracted. Lower the boom until the
bucket rests on the ground. (Figure 3)
3. Stop engine.
WE1400174
Figure 3

5-4-9
(Figure 4)
LOCK
WARNING WARNING
DO NOT OPERATE
or maintenance
ON OFF
6. Operate the joystick levers and pedals several times to

release the remaining pressure in the hydraulic piping.
O O
relieve pressure from accumulate functioning braking. I I
switch.
11. Attach a maintenance warning tag on controls. In Non-Rops Cabin In Rops Cabin
WE1401161
Figure 5

OFF
(Figure 6)
ON
Figure 6 EX1401760
NOTE: Removal (installation) procedure of the bolts.

3
5 8
1 2
7 6
4
EX1401809
Figure 7

5-4-10
WARNING
Release any pressure in the hydraulic oil tank before
doing any work.
13. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Figure 8 EX1402442
Pulling the breather cap upward, the check valve (0.45 bar)
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
14. Open the engine cover and remove bolts and spacers (1,
Figure 9) (4 ea) with cover of control valve (2).
• Tool: 19 mm ( )
1
• Cover weight: 16 kg (35 lb)
2
Figure 9 WE1400175
15. Remove bolts (1, Figure 9) (13 ea) with support (2).
• Tool: 19 mm ( )
• Support weight: about 7 kg (15 lb)
Figure 10 WE1400176
16. Remove bolts (1, Figure 11) (12 ea) with cover (2) and
1
support (3).
2
• Tool: 19 mm ( )
3
• Cover (2): about 7 kg (15 lb)
Figure 11 WE1400177

5-4-11
17. Oil drain method.
NOTE: Check the level on the oil level gauge before
draining the oil.
Figure 12 WE1400178
A. Remove cover (2 ea) on oil tank (bolt: 12 ea) and

drain hydraulic oil using oil pump. (Figure 13) Suction Filter Cover Return Filter Cover
Also pump oil from the suction pipe.
• Tool: 17 mm ( )
• Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
Figure 13 WE1400179
B. Drain hydraulic fluid using drain plug. (without oil

pump) (Figure 10)
• Tool: 27 mm ( )
• Torque: 93.1 N.m (9.5 kg.m, 68.7 ft lb)
• Hydraulic oil tank volume
– Approximately: 205 L (54.2 U.S. gal)
– Effective level: 122 L (32.2 U.S. gal)
Figure 14 Bottom of Main Frame WE1400180
18. Install eyebolts (2 ea) on the oil tank. (Figure 15)

And tie the rope to the bolts to lift oil tank.
• Thread of hole: M10 x 1.5
Figure 15 WE1400181

5-4-12
19. Remove bolts (1, Figure 16) (4 ea) with the tank front cover
(2) from fuel tank.
• Tool: 17 mm ( )
1
• Tank front cover weight: 10 kg (22 lb)
1
2
Figure 16 WE1400182
20. Open the storage box door, remove bolts (Figure 17) (2 ea).
• Tool: 19 mm ( )
Figure 17 WE1400183
21. Open the right side door, remove bolts (2 ea) with tank side
cover. (Figure 18)
• Tool: 19 mm ( )
• Tank cover weight: 18 kg (40 lb)
Figure 18 WE1400184
22. Remove bolts and washers (1, Figure 19) (6 ea) under
• Tool: 19 mm ( )
1
• Under cover weight: 3 kg (6.6 lb)
2

5-4-13
23. Remove oil tank mounting bolts and spacers (1, Figure 20)
(4 ea) from the main frame.
• Tool: 24 mm ( )
1
24. Remove bolts (2, Figure 20) (6 ea) of suction pipe from the 2
oil tank.
• Tool: 17 mm ( )
25. Disconnect the connector of oil temperature sensor (1, Figure 21) and pressure switch (2).
26. Remove bolts (3, Figure 21) (1 ea) and clips with harness.
• Tool: 12 mm ( )
1 Remove Clip Pressure

Switch
2 2
1 3 1
Temperature
Sensor 2
Figure 21 WE1400187
27. Remove hoses, pipes and adapters (Figure 22) from the oil tank.
NOTE: Attach an identification tag onto the removed hoses for reassembly.
Disconnect the hoses from the bottom to top of oil tank. After disconnecting hoses, plug them to
prevent dirt or dust from entering.
1 14
2 12 13
3 4 5 6
7
15 16
8 9 10 11
17
18
Figure 22 WE1400188

5-4-14
• Hoses and plugs ports
Plug/Flange Torque
Port Name
Size (Hose) (mm) (mm) N.m kg.m ft lb
1 from Control Valve "Xop" PF 1/4 19 39.2 4 28.9
from Control Valve "Dr4" PF 1/4 19 39.2 4 28.9
3
from Control Valve "Dr3" PF 1/4 19 39.2 4 28.9
5 from Control Valve "Dr1" PF 1/4 19 39.2 4 28.9
6 from Brake Pedal Valve "T1" PF 3/8 22 49.0 5 36.2
7 from Radiator SAE 2", D48 10 107.8 11 79.6
9 from Center Joint (Spindle) "15" PF 1/4 19 39.2 4 28.9
10 from T Block PF 1/2 27 93.1 9.5 68.7
11 from Brake Pedal Valve "T2" PF 3/8 22 49.0 5 36.2
from Solenoid Valve "T" PF 1/2 27 93.1 9.5 68.7
12
from Control Valve "XAk2" PF 1/4 19 39.2 4 28.9
13 from T/M Control Valve "T" PF 3/8 22 49.0 5 36.2
14 from Solenoid Valve "T" PF 1/2 27 93.1 9.5 68.7
from Control Valve "XBo" PF 1/4 19 39.2 4 28.9
15
from Control Valve "XAo" PF 1/4 19 39.2 4 28.9
17 Bolt and Clip 12 29.4 3 21.7
18 Oil Temperature Sensor 19 14.7 1.5 10.8
• Fitting
Size Torque
Port Name
A B (C) (mm) N.m kg.m ft lb
1, 9, 16 Adapter PF 3/8 PF 1/4 22 49.0 5 36.2
3, 15 Tee PF 3/8 PF 1/4 22 49.0 5 36.2
5 Elbow PF 3/8 PF 1/4 22 49.0 5 36.2
6, 11 Elbow PF 3/8 PF 3/8 22 49.0 5 36.2
10, 14 Elbow PF 1/2 PF 1/2 27 93.1 9.5 68.7
12 Tee PF 1/2 PF 1/2, PF 1/4 25 93.1 9.5 68.7
13 Elbow PF 1/2 PF 3/8 27 93.1 9.5 68.7
2, 4, 8, 16 Plug PF 3/8 22 49.0 5 36.2
1, 2, 3, 4, 5,
1B, P14
6, 8, 9, 11, O-ring
(S8000141)
15, 16
7 O-ring ID: 56.74, W: 3.53, 1B (2180-1026D27)
10, 12, 13, 1B, P18
O-ring
14 (S8000181)
* A: Opposite side of hose, B (C): Hose side
28. Lift up the oil tank 50 mm and make it is balanced.
• Oil tank weight: about 143 kg (315 lb)

5-4-15
INSTALLATION
WARNING
INCORRECT INSTALLATION CAN CAUSE DEATH OR
SERIOUS INJURY
Any change in the connections will lead to malfunctions
(e.g. lift instead of lower).
• When connecting hydraulic components, observe the
specified piping according to the hydraulic schematic
diagram of the machine.
NOTE: First, assemble the bolts and spacers (4 ea) of oil

tank mounting to main frame. (Figure 23)
1. Install the oil tank with bolts and spacers (1, Figure 23)
(4 ea) to the main frame.
• Tool: 24 mm ( ) 1
2
2. Install the bolts (2, Figure 23) (6 ea) through suction pipe to
the oil tank.
• Tool: 17 mm ( ) Figure 23 Bottom of Main Frame WE1400186

3. Perform installation in the reverse order to remove.
4. If removed the level gauge, install level gauge as the
following torque.
5. When assembling rod to suction filter, adjust the
assembling length as Figure 24.
3
Reference
Description
Number
A
1 Suction Filter
2 Nut 2
3 Rod
1
• Length (A): 650 mm
EX1402872
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) Figure 24

5-4-16
6. Location of air breather (1) must be as Figure 25 when
assembling cover (2).
Figure 25 WE1400189
COMPLETING WORK
1. Hydraulic oil tank volume:
• Approximately: 205 L (54.2 U.S. gal)
• Effective level: 122 L (32.2 U.S. gal)
2. Adjusting standard for hydraulic oil level
A. Front position: Extend the arm and dump the bucket
until both cylinders are fully retracted. Lower the
boom until the bucket rests on the ground.
B. Engine condition: Low idle WE1400174
Figure 26
C. Fill hydraulic oil until fluid in level gauge is positioned
between low and high marks. If hydraulic oil level is
too high, drain excess hydraulic oil from tank by
removing drain plug located on bottom of tank.

5-4-17
5-4-18
1Fuel Tank
Edition 1
DX210WA Fuel Tank

5-5-1
MEMO
Fuel Tank DX210WA

5-5-2
Table of Contents
Fuel Tank
General ...........................................................5-5-5
Specification .............................................................. 5-5-5
Parts List ................................................................... 5-5-6
Removal .........................................................5-5-8
Installation ....................................................5-5-13
Completing Work ..........................................5-5-14
DX210WA Fuel Tank

5-5-3
Fuel Tank DX210WA
5-5-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
WARNING
Diesel fuel is highly flammable and can be potentially
explosive. To prevent fires or explosion, keep arcs, sparks or
other ignition sources away from diesel fuel or fuel
containers.
Specification
Volume (Full) 350 L (92.5 U.S. gal)
Tank Size (mm) 628 x 845 x 976
Tank Weight about 169 kg (373 lb) (Empty)
Fuel Strainer Filter Filtration Ratio 24 mesh
(3, Figure 1) Working Oil Temp. -40 ~ +80°C
0.25 ~ 0.05 bar
Positive Pressure
Fuel Cap (0.25 ~ 0.05 kg/cm2, 3.63 ~ 0.73 psi)
Check Valve
(16, Figure 1) below 0.035 bar
Negative Pressure
(0.035 kg/cm2, 0.51 psi)
DX210WA Fuel Tank

5-5-5
Parts List
16
16-1
FR
ON
T
23 3
22
18
19
20
102
4
101
6
5
6
5
14
14 13 15
13 12 13
8
12 15 12
7
13
10
9 11 12
21
17
WE1400190
Figure 1
Fuel Tank DX210WA

5-5-6
Reference Reference
Number Number
1 Tank, Fuel 14 Shim
2 Sender, Fuel 15 Shim
3 Filter; Fuel Strainer 16 Cap, Fuel
4 Gauge; Level 16-1 Element (Fuel Cap)
5 Bolt 17 Hose
6 Clip 18 Screw
7 Cover 19 Washer; Spring
8 O-ring 20 Bracket
9 Bolt M10 x 1.5 x 25 21 Clamp; Hose
10 Washer, Spring 22 Cover
11 Cock; Drain 23 Bolt; Set
12 Bolt 101 Plug
13 Spacer 102 O-ring
DX210WA Fuel Tank

5-5-7
REMOVAL
WARNING
Fire hazard!
Fuel is easily flammable.
workplace.
1. Look at fuel level display (Figure 2) on instrument panel in

operator's cabin to see what it displays. The display is
divided into five separated segments. Also, look at level
gauge on side of tank to estimate volume of fuel left in
tank.
NOTE: If possible, work excavator until available fuel E F
supply in tank has been run down as far as
possible.
Figure 2 FG018115
2. Park on firm and level ground and swing turntable to

approximately a 180° with respect to tracks. See Figure 3.
FG025922
Figure 3
3. Lower front attachment (bucket) to ground. O I

4. Stop engine.
5. Move safety lever to "RELEASED" (UNLOCK) position.
6. Turn starter switch to "I" (ON) position. LOCK
WARNING
WARNING DO NOT OPERATE

or maintenance
190-00695A
ON OFF
EX1401660
If engine must be running while performing Figure 4
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.

Fuel Tank DX210WA

5-5-8
8. Move safety lever to "LOCK" position.
O O
switch.
WE1401161
Figure 5

OFF
(Figure 6)
ON
Figure 6 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 7
14. Clean area around fuel tank fill cap. Open fuel cap.
Figure 8 WE1400191
DX210WA Fuel Tank

5-5-9
15. Remove bolts and washers (1, Figure 9) (5 ea) under cover
(2) on bottom of main frame.
• Tool: 19 mm ( )
2
• Under cover weight: 5 kg (11 lb)
1
16. Open drain valve (Figure 10) at bottom of tank and

carefully drain.
• Fuel tank capacity: 350 L (92.5 U.S. gal).
Figure 10 Bottom of Tank WE1400193
17. Remove bolts and washers (1, Figure 11) (8 ea) with the
handrail (2) from fuel tank and frame. 2
3
18. Remove bolts (3, Figure 11) (4 ea) with the tank front cover 1
(with tank cover bracket) (4) from fuel tank.
• Bolt (1)
3
– Tool: 19 mm ( ) 4
1
– Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
• Bolt (3)
– Tool: 17 mm ( ) Figure 11 WE1400194
– Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)

• Weight
Reference
Description kg (lb)
Number
2 Handrail 20 (44.1)
4 Tank Front Cover 10 (22)
Fuel Tank DX210WA

5-5-10
19. Disconnect the connector of fuel sensor (1, Figure 12).
1
20. Open the storage box door, remove bolt (2, Figure 12) and
clip with harness (3).
• Tool: 12 mm ( )
3
Figure 12 WE1400195
How to disconnect the harness connector.

1
Figure 13 WE1400196
21. Remove hose from fuel tank.

• Tool for clip (1): Driver
1
3
Figure 14 WE1400197
Plug/Flange Size Torque

Port Name
(Hose) (mm) N.m kg.m ft lb
2 Clip 12 29.4 3 21.7
3 Plug PF 1/2 27 93.1 9.5 68.7
DX210WA Fuel Tank

5-5-11
22. Remove bolts (1, Figure 15) (5 ea) and cover (2) from fuel
tank.
• Tool: 19 mm ( )
Figure 15 WE1400198
23. Install eyebolts (2 ea) on the fuel tank.

And tie the rope to the bolts to lift tank.
• Thread of hole: M12 x 1.75
• Fuel tank weight: 169 kg (372.6 lb)
Figure 16 WE1400199
24. Remove bolts (Figure 17) (2 ea).
• Tool: 19 mm ( )
Figure 17 WE1400200
25. Open the right side door, remove bolts (Figure 18) (2 ea)
with tank side cover.
• Tool: 19 mm ( )
• Tank cover weight: 18 kg (40 lb)
Figure 18 WE1400201
Fuel Tank DX210WA

5-5-12
26. Remove hose from fuel tank
• Tool for clip (1): Driver
27. Remove fuel tank mounting bolts and spacers (3, Figure 19) 1
(4 ea) from the main frame.
• Tool: 24 mm ( )
28. Lift tank 25 mm and make sure it is balanced. 3
29. Make sure there are no other electrical wires or hoses

connected to tank. Figure 19 Bottom of Tank WE1400202
30. Completely remove tank after inspection
• Fuel tank weight: 169 kg (372.6 lb)
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
INSTALLATION
NOTE: First, assemble the bolts and spacers (4 ea) of fuel
tank mounting to main frame. (Figure 20)
1. Install the fuel tank with bolts and spacers (3, Figure 20) 1
(4 ea) to the main frame.
• Tool: 24 mm ( )
NOTE: The clear level gauge on the side of the tank is 3
easily damaged. Be careful of obstacles and
wind gusts.
2. Connect fuel supply line (1, Figure 20). Figure 20 Bottom of Tank WE1400203

4. Make sure fuel tank drain valve (2, Figure 20) is closed.
5. Fill fuel tank and check for signs of leaks. Correct any
problems found.
6. Fuel tank capacity: 350 L (92.5 U.S. gal)
DX210WA Fuel Tank

5-5-13
COMPLETING WORK
If engine does not start, the fuel system may need priming.
Prime the fuel system using the following procedure:
1. Stop engine.
2. Open left side door and then there is fuel filter.
Figure 21 WE1400204
3. Loosen plug (1, Figure 22) on top of fuel filter head.

4. Pump hand operated primer pump (2, Figure 22).
Pump primer until fuel is present at plug hole in fuel filter
2
head.
5. Tighten plug in fuel filter head. 1
6. Continue to pump primer pump until a strong resistance is
felt.
7. Start engine and look for signs of leaks.
Repeat procedure if necessary.
Figure 22 WE1400205
Fuel Tank DX210WA

5-5-14
1Main Pump
Edition 1
DX210WA Main Pump

5-6-1
MEMO
Main Pump DX210WA

5-6-2
Table of Contents
Main Pump
General ...........................................................5-6-5
Specifications ............................................................ 5-6-5
Overview ................................................................... 5-6-8
Hydraulic Circuit ........................................................ 5-6-9
Parts List ................................................................. 5-6-10
Theory of Operation ................................................ 5-6-14
Section View .................................................5-6-27
Removal .......................................................5-6-28
Installation ....................................................5-6-36
Completing Work ..........................................5-6-37
Assembly Guidelines for Tightening Torques ...5-6-38
Bolts ........................................................................ 5-6-38
Plugs with Internal Hexagon and Profile Seal Ring. 5-6-39
Seal-lock - Sealing Nuts .......................................... 5-6-39
Disassembly and Reassembly......................5-6-40
General Repair Guidelines ...................................... 5-6-40
Seal Kits and Subassemblies.................................. 5-6-42
Sealing the Driveshaft ............................................. 5-6-46
Gear Pump Sealing ................................................. 5-6-48
Removing Control Housing ..................................... 5-6-49
Control Module ........................................................ 5-6-52
Removing the Controller.......................................... 5-6-54
Valve Plate with Valves ........................................... 5-6-56
Remove Rotary Groups........................................... 5-6-57
Remove Intermediate Wheel................................... 5-6-60
Remove Auxiliary Drive ........................................... 5-6-62
Inspection ................................................................ 5-6-65
Assembling the Rotary Group ................................. 5-6-70
Pump Assembly ...................................................... 5-6-72
Hydraulic Component - Measurement "D" .............. 5-6-75
Installation of Control Housing ................................ 5-6-78
DX210WA Main Pump

5-6-3
Assembly of Intermediate Wheel............................. 5-6-81
Installation of Gear Pump........................................ 5-6-82
Installation of Cover/Auxiliary Drive......................... 5-6-83
Troubleshooting ............................................5-6-84
How to Proceed for Troubleshooting....................... 5-6-84
Malfunction Table .................................................... 5-6-85
Main Pump DX210WA

5-6-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Engine Power (P) 127 kW (172 PS) @ 2,000 rpm
Rated Speed (N) 2,000 rpm
High Idle (N) 2,200 rpm
Max. Flow (Q max.) 2 x 232 L/min @ 2,000 rpm & 35 bar
Min. Flow (Q min.) 2 x 15 L/min @ 2,000 rpm
Max. Displacement (V g max.) 116 cm3 / rev x 2
Weight 120 kg (265 lb)
Negative Control Pressure
Beginning of Regulation (P) 9.8 ±0.5 bar (10 ±0.5 kg/cm2, 142 ±7 psi)
End of Regulation (P) 31 ±1 bar (31.6 ±1 kg/cm2, 449 ±14 psi) @ 50 L/min
Pilot Pressure Pump Relief Valve
Pilot Pressure (P) 39 ±2 bar (40 ±2 kg/cm2, 569 ±28 psi) @ 1,900 rpm
DX210WA Main Pump

5-6-5
Performance Curves
1. P - Q Curve
141 K 171 K
250 206 L 228 L
125 K
195 L
200
114 K
183 L
150
252 K
222 K 126 L
Q Flow (L/min)
114 L
100
357 K
192 K 75 L
102 L 203 K
109 L 357 K
56 L
343 K
50 49 L
343 K
42 L
0 50 100 150 200 250 300 350
P Discharge Pressure (kg/cm 2)
WE1400319
Figure 1
Secondary
Input Input Current Input Power Power Ratio
Mode Pressure Remarks
(rpm) (mA) (PS) (%)
(bar (kg/cm2))
Travel 2,000 200 ±30 1.1 ±1 (1.1 ±1) 205 100 Variable
Power 1,950 280 ±30 3.8 ±1 (3.8 ±1) 154.8 76 Variable
Standard 1,850 310 ±30 5.1 ±1 (5.2 ±1) 131.3 64 Variable
Economy 1,750 340 ±30 6.5 ±1 (6.6 ±1) 114.9 56 Variable
Low 1,400 650 ±30 24.5 ±1 (25 ±1) 71.2 35 Variable
Main Pump DX210WA

5-6-6
2. P - I Curve
A3
EPPR Valve
Input Current
R3
25.0
R1
22.5
Secondary Pressure (kg/cm2)

20.0
M2 17.5
A2
15.0
12.5
Vg max Vg min X1
10.0
7.5
M3 5.0
X3 2.5
Vg max Vg min
0.0
0 100 200 300 400 500 600 650
X1
Controlled Current (mA)
A1
M1
R2 S
WE1400320
Figure 2
DX210WA Main Pump

5-6-7
Overview
This pump is a pressure control type which has an axial piston
variable double pump structure equipped with two axial piston
rotary groups in a joint shaft design for hydraulic drive. It
consists of the EPPR valve to control the pump's pressure,
regulator to control the swivel angle of the pump, pilot sensor to
convert the pump displacement flow into an electric signal, gear
pump for pilot pressure, PTO for an optional pump, and pump
cover to be engaged with the engine to fix the pump.
Port
A3
X1
M3
R3 X1
M1
S
M2 R1
A2
A R2 A1
View A EX1403144
Figure 3
Port Description Size

S Suction Port SAE 3 1/2"
A1 Piston Pump Delivery Port SAE 1"
A2 Piston Pump Delivery Port SAE 1"
A3 Gear Pump Delivery Port (39 bar (40 kg/cm )) 2 M18 x 1.5
X1 Control Pressure Ports for Negative Control (ps1 and ps2) M14 x 1.5
M1 Measurement Port A1 9/16"-18UN-2B
M2 Measurement Port A2 9/16"-18UN-2B
M3 Measurement Port for Power Override M14 x 1.5
R1 Air Bleed Port M14 x 1.5
R2 Drain port M14 x 1.5
R3 Air Bleed Port M14 x 1.5
Main Pump DX210WA

5-6-8
Hydraulic Circuit
A3
EPPR Valve
R3
R1
M2
A2
Vg max Vg min X1
M3
X3
Vg max Vg min
X1
A1
M1
R2 S
EX1403145
Figure 4
DX210WA Main Pump

5-6-9
Parts List
The exploded view of the pump shows the parts necessary for
internal repair and assembling and the parts available when
required.
Rotary Group
4
3
4B
4A
5
24
4D 4C
4E
23 2
8 25
27
7
25
22
21
20
2Ac
2Ad 2Ac2
2Ae 2Ac1
2Af 2Ab
2 2B 2Ba
2D
2Aa
2Be
2Ag
2Bb
2Bf
2Bc 2A
2Bd
3Ac
3Ad 3Ac2
3Ae 3Ac1
3 3Ab
3B 3Ba 3Af
3D
3Be 3Aa
3Bb 3Ag
3Bf
3Bc
3Bd
3A
Figure 5 EX1403163
Main Pump DX210WA

5-6-10
Reference Reference
Number Number
2 Rotary Group 3Ad Collar; Spring
2A Rotary Group; Section 3Ae Cup Spring
2Aa Cylinder 3Af Plate; Retaining
2Ab Pin; Center 3Ag Screw; Pan Head
2Ac Piston & Piston Rings 3B Shaft; Drive
2Ac1 Piston 3C Shim
2Ac2 Ring; Steel Sealing 3D Control Lens; Left-hand
2Ad Collar; Spring 3E Plate; Back-up
2Ae Cup Spring 3F Ring; Retaining
2Af Plate; Retaining 3G Bearing; Unit Tapered-roller
2Ag Screw; Pan Head 3H Bearing; Tapered-roller
2B Shaft; Drive 4 Pump; Gear
2C Shim 4A Bolt; Socket M10 x 20
2D Control Lens; Right-hand 5 Housing; Pump
2E Plate; Back-up 7 Gear
2F Ring; Retaining 8 Shaft; Stub
2G Bearing; Unit Tapered-roller 9 Stud; Connect
2H Bearing; Tapered-roller 20 Ring; Retaining
3 Rotary Group 21 Seal; Oil
3A Rotary Group; Section 22 Shim
3Aa Cylinder 23 Screw; Locking
3Ab Pin; Center 24 Screw; Locking
3Ac Piston & Piston Rings 25 Bearing; Plain Roller
3Ac1 Piston 27 Shaft; Key
3Ac2 Ring; Steel Sealing 28 O-ring
DX210WA Main Pump

5-6-11
Control Part
2Aj
2Ai
2Ah
2Am
2Af
2Ag
2An
2A 2Af 2As
2Ao
2Aq
2Ar
2Aa
2Al 2Ad
2Ac 2A
2Ap
2Ab
2C
2Ae 2O
2Ak
2E
2D 2F 2N
49 46
2M
2B
18
50 2G
2I
48
2H
10 2
47 2L 2J
11
2K
44
43
42
15
42
14
13
12
17
16
37
26 EX1403164
Figure 6
Main Pump DX210WA

5-6-12
Reference Reference
Number Number
2 Control Module 2H Collar; Spring
2A Control Module 2I Spring
2Aa Housing; Control 2J Spring
2Ab Piston; Control 2K O-ring
2Ac Bush; Control 2L O-ring
2Ad Piston; Positioning 2M Screw; Locking
2Ae Pin 2N Nut; Seal Lock
2Af Collar; Spring 2O Bolt
2Ag Spring; Pressure 10 Plate; Port
2Ah Screw; Locking 11 Gasket
2Ai Pin; Threaded 12 Piston; Positioning
2Aj Nut; Seal Lock 13 Trunnion; Positioning
2Ak O-ring 14 Collar; Spring
2Al O-ring 15 Spring
2Am O-ring 16 Piston
2An Screw; Socket-head 17 Pin; Threaded
2Ao Plug 18 Plug
2Ap Pin; Cylinder 26 Screw; Hex
2Aq Plug 37 Ring; Steel Sealing
2Ar Plug 42 Bolt; Socket
2As Screw; Locking 43 Bolt; Socket M12 X 1.75 X 80
2B Housing; Control 44 Pin; Cylinder
2C Piston; Control 46 Plug
2D Bush; Spring 47 Nut; Seal Lock
2E Spring; Pressure 48 Pin; Threaded
2F Pin; Threaded 49 O-ring
2G Collar; Spring 50 Screw
DX210WA Main Pump

5-6-13
Theory of Operation
The axial piston variable double pump with two axial tapered
piston rotary groups with bent-axis design for open-circuit
hydrostatic drives. The axial piston variable double pump has a
common suction port (S) for both circuits and the auxiliary pump.
It generates two flows for supplying two separate circuits.
Flow is proportional to drive speed and displacement.
By adjusting the bent-axis rotary groups, the two flows can be
steplessly changed independent of one another. For axial piston
units with bent-axis design, the pistons (3) are arranged at an
angle to the driveshaft (1). When the driveshaft is turned, the
cylinder (4) is picked-up and set into motion cardan free by the
pistons, which are arranged in a ring on and flexibly connected
to the driveshaft flange. The cylinder then rotates over the
spherical control lens (5), in which two kidney-shaped control
slots have been incorporated. As they turn, each of the pistons
moves from top to bottom dead center and back, executing a
stroke that depends on the swivel angle. The driveshaft flange of
both rotary groups, which lie parallel next to one another, are
interlocked. The rotary group with the long driveshaft drives the
second rotary group by way of the interlocked drive-shaft flange.
On the low-pressure side, fluid flows into the enlarging piston
chamber. At the same time, on the pressure side the fluid is
pushed out of the cylinder chamber into the hydraulic system by
the pistons. The pistons are braced against the driveshaft flange
by the load of the hydraulic pressure.
Main Pump DX210WA

5-6-14
Ad1
6
2 A3 X1 Relief Valve (40 bar)
M3
Power Shift
Pressure
Pilot Ad2
Pump
Servo Piston (7)
8 EPPR Valve
3
4
5
Ad3
A1
P2
S
P1
P3
A2
Option
Figure 7 EX1403146
Reference Reference
Number Number
1 Drive Shaft 7 Positioning Piston
2 Gear Pump (Pilot) 8 Positioning Trunnion
3 Piston S Suction Port
4 Cylinder A1, A2 High-pressure Delivery Port
5 Control Lens A3 Pilot Port
6 EPPR Valve
DX210WA Main Pump

5-6-15
Engine torque is transferred to the shaft and the seven plungers,
causes the cylinder block to rotate while sliding along the valve
plate surface.
The plunger oscillates in the cylinder block bores and alternately
hydraulic oil is drawn and delivered.
Piston
Control Lens
Driveshaft
Cylinder
EX1400245
Figure 8
Increasing and Decreasing Flow Rate

Changing inclination of cylinder (4, Figure 7) causes the piston (3,
Figure 7) stroke to increase or decrease depending on the slant
angle in order to control the main pump flow rate.
Up-down movement of positioning piston (7, Figure 7) changes
inclination of cylinder (4, Figure 7). Positioning piston (7, Figure 7)
is interlocked with control lens (5, Figure 7) positioning trunnion
(8, Figure 7).
The one end of cylinder (4, Figure 7) is kept in contact with the
surface of control lens (5, Figure 7) and slides along it.
Maximum Displacement Angle: Minimum Displacement Angle (Operable Limit Angle):
Piston Swash Plate Cylinder Block Piston Swash Plate
Cylinder Block EX1400646

Figure 9
Main Pump DX210WA

5-6-16
Pressure Control
As the magnetic pump discharge pressure A1 and the relative
pump pressure A2 rise, the pump's swivel angle (discharge flow
rate) is automatically decreased to limit the input torque under a
certain level. (While the RPM is constant, the input power (HP)
is constant as well.)
As the system is operated with the combined load pressure of
double pumps in parallel, the regulator for each pump is
controlled with the same swivel angle (discharge flow rate)
during power control.
This mechanism prevents overload of the motor regardless of
load application on two pumps.
• Pump Input Pressure (PS) = (P x Q)/450
P: External System or Load Pressure, (P1 + P2)/2
Q: Pump Discharge Flow Rate
DX210WA Main Pump

5-6-17
Decrease of Pump Pressure
1. Decrease input pressure signal to EPPRV.
2. Regulator spool moves upward and connect the pump
pressure to head side of control piston.
3. Control piston moves right and decrease swash plate.
4. Decreasing flow rate decreases pump pressure.
A3
EPPR Valve
Input Current
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S
Pilot
Pump High System
Pressure
Minimum Flow Position EX1403147

Figure 10
Main Pump DX210WA

5-6-18
Increase of Pump Pressure
1. Increase input pressure signal to EPPRV.
2. Regulator spool moves downward and connect head side
of control piston to drain.
3. Control piston moves left and increase swash plate.
4. Increasing flow rate increases pump pressure.
A3
EPPR Valve
Input Current
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S
Pilot
Pump Low System
Pressure
Maximum Flow Position

EX1403148
Figure 11
DX210WA Main Pump

5-6-19
Flow Control
As shown in the figure below, the pump's discharge flow rate is
arbitrarily controlled according to change in the pilot pressure.
The servo valve is a negative flow control type to decrease the
main pump's discharge flow rate according to increase of the
pilot pressure.
Therefore, fuel consumption can be decreased during operation
by discharging only the required amount of oil with pilot
pressure.
380
360
340
320
300
280
Pump Discharge Flow Rate (L/min)
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 10 20 30 40
Pilot Presuure (kg/cm2)
EX1401128
Figure 12
Main Pump DX210WA

5-6-20
Decrease Oil Flow
When receiving high negacon pressure through the port ps1 or
ps2 from the control valve by the operating signal (neutral
position), pressure in the large-diameter chamber is increased.
Even though pressure is always built in the small-diameter
chamber, their volumetric difference pushes the servo piston,
decreasing the angle of the swash plate and reducing the
discharge flow rate of the pump. As the pump's discharge flow
rate is minimized, power loss and heat by excessive oil flow from
cut-out valve are prevented.
A3
EPPR Valve
Input Current
R3
R1
M2 High Negacon
A2 Pressure
X1
M3
X3
X1
A1
M1
R2 S
High Negacon
Pressure
Pilot
Pump
Minimum Flow Position

Figure 13 EX1403149
DX210WA Main Pump

5-6-21
Increase Oil Flow
When receiving low negacon pressure through the port ps1/ps2
by operation of each spool of the control valve through the pilot
line, oil flows to the large-diameter chamber, control piston and
drain port, so pressure in the large-diameter chamber is
decreased. As the small-diameter chamber is always applied
with discharge pressure, the swivel angle is increased to push
the servo piston. Then, the angle of the swash plate is increased
to maximize the pump's discharge flow rate, making an efficient
operating condition.
A3
EPPR Valve
Input Current
R3
R1
M2 Low Negacon
A2 Pressure
X1
M3
X3
X1
A1
M1
R2 S
Low Negacon
Pressure
Pilot
Pump
Maximum Flow Position

Figure 14 EX1403150
Main Pump DX210WA

5-6-22
Power Shift
The power shift function controls the setting power of the pump
by changing current of the EPPR (Electronic Proportional
Pressure Reducing) valve which is attached to the pump.
The power shift EPPR valve sends its secondary pressure to the
power control section of each pump regulator through the
internal passage of the pump to change power to the same
level. With this mechanism, power of the pump can be arbitrarily
adjusted in order to obtain optimum level of power suitable for
various operating conditions.
A3
EPPR Valve
Input Current
R3
25.0
R1
22.5
Secondary Pressure (kg/cm2) 20.0
M2 17.5
A2
15.0
12.5
Vg max Vg min X1
10.0
7.5
M3 5.0
X3 2.5
Vg max Vg min
0.0
0 100 200 300 400 500 600 650
X1
Controlled Current (mA)
A1
M1
R2 S
WE1400320
Figure 15
Secondary Pressure Input Current

Mode
(bar (kg/cm2)) (mA)
Travel 1.1 ±1 (1.1 ±1) 200 ±30
Power 3.8 ±1 (3.8 ±1) 280 ±30
Standard 5.1 ±1 (5.2 ±1) 310 ±30
Economy 6.5 ±1 (6.6 ±1) 340 ±30
Low 24.5 ±1 (25 ±1) 650 ±30
DX210WA Main Pump

5-6-23
Power Shift (STD Mode/Economy Mode: 5.1 ~ 6.5 bar (5.2 ~ 6.6 kg/cm2, 74 ~ 94 psi)
A3
EPPR Valve
Input Current
300 ~ 340 mA
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S WE1400321
Figure 16
Power shift pressure helps moving power control spool easily

with low system pressure.
310 ~ 340 mA
Check
Point
Pilot
Pump
WE1400322
Figure 17
Main Pump DX210WA

5-6-24
Power Shift (Travel Mode/Power Mode: 1.1 ~ 3.8 bar (1.1 ~ 3.9 kg/cm2, 16 ~ 55 psi)
A3
EPPR Valve
Input Current
200 ~ 280 mA
R3
R1
M2
A2
X1
M3
X3
X1
A1
M1
R2 S
200 ~ 280 mA
Pilot
Pump
WE1400323
Figure 18
To control flow, it needs more system pressure then standard mode pressure.
DX210WA Main Pump

5-6-25
Adjusting and Measuring Point
Ad1
Ad3
X1 (Pilot Nagative
Pressure)
A3
M3
Power Shift Ad2

Pressure
Pilot Ad2
Q Flow (L/min)
Pump
Ad1
Pi - Q Curve
Servo Piston
P Dischage Pressure (kg/cm2)

Ad3
10 20 30 40
X1 Pilot Pressure (kg/cm ) 2
Figure 19 EX1403155
• Flow adjusting
– Ad1: Flow control adjust screw (The flow rate by pilot pressure adjusted)
– Ad2: Pressure control adjust screw (Pump input pressure adjust)
– Ad3: Max. flow adjust screw (Servo Piston Stroke Limitation)
• Measuring point
– M3: Power shift pressure check point (EPPR Valve 2nd pressure)
Main Pump DX210WA

5-6-26
SECTION VIEW
Ad1
6
2 A3 X1 Relief Valve (40 bar)
M3
Power Shift
Pressure
Pilot Ad2
Pump
Servo Piston (7)
8 EPPR Valve
3
4
5
Ad3
A1
P2
S
P1
P3
A2
Option
EX1403146
Figure 20
Reference Reference
Number Number
1 Drive Shaft 5 Control Lens
2 Gear Pump (Pilot) 6 EPPR Valve
3 Piston 7 Positioning Piston
4 Cylinder 8 Positioning Trunnion
DX210WA Main Pump

5-6-27
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Park the machine on flat level ground.

2. Swing upper structure to approximately a 90° with respect
to wheels. (Figure 21)
3. Stop the engine.
EX1402441
Figure 21
Main Pump DX210WA

5-6-28
(Figure 22)
LOCK
WARNING WARNING
DO NOT OPERATE
or maintenance
ON OFF

7. Move safety lever on "LOCK" position. (Figure 22)
O O
switch.
WE1401161
Figure 23

OFF
(Figure 24)
ON
Figure 24 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 25
DX210WA Main Pump

5-6-29
WARNING
doing any work.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 26 EX1402442
14. Oil drain method
A. Remove cover (2 ea) on oil tank (bolt: 12 ea), drain Suction Filter Cover Return Filter Cover
hydraulic oil using oil pump. (Figure 27)
• Tool: 17 mm ( )
Figure 27 WE1400179
B. Drain hydraulic fluid using drain plug.

(without oil pump) (Figure 28)
• Tool: 27 mm ( )
• Hydraulic oil tank capacity
– Approximately: 205 L (54 U.S. gal)
– Effective level: 122 L (32 U.S. gal)
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1008
EX1402445
Figure 29
Main Pump DX210WA

5-6-30
Reference
Description
Number
3
1 Suction Filter
2 Nut
A
3 Rod
2
When installing
• Length (A): 650 mm 1
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) EX1402872
Figure 30
15. Remove bolt (3, Figure 31) (7 ea) and remove under cover
2 1
(2, Figure 31) under pump side.
• Tool: 19 mm ( )
• Cover weight: about 9 kg (20 lb)
Figure 31 Bottom of Main Frame EX1402446
16. Open the right side door.
Figure 32 EX1402447
17. Remove bolts (3, Figure 33) (11 ea) related baffles, covers
1 3
around pump and remove baffles and covers.
• Tool: 19 mm ( )
• Cover weight
Reference Weight 2
Number kg lb
1 2 4.4
2 4 8.8 Figure 33 EX1402448
DX210WA Main Pump

5-6-31
18. Remove bolts and nuts (1, Figure 34) (2 ea) with gas
springs (2 ea) from engine bonnet.
• Tool: 13 mm ( )
19. Remove lock pin (2, Figure 34) with stay from support. 1 3
20. Stay engine bonnet with stick or pipe (3, Figure 34).
Figure 34 EX1402449
21. Remove bolts and nuts (2 ea) with clamp from exhaust
pipe.
• Tool: 19 mm ( )
Figure 35 EX1402450
22. Remove bolts (1, Figure 36) (5 ea) with cover (2).
• Tool: 19 mm ( ) 2
1
• Cover weight: about 7 kg (15.4 lb)
Figure 36 EX1402451
23. Tie rope around muffler assembly to support it, and tighten
the rope when remove remaining bolts (4 ea).
• Weight: about 30 kg (66 lb)
Figure 37 EX1402452
Main Pump DX210WA

5-6-32
24. Remove bolts and washers (3 ea) (Figure 38).
• Tool: 17 mm ( )
Figure 38 EX1402453
25. Lift the muffler assembly from engine slowly and carefully.
Figure 39 EX1402454
26. Disconnect the connector of main harness from EPPR

valve and pressure sensor.
Figure 40 EX1402456
Figure 41 EX1402455
DX210WA Main Pump

5-6-33
27. Remove bolts (4 ea) and remove suction pipe of bottom of
pump. Drain the hydraulic oil of suction pipe to bowl.
• Tool: 24 mm ( )
Figure 42 EX1402458
28. Remove hoses and adapters from main pump.

NOTE: Attach an identification tags to the removed A3
hoses for reassembling.
After disconnecting hoses, plug them to prevent
dirt or dust from entering. X1
Disconnect the hoses from the bottom to top of X1
main pump. M1
M2
A2 S A1
Figure 43 EX1402459
• Hoses and plug ports

Port Name
(Hose) (mm) (mm) N.m kg.m ft lb
A1 to Control Valve "P1" SAE 1", D25 10 107.9 11 79.6
A2 to Control Valve "P2" SAE 1", D25 10 107.9 11 79.6
X1
from Control Valve "Fl" PF 1/4 19 39.2 4 28.9
(Rear)
X1
from Control Valve "Fr" PF 1/4 19 39.2 4 28.9
(Front)
A3 to Pilot Filter PF 1/2 27 93.1 9.5 68.7
M1,
Pressure Sensor PF 3/8 27 6.0 0.6 4.4
M2
• Fitting
Size Torque
Port Name
A B (mm) (mm) N.m kg.m ft lb
A2 Block SAE 1", D25 SAE 1", D25 10 107.9 11 79.6
X1 Adapter M14 x 1.5 PF 1/4 19 176.4 18 130.1
A3 Adapter M18 x 1.5 PF 1/2 27 392 40 289.2
M1, M2 Adapter UNF 9/16-18 PF 3/8 24 25.5 2.6 18.8
A1, A2 O-ring ID: 32.92, W: 3.53, 1B (2180-1026D19)
ID: 98.02, W: 3.53, Class 1
S O-ring
(2180-1026D33)
M1, M2 O-ring 1B B-06 (S8040061)
* A: Opposite side of hose, B: Hose side
Main Pump DX210WA

5-6-34
29. Remove bolts (7 ea) of pump without top bolts (2 ea).
• Tool: 17 mm ( )
Figure 44 EX1402460
30. Attach a lifting device around pump. Raise the lifting device
until the pump is supported prior to removing remaining
bolts (2 ea).
• Main pump weight: about 123 kg (271 Ib)
CAUTION
AVOID INJURY
Support the pump prior to removing remaining bolts to
prevent pump from falling.
Figure 45 EX1402461
31. Remove remaining bolts (2 ea).
• Tool: 17 mm ( )
EX1402462
Figure 46
DX210WA Main Pump

5-6-35
32. Lift the pump from engine slowly and carefully.
Figure 47 EX1403069
INSTALLATION
WARNING
SERIOUS INJURY
1. Perform installation in the reverse order to removal.

2. When installing the pump to engine, be careful assembling
pump shaft and drive coupling. Refer to drive coupling
installation.
Main Pump DX210WA

5-6-36
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill the
hydraulic oil tank.
IMPORTANT
If pump is run without sufficient oil in the main
hydraulic pump, damage can occur. Always vent pump
of air after draining hydraulic system. Figure 48 EX1402464
2. With the engine stopped, remove vent plug (Figure 48) to

see if any oil is present.
3. If oil is not present, fill pump with oil through port (Figure
48).
4. Install vent plug (Figure 48) first.
5. Start engine and run it for several minutes at "LOW IDLE".
This will pressurize the hydraulic oil tank and system.
6. Slowly loosen vent plug (Figure 48) several turns, until
hydraulic oil flows out of plug.
This shows that air has been released.
7. Tighten the plug (Figure 48).
Plug (R3 port)
• Tool: 6 mm ( )
8. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly, about 100 mm before the
end of stroke.
9. Operate the rod of cylinder to the end of stroke to relieve
the hydraulic piping. (The air breather of oil tank is
actuated to bleed the air)
DX210WA Main Pump

5-6-37
ASSEMBLY GUIDELINES FOR TIGHTENING TORQUES
Bolts
Values stated are valid for bolts with metric ISO threads to DIN
13 part 13, and head areas to DIN 912 socked head cap screws,
DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up
to the head.
FG021156
Figure 49
Tensile Strength Class

Thread 8.8 10.9 12.9
Tightening Torque (N.m)
M3 1.1 1.6 1.9
M4 3.1 4.5 5.3
M5 6.1 8.9 10.4
M6 10.4 15.5 18
M8 25 37 43
M 10 51 75 87
M 12 87 130 150
M 14 140 205 240
M 16 215 310 370
M 18 300 430 510
M 20 430 620 720
M 22 480 830 970
M 24 740 1060 1240
Main Pump DX210WA

5-6-38
Plugs with Internal Hexagon and Profile Seal Ring
Thread Tightening Torque (N.m)
M8 x 1 5
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 30 Seal
M16 x 1.5 35
M18 x 1.5 40
M20 x 1.5 50
M22 x 1.5 60 EX1401130
M26 x 1.5 70 Figure 50
M27 x 2 90
M30 x 1.5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
G 1/8 A 10
G 1/4 A 30
G 3/8 A 35
G 1/2 A 60
G 3/4 A 90
G1A 140
G 1 1/4 A 240
G 1 1/2 A 300
Seal-lock - Sealing Nuts

Thread Tightening Torque (N.m)
M6 10
M6 x 0.5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1.5 72 FG021159
M14 110 Figure 51
M14 x 1.5 120
M16 170
M16 x 1.5 180
DX210WA Main Pump

5-6-39
DISASSEMBLY AND REASSEMBLY
General Repair Guidelines

NOTE: Observe the following cautions when performing
repairs on hydraulic units.
WARNING
Observe the following notices and instructions when
carrying out repairs on hydraulic units.
ASS1140L
Figure 52
1. Close off all openings of hydraulic unit.
HB7M3003
Figure 53
2. Replace all seals.

Use only original spare parts
HB7M3004
Figure 54
Main Pump DX210WA

5-6-40
3. Check all sealing and sliding surfaces for wear.
IMPORTANT
Using abrasive materials on sliding surfaces can
damage the surface.
HB7M3005
Figure 55
4. Fill hydraulic unit with hydraulic oil before putting into

operation.
ASS0060L
Figure 56
DX210WA Main Pump

5-6-41
Seal Kits and Subassemblies
1. Seal kit for driveshaft.
ASS0070L
Figure 57
2. Peripheral seal kit.
ASS0080L
Figure 58
3. Rotary group 1, ready to install.
ASS0090L
Figure 59
4. Rotary group 2, ready to install.
ASS0100L
Figure 60
Main Pump DX210WA

5-6-42
5. Rotary group, hydraulic component (order rotary groups 1
and 2 separately).
IMPORTANT
Adjustment is necessary.
Pay attention to direction of rotation.
ASS0110L
Figure 61
6. Rotary group 1, mechanical section, ready to install.
ASS0120L
Figure 62
7. Rotary group 2, mechanical section, ready to install.
ASS0130L
Figure 63
DX210WA Main Pump

5-6-43
8. Control, pre-adjusted.
ASS0140L
Figure 64
9. Gear pump, complete.
ASS0150L
Figure 65
10. Intermediate gear.
ASS0160L
Figure 66
Main Pump DX210WA

5-6-44
11. Auxiliary drive.
ASS0170L
Figure 67
12. Valve plate with valves.
EX1401142
Figure 68
13. Pipe, complete with fittings.
EX1401143
Figure 69
DX210WA Main Pump

5-6-45
Sealing the Driveshaft
ASS0200L
Figure 70
1. Protect driveshaft. (e.g. with tape).
ASS0210L
Figure 71
2. Remove retaining ring and shim.
ASS0220L
Figure 72
Main Pump DX210WA

5-6-46
3. Screw sheet metal screw(s) into holes fitted with rubber.
Pull out seal with pliers.
ASS0230L
Figure 73
4. Press in shaft seal ring and shim with bushing to stop.
IMPORTANT
Take note of press-in depth. Install mark for press-in
depth of safety ring.
ASS0240L
Figure 74
DX210WA Main Pump

5-6-47
Gear Pump Sealing
Figure 75 EX1403156
Remove gear pump.

Visually check
1. O-ring (1, Figure 76).
1 ASS0260L
Figure 76
2. Sealing surface of housing (2, Figure 77).
ASS0270L
Figure 77
Main Pump DX210WA

5-6-48
Removing Control Housing
Figure 78 EX1403157
1. Place pump into a disassembly / assembly device with a

crane and secure it into position.
Figure 79 ASS0290L
DX210WA Main Pump

5-6-49
2. Remove screws holding port plate.
3. Using a suitable lifting device, remove port plate.
IMPORTANT
Mark installation position. Be careful, control lenses
can fall out.
Figure 80 ASS0300L
4. Remove paper seal, and clean sealing surface.
ASS0310L
Figure 81
Main Pump DX210WA

5-6-50
2
2
1
1 ASS0320L
Figure 82
Reference
Description
Number
1 Setting Screw: Qmax
2 Setting Screw: Hydraulic Stroke Limitation
3 Setting Screw: Power Characteristic (Begin of Regulation)
NOTE: Before performing setting or disassembly of

regulator, measure distance "X" of adjustment screw
and record value.
X
ASS0330L
Figure 83
DX210WA Main Pump

5-6-51
Control Module
Control Module LR
ASS0340L
Figure 84
Remove and disassemble control module LR.

* *
ASS0350L
Figure 85
Main Pump DX210WA

5-6-52
Control Module H
ASS0360L
Figure 86
Remove and disassemble control module H.
ASS0370L
Figure 87
DX210WA Main Pump

5-6-53
Removing the Controller
Figure 88 EX1403158
1. Remove screws.
NOTE: Install control lens - torque support.
ASS0400L
Figure 89
Main Pump DX210WA

5-6-54
2. Remove locking screw and replace with a new one.
NOTE: Loosen adhesive with a "gentle" flame
(approximately 120°C).
ASS0410L
Figure 90
ASS0420L
Figure 91
3. Remove swivel pin.
ASS0430L
Figure 92
DX210WA Main Pump

5-6-55
Valve Plate with Valves
Figure 93 EX1401144
1. Pressure relief valve.

2. Electro- proportional pressure reducing valve (EPPR).
Main Pump DX210WA

5-6-56
Remove Rotary Groups
EX1403160
Figure 94
1. Keep cylinder with device (Remove it completely with

driveshaft).
ASS0460L
Figure 95
2. Remove cylinder (remove driveshaft without cylinder).
ASS0470L
Figure 96
DX210WA Main Pump

5-6-57
3. Remove cup springs 1 and spring cup 2.
ASS0480L
Figure 97
4. Note disassembly position: (1, 2 and 3, Figure 98).

3
2
Rotary Group 2
Rotary Group 1
ASS0490L
Figure 98
5. Press out rotary group with an appropriate device.
2
1
ASS0500L
Figure 99
Main Pump DX210WA

5-6-58
Fixing screws are glued
A Adjustment of measurement D
*
1. Holding device
Drive shaft 2
Drive shaft 1
1. Holding device
*
A
Adjustment of measurement D
Fixing screws are glued

ASS0510L
Figure 100
NOTE: 1) Position (*) driveshafts with bearing set

are the smallest assembly group.
2) The assembly group is adjusted to
measurement A.
3) The tapered roller bearings are adjusted to
the specified through-torque.
NOTE: 1) Fixing screw - Retaining device.
2) Removal of screws is only possible if
driveshaft is warmed up to a temperature
of approximately 120°C for 1/2 hour in an
oil bath or heat air furnace.
3) Remove screw quickly.
DX210WA Main Pump

5-6-59
Remove Intermediate Wheel
1. Press bolt (*, Figure 101) into gear wheel. (Installed
pressing fit).
NOTE: Can only be disassembled with a hydraulic
press. *
ASS0520L
Figure 101
2. Install sleeve.
NOTE: Press out bolt with a hydraulic press.
ASS0530L
Figure 102
Main Pump DX210WA

5-6-60
3. Remove gear wheel through side drive opening.
ASS0540L
Figure 103
4. Remove bearing with extraction device.
ASS0550L
Figure 104
DX210WA Main Pump

5-6-61
Remove Auxiliary Drive
ASS0560L
Figure 105
1. Remove screws and auxiliary drive.
ASS0570L
Figure 106
2. Press off bearing cap.
ASS0580L
Figure 107
Main Pump DX210WA

5-6-62
3. In the event of oil leakage, visually check O-ring, housing
and groove.
ASS0590L
Figure 108
4. Install extractor device.
ASS0600L
Figure 109
5. Pull out output pinion.
ASS0610L
Figure 110
6. Install bearing extractor device.
ASS0620L
Figure 111
DX210WA Main Pump

5-6-63
7. Completely mount device and pull out bearing.
ASS0630L
Figure 112
8. Pull out pinion bearing.
ASS0640L
Figure 113
Main Pump DX210WA

5-6-64
Inspection
1. Check to see that bearing bore is free of scores and there
is no evidence of wear.
ASS0650L
Figure 114
2. Visually check:
To ensure that bearing seats are free of scores.
ASS0660L
Figure 115
3. Visually check:
Check to see that bearing bores are free of scores and
there is no evidence of wear.
ASS0670L
Figure 116
4. Axial piston play:

Checked with retaining plate installed.
ASS0680L
Figure 117
DX210WA Main Pump

5-6-65
5. Driveshafts:
Check to ensure that cups are free of scores and there is
no pitting (1, Figure 118).
Check to see there is no evidence of corrosion and wear
steps (2, Figure 118).
ASS0690L
Figure 118
6. Piston:
Check to ensure that they are free of scores and there is
no pitting.
ASS0700L
Figure 119
7. Central pin:
Check to ensure that it is free of scores and there is no
pitting.
ASS071L
Figure 120
8. Retaining plate:
Check to ensure that it is free of scores and there is no
evidence of wear.
ASS0720L
Figure 121
Main Pump DX210WA

5-6-66
9. Check cylinder block / control lens.
Bores (1, Figure 122) are free of scores, no evidence of
wear.
Faces (2, Figure 122) are even, there are no cracks, no
scores.
Side guides (3, Figure 122) show no evidence of wear, free
of scores.
ASS0730L
Figure 122
10. Check:
Control land (1, Figure 123), internal control drilling (2,
Figure 123) and pin cups (3, Figure 123).
ASS0740L
Figure 123
11. Check:
That sliding surfaces (1, Figure 124) are free of scores.
Seal (2, Figure 124).
ASS0750L
Figure 124
DX210WA Main Pump

5-6-67
12. Complete rotary group.
NOTE: Adjustment of the hydraulic component is
necessary.
Mechanical component: driveshaft is adjusted with the
bearing (1, Figure 125).
Hydraulic component (2, Figure 125): Adjustment is
necessary (*, Figure 125).
2
1
1
ASS0760L
Figure 125
Main Pump DX210WA

5-6-68
13. Rotary group: All of the components.
* Adjustment (Figure 126).
For adjustment values and torque values, see service
information.
*
*
*
*
ASS0770L
Figure 126
DX210WA Main Pump

5-6-69
Assembling the Rotary Group
1. Threads must be free of oil, grease, dust or any other
contaminants which may impair locking of screws.
ASS0780L
Figure 127
2. Assemble retaining plate with pistons and center pin in

position. Use screws that have a precoat coating.
NOTE: For tightening torques, see service information.
ASS0790L
Figure 128
3. Insert spring plate (1, Figure 129) and cup springs (2,
Figure 129) into their correct position (and orientation)
using grease to hold them into place.
ASS0800L
Figure 129
4. Ensure that all parts are assembled in correct order and

orientation.
ASS0810L
Figure 130
Main Pump DX210WA

5-6-70
5. Insert pistons into cylinder. Using a soft surface as a
support to prevent sliding surfaces from being damaged.
Preassemble both rotary groups in this manor.
ASS0820L
Figure 131
DX210WA Main Pump

5-6-71
Pump Assembly
1. Warm up housing to approximately 80°C.
ASS0830L
Figure 132
2. Insert preassembled rotary group 2, being sure to align

gear tooth marks.
ASS0840L
Figure 133
3. Insert rotary group 1. Align the marked gear teeth.
ASS0850L
Figure 134
4. Gear tooth marks must align with each other.
ASS0860L
Figure 135
Main Pump DX210WA

5-6-72
5. Adjustment of measurement D.
NOTE: Hydraulic control portion.
Stop
D
A
A
D
Stop
ASS0870L
Figure 136
NOTE: Driveshafts with bearing set.

The assembly group is adjusted to dimension
(A). The tapered roller bearings are adjusted to
the stipulated breakaway torque.
DX210WA Main Pump

5-6-73
Assembly Guideline
Retaining force:
After rotary group has been installed into housing, it has to be
pressed in until end stop is reached. Allow housing to cool down
from its assembly temperature (approximately 80°C) to room
temperature.
Adjustment of the Hydraulic Component of the Rotary Group

The adjustment of dimension "D" is done using spring plates of
differing thickness, so correct clearance is achieved between the
rotary group which is installed in housing and center pin, and
spring plates.
NOTE: Dimension (D) = 0.4 ±0.1 mm.
After assembling complete unit, the breakaway torque of the
rotary group has to be checked with a torque wrench.
Main Pump DX210WA

5-6-74
Hydraulic Component - Measurement "D"
Measuring Device - Hydraulic Component
EX1403917
Figure 137
Measuring Device Centering Device Intermediate Ring Shim S.H.C.S

(*) (1) (4) (5) (6)
1x 2x 2x 2x
9452269 02797872 09452014 09083277 09083105
DX210WA Main Pump

5-6-75
Mounting Position
NOTE: Be sure that correct mounting position is used. The
numbers on the top of the measuring device (*,
Figure 137) refer to the piston diameter.
ASS0900L
Figure 138
Mounting Position Distance (mm)

22 168
ASS0890L
Figure 139
1. Install intermediate ring or plates onto the housing.

(Figure 140)
Figure 140
2. Zero adjustment - measuring device.

Turn using the hand wheel until stop is reached. Set dial
gauge to zero. (Figure 141)
Figure 141
Main Pump DX210WA

5-6-76
Measuring Procedure
1. Turn down by 4 turns on the dial gauge. (Figure 142)
Check: 2 mm clearance, set dial gauge to "Zero".
NOTE: Clearance: Size 28 ~ 160 0.4 mm ±0.1.
ASS0960L
Figure 142
2. Turn down, using the hand wheel, until resistance is met.

Read the measured value. (Figure 143)
NOTE: Do not use excessive force.
Figure 143
DX210WA Main Pump

5-6-77
Installation of Control Housing
EX1403161
Figure 144
1. Install swivel pin into correct position and orientation. Take

hardening time and tightening torque into account.
NOTE: Tightening Torques (*):
M6 = 8.5 N.m (0.87 kg.m (6.27 ft lb))
M8 = 14 N.m (1.43 kg.m (10.33 ft lb))
M10 = 35 N.m (3.57 kg.m (25.81 ft lb))
M12 = 69 N.m (7.04 kg.m (50.89 ft lb))
* ASS1000L
Figure 145
Main Pump DX210WA

5-6-78
2. Push on piston ring by hand. Install adjustment piston.
Take the tightening torques into account.
ASS1010L
Figure 146
3. Install control housing.
EX1403162
Figure 147
4. Install control lens in their correct position using grease to

hold them in place. Direction of rotation Direction of rotation
counterclockwise clockwise
Pressure Pressure
side side
Suction side
ASS1030L
Figure 148
DX210WA Main Pump

5-6-79
ASS1040L
Figure 149
5. Install seal and controller.
ASS1050L
Figure 150
Main Pump DX210WA

5-6-80
Assembly of Intermediate Wheel
1. Press bearing (1, Figure 151) into housing.
2. Install and align intermediate wheel (2, Figure 151) through 1
side drive opening. New Assembly
Position 3
3. Cool down bolt (3, Figure 151) with nitrogen and install it.
4. Press in bearing (4, Figure 151).
2
ASS1060L
Figure 151
5. Press bearing into housing.
ASS1070L
Figure 152
DX210WA Main Pump

5-6-81
Installation of Gear Pump
EX1403159
Figure 153
1. Assemble shaft seal, disk and safety ring. Press-in with

assemble sleeve.
IMPORTANT
Take note of press-in depth.
Figure 154 ASS0240L
Main Pump DX210WA

5-6-82
Installation of Cover/Auxiliary Drive
ASS1100L
Figure 155
DX210WA Main Pump

5-6-83
TROUBLESHOOTING
The following table may assist you in troubleshooting. The table
makes no claim for completeness.
In practical use, problems which are not listed here may also occur.
How to Proceed for Troubleshooting

1. Always act systematically and targeted, even under
pressure of time. Random and imprudent removal and
readjustment of settings could result in the inability to
ascertain the original error cause.
2. First obtain a general overview of how your product works
in conjunction with the entire system.
3. Try to determine whether the product worked properly in
conjunction with the entire system before the error
occurred.
4. Try to determine any changes of the entire system in which
the product is integrated.
• Were there any changes to the product's application
conditions or operating range?
• Were there any changes (conversions) or repairs on
the complete system (machine/system, electrics,
control) or on the product? If yes, which?
• Has the hydraulic fluid been changed?
• Was the product or machine operated as intended?
• How did the malfunction appear?
5. Try to get a clear idea of the error cause. Directly ask the
(machine) operator.
6. If you cannot rectify the error, contact one of the contact
addresses which can be found under:
www.doosaninfracore.co.kr
Main Pump DX210WA

5-6-84
Malfunction Table
Fault Possible cause Remedy
Unusual noises Drive speed too high. Machine or system manufacturer.
Wrong direction of rotation. Ensure correct direction of rotation.
Insufficient suction conditions, e.g. air in Machine or system manufacturer (e.g.
the suction line, inadequate diameter of optimize inlet conditions, use suitable
the suction line, viscosity of the hydraulic hydraulic fluid).
fluid too high, suction height too high, Completely air bleed the axial piston unit,
suction pressure too low, contaminants in fill the suction line with hydraulic fluid.
the suction line.
Remove contaminants from the suction line.
Improper fixing of the axial piston unit. Check fixing of the axial piston unit
according to the specifications of the
machine or system manufacturer.
Observe tightening torques.
Improper fixing of the attachment parts, Fix attachment parts according to the
e.g. coupling and hydraulic lines. information provided by the coupling or
fitting manufacturer.
Malfunction of the pressure relief valve of Bleeding the axial piston unit.
the axial piston unit (pressure cut-off). Check viscosity of the hydraulic fluid.
Contact our service.
Mechanical damage to the axial piston unit Exchange axial piston unit, contact our
(e.g. bearing damage). service.
No or Faulty mechanical drive (e.g. defective Machine or system manufacturer.
insufficient flow coupling).
Drive speed too low. Machine or system manufacturer.
the suction line.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid (machine or
range. system manufacturer).
External control of the control device Check external control (machine or
defective. system manufacturer).
Insufficient pilot pressure or control Check pilot pressure or control pressure,
pressure. contact our service.
Malfunction of the control device or Contact our service.
controller of the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact our
service.
DX210WA Main Pump

5-6-85
Fault Possible cause Remedy
No or Faulty mechanical drive (e.g. defective Machine or system manufacturer.
insufficient pressure coupling).
Drive power too low. Machine or system manufacturer.
the suction line.
Hydraulic fluid not in optimum viscosity Use suitable hydraulic fluid (machine or
range. system manufacturer).
External control of the control device Check external control (machine or
defective. system manufacturer).
Insufficient pilot pressure or control Check pilot pressure or control pressure,
pressure. contact our service.
Malfunction of the control device or Contact our service.
controller of the axial piston unit.
Wear of axial piston unit. Exchange axial piston unit, contact our
service.
Output unit defective (e.g. hydraulic motor Machine or system manufacturer.
or cylinder).
Pressure/ Axial piston unit and/or control unit not or Completely air bleed axial piston unit.
flow fluctuations insufficiently air bled. The pressure reducing valve must be
exchanged. contact service.
the suction line.
Excessive Excessive inlet temperature at the axial Machine or system manufacturer:
hydraulic fluid and piston unit. Inspect system, e.g. malfunction of the
case temperature cooler, insufficient hydraulic fluid in the
reservoir.
Malfunction of the pressure control valves Contact Service.
(e.g. pressure cut-off, pressure controller).
Wear of axial piston unit. Exchange axial piston unit, contact
service.
Instability/vibrations Setpoint value not stable. Machine or system manufacturer.
Resonance in the reservoir line. Machine or system manufacturer.
Axial piston unit and/or control unit not Completely air bleed axial piston unit.
insufficiently air bled. The pressure reducing valve must be
exchanged. Contact service.
Malfunction of the control devices or Contact service.
controller.
Main Pump DX210WA

5-6-86
Drive Coupling
(Main Pump)
Edition 1
DX210WA Drive Coupling (Main Pump)

5-7-1
MEMO
Drive Coupling (Main Pump) DX210WA

5-7-2
Table of Contents
Drive Coupling (Main Pump)

General ...........................................................5-7-5
Description ................................................................ 5-7-5
Specification .............................................................. 5-7-5
Parts List ................................................................... 5-7-6
Section View ...................................................5-7-8
Tools.......................................................................... 5-7-9
Disassembly .................................................5-7-10
Reassembly ..................................................5-7-11

5-7-3
5-7-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Description
When installing the main pump on the engine, it is very
important to properly adjust clearance between the face of the
coupling hub and end of pump drive shaft to a specific value.
Specification
Nominal Torque 785 N.m (80 kg.m, 579 ft lb)
Max. Torque 1,560 N.m (160 kg.m, 1,157 ft lb)
Max. Speed 4,000 rpm
Radial 0.4 mm (0.015 in)
Max. Permissible Displacements Angular 0.5°
Axial ±2 mm (±0.08 in)
Dynamic Torsion Spring Stiffness Cdyn 1.96 x 106 kg.cm/Rad
Mass Moment of Inertia 2.33 kg.cm. S2
Allowable Environment Temperature -40 ~ +120 °C

5-7-5
Parts List
FR
ON
T
7
2
6
5
1 4
7
EX1403312
Figure 1
Reference Reference
Number Number
1 Hub 5 Socket Bolt Set (8 ea)
2 Element 6 Bolt; Clamping M16 x 20
3 Insert (A) 7 Pin; Spring D5 x 10
4 Insert (R)

5-7-6
5-7-7
SECTION VIEW
Whenever the drive coupling for main pump is installed, the
following mounting dimensions and installation procedures must
be observed.
NOTE: If these procedures are not followed, noise will occur
and/or the service life of drive coupling or main pump
will be reduced.
10
7 Main Pump
H
11
EX1403313
Figure 2 Drive Coupling Installation

5-7-8
Reference
Description Qty. Torque
Number
1 Spring Pin 4
2 Insert 4
3 Socket Bolt M16 x 50 4 206 ~ 226 N.m (21 ~ 23 kg.m, 152 ~ 166 ft lb)
4 Flywheel 1
5 Spring Pin 8
6 Insert 4
7 Hub 1
8 Socket Bolt M16 x 50 4 206 ~ 226 N.m (21 ~ 23 kg.m, 152 ~ 166 ft lb)
9 Pump Shaft 1
10 Clamping Screw M16 x 20 2 98 ~ 118 N.m (10 ~ 12 kg.m, 72 ~ 87 ft lb)
11 Element 1
Symbol Dimension Remarks

H 6.5 mm (0.56 in) Distance between from Pump Shaft to Coupling Hub
Tools
Name Description
Allen Wrench 8 mm, 14 mm
Plastic Hammer One Plastic Hammer

5-7-9
DISASSEMBLY
When the pump is removed from an engine, the hub and insert
would be attached on the pump.
1. After removing pump remove socket bolts (5, Figure 3)

(4 ea) and remove insert (4) (4 ea).
6
• : 14 mm 4
2. Remove calmp bolts (6, Figure 3) (2 ea) and remove hub

(1).
5
• : 8 mm 1
EX1403071
Figure 3
3. Remove socket bolts (5, Figure 4) (4 ea) and insert (3,

3
Figure 4) (4 ea) with element (2) from flywheel.
• : 14 mm
5
2
Figure 4 WE1400292

5-7-10
REASSEMBLY
1. Install insert (3, Figure 5) (4 ea) and spring pin (7, Figure 6)
(4 ea) with socket bolts (5) (4 ea) to engine flywheel. 3
• : 14 mm
5
• Torque: 205.9 ~ 225.6 N.m
(21 ~ 23 kg.m, 151.9 ~ 166.4 ft lb)
Figure 5 WE1400293
Flywheel Side
7
5
EX1403074
Figure 6
2. Assemble the insert (4, Figure 7) (4 ea) with socket bolts (5)
(4 ea) to hub (attached by spring pin) (7, Figure 6) (8 ea).
• Torque: 205.9 ~ 225.6 N.m 4
(21 ~ 23 kg.m, 151.9 ~ 166.4 ft lb) 5
1
Figure 7 EX1402032

5-7-11
3. Slide hub into place on pump shaft (8, Figure 8). Keep the
dimension 6.5 mm between end of pump shaft to hub and
secure it in position with clamping bolts (6). 8
• Torque: 98 ~ 117.7 N.m 6

(10 ~ 12 kg.m, 72.3 ~ 86.8 ft lb)
NOTE: Coat clamping bolts (6, Figure 8) with Loctite
#262.
NOTE: Refer to "Dimension" of "H" on page 5-7-9.
EX1403075
Figure 8
4. Install element (2, Figure 9) to inserts (3) on engine flywheel.

5. Install main pump and hub (Figure 9) by pushing it softly 2
into element (2).
IMPORTANT
3
1. Bolts are coated against loosening with a
bonding compound. Do not use any additional
bonding compounds, oils or cleaning solvents on
them.
Figure 9 WE1400294
2. Element (2, Figure 9) is not resistant to bonding
compounds, oil or grease. Be careful not to
expose them to it.
3. Remove oil or dirt from flywheel cover and pump
shaft before assembly.
4. Misalignment between pump and engine must be
controlled to less than 0.6 mm (0.023 in).

5-7-12
z
Main Control Valve
Edition 1
DX210WA Main Control Valve

5-8-1
MEMO
Main Control Valve DX210WA

5-8-2
Table of Contents
Main Control Valve

General ...........................................................5-8-5
Specification .............................................................. 5-8-5
Overview ................................................................... 5-8-6
Port and Hydraulic Circuit..................................... 5-8-8
Parts List ................................................................. 5-8-10
Boom Holding Valve........................................... 5-8-12
Arm Holding Valve.............................................. 5-8-15
Arm Regeneration Valve .................................... 5-8-18
Single Operation................................................. 5-8-20
Foot Relief Valve ................................................ 5-8-27
Relief Valve ........................................................ 5-8-28
Orifice (Nzx, Nzy) ............................................... 5-8-32
BP Valve (Boom Priority Valve).......................... 5-8-33
Removal .......................................................5-8-34
Installation ....................................................5-8-46
Completing Work ..........................................5-8-46
Disassembly .................................................5-8-47
Caution on Disassembly.......................................... 5-8-47
Housing ................................................................... 5-8-48
Main Plunger Element - Disassembly and Assembly... 5-8-48
Arm Load Holding Valve.......................................... 5-8-51
Check Valve Main Body ..................................... 5-8-51
Cover Assembly ................................................. 5-8-52
Boom Load Holding Valve .................................. 5-8-53
Arm Regeneration Valve ......................................... 5-8-55
Bucket Unity Check ................................................. 5-8-56
Foot Relief Valve ..................................................... 5-8-57
Bypass Cut Valve (BC Valve).................................. 5-8-58
Check Valve - Locations.......................................... 5-8-59
Check Valve ............................................................ 5-8-60

5-8-3
A: Check Valve (Main Relief Valve) ................... 5-8-60
B: Check Valve (P2) ........................................... 5-8-60
C: Check Valve (Arm 2)...................................... 5-8-61
D: Check Valve (Option, Bucket, Boom 1,
Boom 2, Arm 1) .................................................. 5-8-61
E: Check Valve (Travel) ..................................... 5-8-61
F: Check Valve (Swing)...................................... 5-8-62
Reassembly ..................................................5-8-63
Caution on Assembly .............................................. 5-8-63
Caution on Handling O-ring................................ 5-8-63
Caution on Handling Spool................................. 5-8-63
Method of Painting the Adhesives (Screw Part
and Arm Screw Part of Parts Requiring the
Adhesiveness).................................................... 5-8-63
Cleaning and Inspection ...............................5-8-64
Cleaning .................................................................. 5-8-64
Inspection ................................................................ 5-8-64
Overall Control Valve .............................................. 5-8-65
Relief Valve ............................................................. 5-8-66
Overall Oil Pressure ................................................ 5-8-66
Start-up Procedures .....................................5-8-67

5-8-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
High-pressure Valve Setting 343 -+4.9
0 bar (350 kg/cm , 4,974 - 0 psi) at 90 L/min
2 +71.1
Low-pressure Valve Setting 323 -+4.9

0 bar (330 kg/cm , 4,684 - 0 psi) at 90 L/min
2 +71.1
353 +9.8
- 0 bar (360 kg/cm , 5,120 - 0 psi) at 20 L/min
2 +142.2
Over Load Relief Valve Setting
(Boom, Arm, Bucket, Dozer)
33 -+5.9
0 bar (34 kg/cm , 483 - 0 psi) at 40 L/min
2 +85.3
Foot Relief Valve Setting
44 -+4.9
0 bar (45 kg/cm , 638 - 0 psi) at 90 L/min
2 +142.2
Rated Flow 270 L/min (50 L/min in neutral)

Rated Pressure 343 bar (350 kg/cm2, 4,974 psi)
Normally -20 ~ 80°C (-4 ~ 176°F)
Pemitted Use of Oil Temperature Highest 100°C (212°F)
(Use of the rubber for NBR)

5-8-5
Overview
XAa2 XAb1 XAk XAo XAt Py Px Pz XAd XAs Xop XAa1
XAa2
XAa
XAb1
XAb
XAd
XA
XAs
XAK
XA
XA
Xop
Xo
XAo
XA
XAa1
XAa
XAt
XA
Ab
Ab1 Fr
Ak
Ak1
Ad
As At Pbp
R
Rs
(OPT)
P2
Bd Dr1
Pi
Bs
Dr3 Dr4 Ba1 XAk2 Fl Aa1 P1 Pg Bt Bk1 Bb1
XBk XBb1 XBa2 XBa1 Pal
XBo
XBt
XBb2
XBs
XBd
Figure 1 WE1400351
Port Name Size

At Travel Motor Forward SAE 1", D23
Aa1 Arm Cylinder Tube (Crowd) SAE 1", D23
Ab1 Boom Cylinder Rod (Down) SAE 1", D23
Ad Dozer Cylinder Tube (Down) SAE 3/4", D19
Ak1 Bucket Cylinder Tube (Crowd) SAE 1", D23
As Swing Left Port SAE 3/4", D19
Ba1 Arm Cylinder Rod (Dump) SAE 1", D23
Bb1 Boom Cylinder Tube (Up) SAE 1", D26

5-8-6
Port Name Size
Bd Dozer Cylinder Rod (Up) SAE 3/4", D19
Bk1 Bucket Cylinder Rod (Dump) SAE 1", D23
Bs Swing Right Port SAE 3/4", D19
Bt Travel Motor Backward SAE 1", D23
Dr1 Drain Port PFO 1/4
Dr3 Drain Port PFO 1/4
Dr4 Drain Port (Pilot) PFO 1/4
Fl Negative Signal Port PFO 1/4
Fr Negative Signal Port PFO 1/4
P1 Pump Line SAE 1", D26
P2 Pump Line SAE 1", D26
Pal Arm Holding Signal Pilot Port PFO 1/4
Pbp Boom Priority Line Port PFO 1/4
Pg Auto Idle Sensor Port PFO 1/4
Pi Boom Holding Line Port PFO 1/4
Px Swing Brake Pilot Port PFO 1/4
Py Pressure Switch Port PFO 1/4
Pz Power Up Port PFO 3/8
R Return Port SAE 2", D48
Rs Swing Motor Make Up Port PFO 1
XAa1 Arm Crowd Pilot Port PFO 3/8
XAa2 Arm Crowd Summation Pilot Port PFO 3/8
XAb1 Boom Down Pilot Port PFO 3/8
XAd Dozer Down Pilot Port PFO 1/4
XAk Bucket Crowd Pilot Port PFO 3/8
XAk2 Drain Port (Pilot) PFO 1/4
XAo Option Pilot Port PFO 1/4
XAs Swing Left Pilot Port PFO 1/4
XAt Travel Forward Pilot Port PFO 1/4
XBa1 Arm Dump Pilot Port PFO 3/8
XBa2 Arm Dump Summation Pilot Port PFO 3/8
XBb1 Boom Up Pilot Port PFO 3/8
XBb2 Boom Up Summation Pilot Port PFO 3/8
XBd Dozer Up Pilot Port PFO 1/4
XBk Bucket Dump Pilot Port PFO 3/8
XBo Option Pilot Port PFO 1/4
XBs Swing Right Pilot Port PFO 1/4
XBt Travel Reverse Pilot Port PFO 1/4
Xop Pluged PFO 1/4

5-8-7
Port and Hydraulic Circuit
R P2 Py Pg Px P3 P4 P1 Pz Rs
MRV
5
XBt 323bar@90L/min
343bar@90L/min
1
XAt Bt Travel 12
2
At
XBo XAd
13
Bo Option Dozer/Stab. Rod Bd
XAo 353bar@20L/min
13 353bar@20L/min XBd
Ao 13 Head
Ad
Ck2
XBk Ø0.9
XAs
Rod Bs
Bk1 Bucket Swing Ø0.9
353bar@20L/min
XAk 353bar@20L/min 13 XBs
Ak1 As
Head
13
XBb1
Boom 2
Bb1 Xop
Head Boom 1 4
353bar@20L/min
op
Pi 353bar@20L/min
XBb2
Ab1 7
Rod 6
Dr1 Arm 2 Arm 1
BP
XBa2 13 XBa1
Rod Ba1
353bar@20L/min
14 XAa2 353bar@20L/min
Aa1
XAa1
Head
9
11 8
Arm
BC Dr4
Holding
10
Fr PBP Dr3 Fl XAk2 Par Ck1 Pal
WE1400352
Figure 2
Reference Reference
Number Number
1 Check Valves for Main Relief 8 Arm Holding valve
2 Check Valves to Parallel Line 9 BC (Bypass Cut) Spool
3 Ck2 (Bucket Conflow) Check Valve 10 Left Foot Relief Valve
4 Boom Confluence Check Valve 11 Right Foot Relief Valve
5 Px and Py Orifice 12 Main Relief Valve
6 BP (Boom Priority) Valve 13 Load Check Valve
7 Arm Regeneration Valve 14 Boom Holding Valve

5-8-8
5-8-9
Parts List
28 39
28 39
108
105
109 23
OPTION 105 BOOM 1
112
111 106 BOOM 2
40 64 107 ARM 1
107
106 108 ARM 2
64 110 23 63 109 BUCKET
111
83 110 SWING
63
DOZER TRAVEL
65 111
83 DOZER
65 63 112 OPTION
13
63 14 32
56
78
55
73
77 11 54
62
76 61 57 98
74 60 94 70
4 59 58
95 94
75 96
81 72 3 95
31 5 99 1 96
35 84 92
2 72 93
34
33 29
32 30 7 7
81 8 8
13 21 80 97
14 81 95
101 36 102 96
100
22 95 70
25
37 72 96
38 6 99
67 68
66 1
7 3 11 69 70
8 A
21
73
2
44 58
43 14
42 13
41 72
92
96 104
95 2
94
70 71 1
2 93 72 3
81
11
1 69 42
11 VIEW A
3 69 70 82 5
72 70
92 68
96 68 4 8 20 21
95 21
94 19
85 7 23
18 22
14 84 21
81 81 24
13
12 24
81 26
26 24
27 27 22
8 28
28 7 WE1400353
Figure 3

5-8-10
Reference Reference
Number Number
1 Flange 60 Plunger
2 O-ring 61 Spool; Boom 1
3 Bolt; Socket M10 x 1.5 x 35 62 Plunger; A52 AM2
4 Bolt; Socket M14 x 100 63 Guide; SP
5 Washer; Spring M14 64 Cap; Plunger
6 Orifice 65 Spring
7 Cap 66 Cap
8 O-ring 67 O-ring
11 O-ring 68 Cap
12 Valve; Arm Regeneration 69 Ring; Backup
13 Cap 70 Chip; Nylon
14 O-ring 71 Check
18 Stopper 72 Spring
19 Spring 73 Foot Relief Assembly
20 Check 74 Spring
21 O-ring 75 Check
22 O-ring 76 O-ring
23 O-ring 77 Ring; Backup
24 O-ring 78 Cap
25 Housing; Left 80 Main Relief Valve
26 O-ring 81 Overload Relief Valve
27 Retainer 82 Cap
28 Bolt; Socket M10 x 1.5 x 25 83 Spacer
29 Cap 84 Plug Assembly; Over Load
30 O-ring 85 Cap; Load Check
31 Plunger; Block 92 Check
32 Plunger; M3 93 Cap
33 Spool; Swing 94 Spacer
34 Plunger; D52 95 Ring; Backup
35 Spool; Arm 1 96 O-ring
36 Arm Holding Valve Assembly 97 Cap
37 Spring 98 Cap
38 Poppet 99 Check
39 Cover 100 Cap
40 Retainer 101 Bolt; Socket
41 Cap 102 Expander
42 O-ring 104 Boom Holding Valve Assembly
43 Spring 105 Spool Assembly; Boom 1
44 Spool; BC 106 Spool Assembly; Boom 2
54 O-ring 107 Spool Assembly; Arm 1
55 Cap 108 Plunger Assembly; Arm 2
56 Bolt; Socker 109 Spool Assembly; Bucket
57 Valve; Boom Priority 110 Spool Assembly; Swing
58 Housing; Right 111 Plunger Assembly (Travel/Dozer)
59 Plunger; D 112 Plunger Assembly (Option)
60 Plunger; C57

5-8-11
Theory of Operation
Boom Holding Valve

1. Plunger in neutral state ("Pi" pilot signal: OFF)
The boom holding pilot spool (A) is positioned as shown in the figure, and the chamber (1) and drain (Dr1)
passage are blocked from each other by the spool (A).
Since the chamber (1) is connected to the orifice (4) and chamber (2), its pressure is the same to the
pressure in the chamber (2) (Pc). As (d1) is larger than (d2), the poppet (B) functions as a check valve to
block the chamber (2) and chamber (3) completely.
As a result, oil (at the port Bb1) in the boom cylinder head side is blocked by the poppet (B), so the lowering
distance of the boom cylinder by gravity (leak amount from the block and spool) becomes almost zero.
(Boom Lock)
• Area Ratio = d1 > d2
Pilot signal port A(Spool)

Ab1 Pi Dr1
Bb1
1
Boom Cylinder
4
d1
B
d2
2 (Pc)
3 (Pv)
XBb1 XAb1
(up) (down)
Boom Cylinder
Tank Passage
High-pressure Passage
ROD Ab1
353bar@20L Dr1
HEAD
Boom 1 Pi
Bb1
XBb1
XAb1
P2 WE1400475
Figure 4

5-8-12
2. Boom up ("Pi" pilot signal: "OFF")
As pilot pressure transfer to (xBb1) port, high-pressure oil flows in through chamber (3).
Chamber (1) and chamber (2) pressures are "Pc" and equalized through squeeze (4).
"Pv" overcomes set spring of check valve (B) pressure and high-pressure oil is supplied to the cylinder head.
• Pressure = Pc < Pv

Ab1
Pi Dr1
Bb1
1
Boom Cylinder
2 (Pc)
3 (Pv)
XBb1 XAb1
(up) (down)
Tank Passage
Boom Cylinder
ROD Ab1
353bar@20L
Dr1
HEAD
Boom 1 Pi
Bb1
XBb1
XAb1
P2 WE1400476
Figure 5

5-8-13
3. Boom down (Regeneration) ("Pi" pilot signal: "ON")
When the port (XAb1) is applied with the pilot pressure, oil in the pump is delivered to the port (Ab1) through
the boom spool and it is led to the rod of the boom cylinder to lower the boom.
Then, the boom is lowered rapidly by gravity on its front side, resulting in oil shortage on the rod side.
To compensate this shortage, the pilot pressure on the port (XAb1) is transmitted to it as well as to the port
(Pi). As a result, the boom holding pilot spool (A) is moved to the right, so oil in the passage (1) is returned to
the tank through the port (Dr1).
As oil in the passage (1) is returned to the tank, the pressure (2) (Pc) is applied to the poppet (B) due to area
difference between (d1) and (d2) to open the poppet. Then, returning oil through the passage in the boom
spool is led to the port (Ab1) to compensate for oil shortage for boom lowering operation in order to prevent
cavitations.
• Pressure = Pc > Pv
Boom Down signal: XAb1, Pi
Boom Up signal: XBb1

Ab1
Pi Dr1
Bb1
1
Boom Cylinder
4
d1
d2
2 (Pc)
3 (Pv)
XBb1 XAb1
(up) (down)
Boom Cylinder
Tank Passage
ROD Ab1
353bar@20L
Dr1
HEAD
Boom 1 Pi
Bb1
XBb1
XAb1
P2 WE1400477
Figure 6

5-8-14
Arm Holding Valve
To prevent spontaneous lowering of the arm cylinder, a separate valve is installed to the arm line of the control
valve to prevent oil leak from the gap between the valve block and spool. This is called arm holding (Lock).
The arm cylinder is lowered by gravity excessively than other front cylinders.
Therefore, its spontaneous lowering should be minimized.
The control valve is integrated with the check valve to minimize oil leak from this gap to almost 0 in order to
minimize spontaneous lowering of the arm cylinder.
1. Plunger in neutral state ("Pal" pilot signal: "OFF")
As the "Pal" pilot pressure is 0 bar, the piston (A) and poppet (B) are positioned to block oil in the passage.
When oil (pressure) on the arm cylinder rod side forms pressure in the chamber (Pc) through the orifice, the
chamber of the poppet (D) is blocked completely due to area difference of (d1) and (d2).
As a result, oil flow on the arm cylinder rod by gravitational down movement of the front rod side is
eliminated to prevent spontaneous lowering movement.
• Pressure = Pc > Pv
A(Piston) B(Poppet)
Dr4 Tank
pal
d1
Pc
D(Poppet)
Orifice
Pv
d2
XBa1 XAa1
(dump) (crowd)
Tank
Figure 7 WE1400478

5-8-15
2. Arm crowd ("Pal" piolt signal: "ON")
When the pilot pressure is transmitted to the port (Pal), the piston (A) and poppet (B) are positioned to allow
oil flow through the internal passage. Therefore, oil in the chamber flows to the tank through the open
passage, and the chamber (Pc) pressure at the poppet (D) is released to the tank pressure.
As a result, oil in the arm cylinder rod side flows to the tank.
• Pressure = Pc < Pv
A(Piston) B(Poppet)
Dr4 Tank
pal
d1
Pc
D(Poppet)
Orifice
d2
Pv
XBa1 XAa1
(dump) (crowd)
Tank
Figure 8 WE1400479

5-8-16
3. Arm dump ("Pal" pilot signal: "OFF")
When the piston (A) and poppet (B) are moved to the left to block the internal passage while the "Pal" pilot
pressure is 0 bar, the poppet (D) is opened by high-pressure so oil at the poppet (D) is delivered to the rod
side of the cylinder through the orifice with high-pressure.
• Pressure = Pv > Pc
A(Piston) B(Poppet)
Dr4 Tank
pal
d1
Pc
D(Poppet)
Orifice
Pv
d2
XBa1 XAa1
(dump) (crowd)
High Pressure
Tank
Figure 9 WE1400480

5-8-17
Arm Regeneration Valve
1. Neutral
Oil is returned to the tank through the center bypass line.
• Pal: Boom, Arm, Bucket, Swing, Swing signal
– XAa1: Arm Crowd
– XBa1: Arm Dump
Arm Cylinder
Parallel line
Ba1 Aa1
XBa1 XAa1
(Dump) (Crowd)
Arm 1
B 1 2 A Center Bypass
Arm Cylinder
Dr4 Pal
Arm
Holding
Valve
Aa1 HEAD
353bar@20L
XAa1
Ba1 ROD
Arm 1
353bar@20L
XBa1
Figure 10 P1
WE1400481

5-8-18
2. Arm crowd
A. When the arm plunger is operated to the crowd side, the plunger is moved to the left to block the center
bypass line. Then, the check valve (C1) on the parallel passage is opened to supply oil in the pump to
the arm cylinder head through the high-pressure feed passage.
B. As the arm holding valve is opened by the "Pal" pilot pressure, oil supplied to the head is returned back
to the tank through the passage of the arm regeneration valves (1) and (2).
C. The piston (A) of the arm regeneration valve is moved to the right and the pressure on the rod side is
increased by the spool (B) through the orifice of the passage (1) to open the check valve (C2) in the
arm spool. As a result, oil on the rod side is regenerated to the arm cylinder tube side through the
plunger passage to prevent any fault.
Arm Cylinder
Parallel line
C1
Ba1 Aa1
XBa1 XAa1
(Dump) (Crowd)
Arm 1
B 1 2 A C2 Center Bypass
Arm Cylinder
Dr4 Pal
Arm
Holding
Valve
Aa1 HEAD
353bar@20L
XAa1
Ba1 ROD
Arm 1
353bar@20L
XBa1
P1
Figure 11
WE1400482

5-8-19
Single Operation
1. Bucket
A. In the neutral state, pressure of the bucket plunger is blocked by the joystick valve, so oil flow (P2) at
the pilot ports (XBk, XAk) is returned to the tank through the center bypass line.
Bk1 Ak1
Bucket
XBk XAk
(Dump ) ( Crowd)
Center Bypass
Bucket Cylinder
353bar@20L
HEAD Ak1
XAk
ROD Bk1
Bucket
353bar@20L
XBk
P2 WE1400483
Figure 12

5-8-20
B. For the crowd operation, as the pilot pressure is delivered to the port (XAk), the bucket spool is moved
to the left and the center bypass is blocked. Then, oil supplied to the high-pressure port (P2) flows
through the parallel passage to open the load check valve (C1). As a result, oil is supplied to the
cylinder tube through the high-pressure passage (Ak1) for the bucket crowd operation.
Bk1 C1 Ak1
Bucket
XBk XAk
(Dump ) ( Crowd)
Bucket Cylinder
353bar@20L
HEAD Ak1
XAk
353bar@20L
ROD Bk1
Bucket
XBk
P2 WE1400484
Figure 13

5-8-21
C. For the dump operation, when the pilot pressure is delivered to the port (XBk), the bucket spool is
moved to the right and the center bypass line is blocked. Then, oil supplied to the high-pressure port
(P2) flows through the parallel passage to open the load check valve (C1). As a result, oil is supplied to
the cylinder rod through the high-pressure passage (Bk1) for the bucket dump operation.
Bk1 C1 Ak1
Bucket
XBk XAk
(Dump ) ( Crowd)
Bucket Cylinder
353bar@20L
HEAD Ak1
XAk
353bar@20L
ROD Bk1
Bucket
XBk
P2 WE1400485
Figure 14

5-8-22
2. Swing
In the neutral state, the pressure for the swing spool is blocked by the joystick valve, so oil (P1) at the pilot
ports (XAs and XBs) is returned to the tank through the center bypass line.
For the left swing operation, as the pilot pressure is delivered to the port (XAs), the spool is moved to the
right and the center bypass line is blocked. Then, oil supplied to the high-pressure port (P1) flows through
the parallel passage to open the load check valve.
As a result, oil is supplied to the swing motor port (A) through the high-pressure passage (As).
For the right swing operation, as the pilot pressure is delivered to the port (XBs), the spool is moved to the
left and the center bypass line is blocked. Then, oil supplied to the high-pressure port (P1) flows through the
parallel passage to open the load check valve. As a result, oil is supplied to the swing motor port (B) through
the high-pressure passage (Bs).
Load Check Valve
As(LH) Bs(RH)
XAs(LH) XBs(RH)
Swing Center Bypass
Swing Motor
As
XBs
Bs Swing
XAs
P1 WE1400486
Figure 15

5-8-23
3. Travel
A. Oil should be still supplied smoothly by inertia when the device is stopped during travelling.
When the plunger is set in the neutral state (stopped), oil shortage occurred by area difference of the
plunger can lead to inertial shock. To minimize this shock, oil shortage is compensated by supplying oil
through the orifice in the parallel passage.
Orifice
Bt(Reverse) At(Forward)
XBt XAt
Travel
Travel Motor
At
XAt
Travel Bt
XBt
P2 WE1400487
Figure 16

5-8-24
B. For the forward travelling operation, as the pilot pressure is delivered to the port (XAt), the spool is
moved to the left and the center bypass line is blocked. Then, oil supplied to the high-pressure port
(P2) flows through the parallel passage.
As a result, oil is supplied to the travel motor port (B) through the high-pressure passage (At).
Orifice
XBt XAt
Travel
Travel Motor
At
XAt
Travel Bt
XBt
P2 WE1400488
Figure 17

5-8-25
C. For the reverse travelling operation, as the pilot pressure is delivered to the port (XBt), the spool is
moved to the right and the center bypass line is blocked. Then, oil supplied to the high-pressure port
(P2) flows through the parallel passage.
As a result, oil is supplied to the travel motor port (A) through the high-pressure passage (Bt).
Orifice
XBt XAt
Travel
Travel Motor
At
XAt
Travel Bt
XBt
P2 WE1400489
Figure 18

5-8-26
Foot Relief Valve
1. Oil in the center bypass line is returned to the tank through
Spring To Tank
the orifice (A) of the poppet. Pressure (fp) produced from
oil passing through the orifice (A) of the poppet is supplied Q
to the pump regulator to adjust the pump's discharge
amount. (fp)
2. If pressure (fp) overcomes the setting pressure of the
spring, the oil flow becomes equal to the passing flow, so
the poppet is opened to send oil to the tank. X1 Poppet Orifice A
It functions as a relief valve. To Pump
Regulator From Center Bypass Line
WE1400490
Figure 19
QN orifice
Control Valve
QN
PN(X1)
Q
Center Bypass
Q Pump
PN(X1) Regulator
QN : Negacon Valve Flow PN
PN : Negacon Signal P1
Pressure(X1)
Q : Pump Discharge Flow WE1400500
Figure 20

5-8-27
Relief Valve
Main Relief Valve

1. Low-pressure setting ("PZ" pilot signal pressure: "OFF")
A. Oil sent from the pump is led to the chamber (3) through the orifice (2) of the main poppet (A).
Since (d1) is larger than (d2), the main poppet (A) is kept closed by colliding pressure.
Main Poppet “A” 3 4 5 Pilot Poppet “D” Piston “E” Adjust Screw
“PZ”
From Pump Pilot Signal
To Tank
1 d2 2 Spring “B” d1 Spring “C”

WE1400491
Figure 21
B. When oil pressure reaches the setting pressure of the spring (C), the pilot poppet (D) is opened to
send oil to the tank through the passages (4 and 5).
4 5 Pilot Poppet “D”
“PZ”
From Pump
Pilot Signal
To Tank
Spring “C”
Figure 22 WE1400492

5-8-28
C. As oil flows, pressure before and after the orifice (2) drops. Then, when the pressure (d2) in the
chamber (1) becomes larger than the pressure (d1) in the chamber (3), the main poppet (A) is opened
to send oil back to the tank passage. As a result, the circuit pressure is controlled at a constant level.
Main Poppet “A” 3 d1
“PZ”
From Pump
Pilot Signal
To Tank
1 d2 2 Spring “B”
Figure 23 WE1400493
2. High-pressure setting ("PZ" pilot signal: "ON")

A. The piston is moved to the left. Then, the setting pressure of the spring (C) rises to the high-pressure
setting state. The pressure can be set with the adjusting screw.
Piston “E” Adjust Screw
From Pump “PZ”

Pilot Signal : ON
To Tank
Spring “C” F G H I
Figure 24 WE1400494
How to adjust pressure

1) Adjust the boost pressure (323 bar (330 kg/cm2, 4,693 psi)) first. Before adjusting it, check the (Pz)
signal pressure. Then, loosen the lock nut (F) and adjust the adjusting bolt (G). (Turning the bolt
clockwise increases the pressure.)
2) After adjusting the boost pressure (343 bar (350 kg/cm2, 4,978 psi)), unscrew the lock nut (H) and
adjust the adjusting bolt (I) to adjust the system pressure (323 bar). (Turning the bolt clockwise
increases the pressure.)
Main relief valve setting pressure
– Low (system)-pressure:
323 bar (330 kg/cm2, 4,693 psi) at 90 L (PZ: 0 bar)
– High-pressure:
343 bar (350 kg/cm2, 4,978 psi) at 90 L (PZ: 19.6 bar (20 kg/cm2, 284 psi)/Minimum)

5-8-29
Overload Relief Valve
1. Overload relief valve operation
A. As the usual cylinder port pressure is higher than the tank pressure, the main poppet (B) is fixed.
When the pressure at the cylinder port drops below the tank pressure, the main poppet (B) is applied
with the tank pressure due to area difference of (d1) and (d2) so it is opened.
As a result, oil from the tank passage is led to the cylinder port to prevent cavitations.
B. When the pressure in the chamber (1) reaches the setting pressure of the spring (C), the pilot poppet
(D) is opened to send oil to the tank through the passages (4 and 5).
d2 Main Poppet “B” Piston “A” d1 Pilot Poppet “D”
Cylinder Port
To Tank
1 2 5 6 3 4 Spring “C” WE1400495
Figure 25
C. As operating oil flows, pressure before and after the orifice (2) of the piston (A) drops.
Then, the piston (A) is moved to the right and the pilot poppet (D) is moved and fixed to the end.
Oil of the chamber (1) coming from the cylinder port is returned to the tank through the orifice (6) of the
piston (A) and passages (4 and 5).
d2 Main Poppet “B” 2 Piston “A” d1 Pilot Poppet “D”
Cylinder Port
To Tank
1 5 6 3 4 Spring “C” WE1400496
Figure 26
D. As pressure before and after the orifice (6) of the piston (A) drops, the pressure in the chamber (1)
becomes lower than the pressure in the chamber (3). Then, the main poppet (B) is opened to send
operating pressure at the cylinder port to the tank passage in order to protect the actuator.

5-8-30
2. Main poppet (B) operation
(B) The main poppet (B) is usually fixed as the cylinder port pressure is usually higher than the tank
pressure to keep (d1) higher than (d2). When the pressure at the cylinder port drops (near the negative
pressure) below the tank pressure, the main poppet (B) is applied with the tank pressure due to area
difference between (d1) and (d2). As a result, the main poppet (B) is opened to send oil in the tank passage
to the cylinder port in order to prevent cavitations.
d2 Main Poppet “B” 2 Piston “A” d1 Pilot Poppet “D”
Cylinder Port
To Tank
1 5 6 3 4 Spring “C” WE1400497
Figure 27

5-8-31
Orifice (Nzx, Nzy)
This orifice is designed to detect the operating status of each actuator and turn on/off the automatic idling function
accordingly in order to minimize fuel consumption from unnecessary engine operation.
1. Spool of each actuator in neutral state
As the pressure in the line (Pg) cannot reach the pump relief pressure (40 bar) due to the orifices (Nzx) and
(Nzy), pressure in the lines (Px) and (Py) is between 0 and 6 bar. Therefore, it cannot reach the pressure
switch sensing pressure (19 bar), so the automatic idling function is activated to set the engine idling.
2. Spool of each actuator in operation
When each actuator is operated, operating pressure in the lines (Px) and (Py) is kept higher than the
pressure switch sensing pressure (19 bar). Then, the automatic idling function is deactivated so the engine
runs according to the original working mode.
The orifice at the line (Px) is designed to detect operation of all actuators, except the travel actuator, and
supply the pilot pressure for the lines (Pal) (arm holding valve) and (SH) (swing motor brake).
The orifice at the line (Py) is designed to detect operation of the travel spool only and activate the automatic
idling function for machine stopping situation.
OPTION Px
ORIFICE
BUCKET
Py Py
BOOM 1
Pg
ARM 2
ARM 1
BOOM 2
SWING TRAVEL
DOZER
Px Nzx Pg Nzy Py
19 bar 19 bar
Pal (Arm Holding V/V)
SH (Swing Motor) 40 bar

WE1400498
Figure 28

5-8-32
BP Valve (Boom Priority Valve)
1. Valve (BP) not in operation
(no supply of boom pilot pressure) P1 P2
Operating oil supplied from the pump (P1) is delivered to
the arm with low load through the parallel passage.
As the valve (BP) is not switched, some operating oil
supplied from the pump (P2) is delivered to the arm
through the parallel passage and the remainder is supplied
to the boom.
2. Valve (BP) in operation (supply of boom pilot pressure)
When the combined operation with the boom is performed,
the boom pilot pressure is delivered to the valve (BP) and
the spool (B) is switched. Then, the arm's oil passage is BOOM 2 BOOM 1
formed to send a small amount of operating oil from the
pump (P2) to the arm and the remainder to the boom in
order to ensure preferential operation of the boom. ARM 1 ARM 2
WE1400499
Figure 29

5-8-33
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

ground as shown in Figure 30 before lowering the bucket
on the ground.
2. Stop engine.
WE1400415
Figure 30

5-8-34
(Figure 31)
LOCK
WARNING
WARNING
AVOID DEATH OR SERIOUS INJURY DO NOT OPERATE
or maintenance
ON OFF

O O

switch.
WE1401161
Figure 32

OFF
(Figure 33)
ON
Figure 33 EX1401760
WARNING
doing any work.
Pulling the breather cap upward, the check valve (0.45 bar) EX1402442
opens, and the air is discharged to the atmosphere from Figure 34

5-8-35
13. Oil drain method
NOTE: Check the level on the oil level gauge before Suction Filter Cover Return Filter Cover
draining the oil.
A. Remove cover on oil tank (bolt: 6 ea) and drain
hydraulic oil using oil pump. (Figure 35)
• Tool: 17 mm ( )
Figure 35 WE1400179
B. Drain hydraulic fluid using drain plug.

(without oil pump) (Figure 36)
• Tool: 27 mm ( )
• Hydraulic oil tank volume
– Approximately: 205 L (54.2 U.S. gal)
– Effective level: 122 L (32.2 U.S. gal)
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1008
Figure 37 EX1402445
Reference
Description
Number
3
1 Suction Filter
2 Nut
A
3 Rod
2
When installing
• Length (A): 650 mm 1
• Torque (2 nut): 49 N.m (5 kg.m, 36.2 ft lb) EX1402872
Figure 38

5-8-36
14. Loosen the main control valve mounting bolts from valve
mounting bracket. (bolt: 4 ea) (Figure 39)
NOTE: Do not remove bolts completely to hold the
position of control valve.
• Tool: 19 mm ( )
WE1400355
Figure 39 Bottom of Control Valve

3
5 8
1 2
7 6
4
EX1401809
Figure 40
15. Open the engine cover and remove bolts and spacers (1,
2
Figure 41) (4 ea) with cover (2).
• Tool: 19 mm ( )
• Cover weight: 16 kg (35.3 lb) 1
Figure 41 WE1400356
16. Disconnect the harness connector from "Px" and "Py" port
top of control valve.
Figure 42 WE1400357

5-8-37
How to disconnect the harness connector.
1
EX1401811
Figure 43
17. Remove hoses, pipes and adapters from control valve.

NOTE: Attach identification tags to the removed hoses for reassembling.
After disconnecting hoses from main control valve, plug them to prevent dirt or dust from
entering. Disconnect the hoses from the bottom to top of control valve.
Ak1 Ab1
Pg
At Fr
Pbp
Bt
Bk1 Pi Bb1 Dr1

Figure 44 Right Side View WE1400358

Port Name
Travel Motor "B" Forward
At SAE 1", D23 8 63.7 6.5 47.0
(to Center Joint "13")
Bucket Crowd
Ak1 SAE 1", D23 8 63.7 6.5 47.0
(to Bucket Cylinder Head)
Ab1 Boom Down (to Boom Cylinder Rod) SAE 1", D23 8 63.7 6.5 47.0
Bb1 Boom Up (to Boom Cylinder Head) SAE 1", D26 8 63.7 6.5 47.0
Bucket Dump
Bk1 SAE 1", D23 8 63.7 6.5 47.0
(to Bucket Cylinder Rod)
Travel Motor "A" Backward
Bt SAE 1", D23 8 63.7 6.5 47.0
(to Center Joint "14")
Pg from Solenoid Valve "P3" PF 1/4 19 39.2 4 28.9
Fr to Main Pump "X1" PF 1/4 19 39.2 4 28.9
Pbp Connect with "XBb1" PF 1/4 19 39.2 4 28.9
Dr1 to Oil Tank PF 1/4 19 39.2 4 28.9
Pi from Joint Block Assembly "10" PF 1/4 19 39.2 4 28.9

5-8-38
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
Elbow PF 1/4 PF 1/4 19 39.2 4 28.9
Pg
Screen Filter PF 1/4 PF 1/4 19 39.2 4 28.9
Fr, Dr1, Pi Elbow PF 1/4 PF 1/4 19 39.2 4 28.9
Pbp Adapter PF 1/4 PF 1/4 19 39.2 4 28.9
At, Ak1, Ab1,
O-ring øD: 32.92, øW: 3.53 (2180-1026D19)
Bb1, Bk1, Bt
Pg, Fr, Pbp,
O-ring P11 (S8000111)
Dr1, Pi

5-8-39
Dr3
Front View WE1400359
Figure 45

Port Name
Dr3 to Oil Tank PF 1/4 19 39.2 4 28.9
• Fitting
Size Torque
Port Name
Dr3 Elbow PF 1/4 PF 1/4 19 39.2 4 28.9
Dr3 O-ring P11 (S8000111)

5-8-40
Fl Aa1 As Ad
Dr4 XAk2 Ba1 Bs Bd Rs

Left Side View
WE1400360
Figure 46

Port Name
Aa1 Arm Crowd (to Arm Cylinder head) SAE 1", D23 8 63.7 6.5 47.0
As Left Swing (to Swing Device "A") SAE 3/4", D19 8 63.7 6.5 47.0
Dozer Down
Ad SAE 3/4", D19 8 63.7 6.5 47.0
(to Dozer Cylinder Tube)
Ba1 Arm Dump (to Arm Cylinder Rod) SAE 1", D23 8 63.7 6.5 47.0
Bs Right Swing (to Swing Device "B") SAE 3/4", D19 8 63.7 6.5 47.0
Dozer Up
Bd SAE 3/4", D19 8 63.7 6.5 47.0
(to Dozer Cylinder Rod)
XAk2 to Oil Tank PF 1/4 19 39.2 4 28.9
Fl to Main Pump "X1" PF 1/4 19 39.2 4 28.9
Rs to Swing Device "C" 1 7/16"-12UN-2B 41 169.5 17.3 125
Dr4 to Oil Tank PF 1/4 19 39.2 4 28.9
• Fitting
Size Torque
Port Name
XAk2, Fl Elbow PF 1/4 PF 1/4 19 39.2 4 28.9
Rs Adapter PF 1 UNF 1 7/16-12 41 205.8 21 151.8
Aa1, Ba1 O-ring ID: 32.92, W: 3.53 (2180-1026D19)
As, Ad, Bs, Bd O-ring ID: 24.99, W: 3.53 (2180-1026D2)
XAk2, Fl O-ring P11 (S8000111)
Rs O-ring P29 (S8000291) F-16 (S8030161)

5-8-41
R
P1 P2
Rear View
WE1400371
Figure 47

Port Name
R from Radiator SAE 2", D48 10 107.8 11 79.5
P1 from Main Pump "A1" SAE 1", D26 8 63.7 6.5 47.0
P2 from Main Pump "A2" SAE 1", D26 8 63.7 6.5 47.0
• Fitting
Size
Port Name
A B
R O-ring ID: 56.74, W: 3.53 (2180-1026D27)
P1, P2 O-ring ID: 24.99, W: 3.53 (2180-1026D2)
XAa2
XAa1
XAb1
Xop
XAs XAk
XAd XAo
XAt
Pz
Px
Py
Top View WE1400372

Figure 48

5-8-42

Port Name
Pz from Solenoid "PL" PF 3/8 22 49 5 36.2
XAd from Dozer Valve "1" PF 1/4 19 39.2 4 28.9
XAs Left Swing (from Joystick Valve "3") PF 1/4 19 39.2 4 28.9
Xop to Oil Tank PF 1/4 19 39.2 4 28.9
XAa1 from Joint Block Assembly "13" PF 3/8 22 49 5 36.2
XAa2 from Joint Block Assembly "7" PF 3/8 22 49 5 36.2
XAb1 from Joint Block Assembly "16" PF 3/8 22 49 5 36.2
XAk from Joint Block Assembly "11" PF 3/8 22 49 5 36.2
XAo to Oil Tank PF 1/4 19 39.2 4 28.9
XAt to Solenoid "PAR" PF 1/4 19 39.2 4 28.9
Connect with "Pal" PF 1/4 19 39.2 4 28.9
Px
Pressure Switch PF 1/4 31 39.2 4 28.9
Py Pressure Switch PF 1/4 31 39.2 4 28.9
• Fitting
Size Torque
Port Name
Pz Elbow PF 1/4 PF 3/8 19 39.2 4 28.9
XAd, Xop, XAt, XAo Elbow PF 3/8 PF 1/4 22 49 5 36.2
Adapter PF 3/8 PF 3/8 22 49 5 36.2
XAs
Adapter PF 3/8 PF 1/4 19 49 5 36.2
XAa1, XAa2, XAk Adapter PF 3/8 PF 3/8 22 49 5 36.2
Elbow PF 3/8 PF 3/8 22 49 5 36.2
XAb1
Shockless Valve PF 3/8 PF 3/8 22 49 5 36.2
Adapter PF 1/4 PF 1/4 17 39.2 4 28.9
Px
Reducer PF 1/4 PF 1/4 19 39.2 4 28.9
Elbow PF 1/4 PF 1/4 17 39.2 4 28.9
Py
Reducer PF 1/4 PF 1/4 19 39.2 4 28.9
Pz, Px, Py O-ring P11 (S8000111)
XAd, XAs, Xop, XAa1,
XAa2, XAb1, XAk, O-ring P14 (S8000141)
XAo, XAt

5-8-43
Pal
XBa2
XBa1
XBb1
XBb2
XBk XBs
XBd
XBo
XBt
Bottom View WE1400373

Figure 49

Port Name
XBt to Solenoid "PBR" PF 1/4 19 39.2 4 28.9
XBo to Oil Tank PF 1/4 19 39.2 4 28.9
XBk from Joint Block Assembly "12" PF 3/8 22 49 5 36.2
from Joint Block Assembly "15" PF 3/8 22 49 5 36.2
XBb1
Connect with "Pbp" PF 1/4 19 39.2 4 28.9
XBa2 from Joint Block Assembly "8" PF 3/8 22 49 5 36.2
to Swing Device "SH" PF 1/4 19 39.2 4 28.9
Pal
Connect with "Px" PF 1/4 19 39.2 4 28.9
XBa1 from Joint Block Assembly "14" PF 3/8 22 49 5 36.2
XBb2 from Joint Block Assembly "9" PF 3/8 22 49 5 36.2
XBs Right Swing (from Joystick Valve "1") PF 1/4 19 39.2 4 28.9
XBd from Dozer Valve "2" PF 1/4 19 39.2 4 28.9

5-8-44
• Fitting
Size Torque
Port Name
XBt, XBo, XBd Adapter PF 3/8 PF 1/4 22 49 5 36.2
XBk, XBa2, XBa1 Adapter PF 3/8 PF 3/8 22 49 5 36.2
XBb1 Tee PF 3/8 PF 1/4, PF 3/8 22 49 5 36.2
Elbow PF 3/8 PF 3/8 22 49 5 36.2
XBs
Adapter PF 3/8 PF 1/4 19 49 5 36.2
XBb2 Elbow PF 3/8 PF 3/8 22 49 5 36.2
Pal Tee PF 1/4 PF 1/4 19 39.2 4 28.9
XBt, XBo, XBk,
XBb1, XBa2, XBa1, O-ring P14 (S8000141)
XBb2, XBs, XBd
Pal O-ring P11 (S8000111)
18. Install eyebolts (2 ea) to lift in threaded holes on top of

control valve. (Figure 50)
• Thread of hole: M12 x 1.75 (Depth 20 mm)
• Control valve weight: about 143 kg (315 lb)
Figure 50 WE1400374
19. Remove main control valve mounting bolts from valve

mounting bracket. (bolt: 4 ea) (Figure 51)
20. Lift the control valve by crane from frame slowly and
carefully.
Figure 51 WE1400375

5-8-45
INSTALLATION
WARNING
SERIOUS INJURY
NOTE: First, assemble the bolts (4 ea) of main control valve

mounting to valve mounting bracket. (Figure 52)
IMPORTANT
After completing the work, check the oil level. Start the
engine and check for any oil leaks.
2. Be careful not to apply stress on control valve when Figure 52 WE1400375

attaching piping and hoses. Unnecessary stress can cause
spools to bind and the control valve from functioning
properly.
3. Tighten the assembling bolts alternately and evenly to the
specified torque.
4. If welding procedures are being performed near the control
valve, the valve could be damaged by weld spatter and
heat. Use adequate shielding to protect valve.
5. Valve ports must be covered with caps, plugs or tape to
protect them from dust and other foreign materials, until
pipe laying work is started.
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill the
hydraulic oil tank.
cylinder 4 ~ 5 times very slowly, about 100 mm before the
end of stroke.
the hydraulic piping.
(The air breather of oil tank is actuated to bleed the air)

5-8-46
DISASSEMBLY
Caution on Disassembly
1. Stop engine when pressure of actuator is not indicated.
It is dangerous to disassemble control valve while it is
under pressure. High-pressure oil can squirt out or
components can spring out. When partially disassembling
control valve that is on machine, be careful to follow the
following caution.
WARNING
Always relieve hydraulic pressure and fully lower
bucket (or attachment) to the ground, before
disassembly. Failure to follow instructions can cause
sudden release of component parts or boom dropping,
resulting in death or serious injury.
2. Vent pressurized air from hydraulic oil tank.

3. Clean all exterior surfaces of valve before to disassembly
and protect it from dirt and foreign materials.
4. Match mark the disassembled parts to make sure of proper
reassembling position.
5. Replace all sealing parts such as O-rings and backup rings
with a new ones.
6. Do not replace spools, they are matched with valve
housing and sleeve.
NOTE: The further part numbers of an assembly part
are shown as (assembly part number - further
part number).

5-8-47
Housing
To disassemble control valve, remove bolts from left and right
side of the control valve.
• Tool: 12 mm ( )
Stand control valve on flat surface and tighten bolts with correct
torque.
• Tool: 12 mm ( )
• Torque: 147 N.m (15 kg.m, 108 ft lb)
IMPORTANT
Socket Bolt
Be sure to use extreme care when assembling and
FG007251
disassembling control valve. All O-rings should be replaced
Figure 53 Bottom View
with new ones. Never reuse old O-rings.
Main Plunger Element - Disassembly and

Assembly
IMPORTANT
When disassembling Main Plunger element tag and label
each component so that all parts can be reassembled in the
proper order.
IMPORTANT
Care should be taken when disassembling and
reassembling plunger assemblies.
This holding tool is used to clamp and hold plunger for further
disassembly, without damaging it. The holder is comprised of 2
halves of a hexagonal rod made from soft brass, with the
appropriate size hole and outside dimensions.
Inside Diameter Outside Diameter Application

28.20 mm 41.0 mm
Main Plunger
(1.1102 in) (1.6142 in)
Length 100.0 mm (3.9370 in)
Figure 54

5-8-48
Figure 55
Reference Reference
Number Number
1 8 mm Hex Head Bolts 3 Plunger Cap Bolt
2 Plunger Cover
1. Remove two bolts (1, Figure 55) from cover and remove
cover (2) from valve housing.
• Tool: 8 mm ( )
2. Pull out plunger sub-assembly from housing.
IMPORTANT
Do not force out plunger. Pull out plunger slowly, to
avoid damage.
Figure 56
3. Use the holder tool described above to clamp plunger

assembly and loosen plunger cap bolt.
Reference
Description
Number
1 Plunger Holding Tool
2 Spring Guide
3 Plunger Cap Bolt
• Torque (3): 59 N.m (6 kg.m, 43 ft lb)
Figure 57

5-8-49
4. Remove plunger cap bolt (3, Figure 58), upper spring
guide (4), spring (5), spacer (6) and lower spring guide (4).
IMPORTANT
Use caution when disassembling and assembling
plungers. The travel straight plunger does not have a
spacer. In addition the spring and plunger cap bolts
are different.
Figure 58
5. Plunger (Lower side)

Arm 1: Remove cap (7, Figure 59), O-rings, backup ring,
spring (8) and check valve (9).
• Tool: 8 mm ( )
Figure 59
Boom 1: Remove cap (7, Figure 60), O-ring, backup ring,

sleeve (10), check valve (11) and spring (12).
• Tool: 8 mm ( )
Figure 60

5-8-50
Arm Load Holding Valve
IMPORTANT
When disassembling Arm Load Holding Valve, tag and label
proper order.
Check Valve Main Body

1. Remove allen-style bolts (1) and cover (2).
2
3
1
Z View Z WE1400501
Figure 61
• Tool: 10 mm ( )
IMPORTANT
When assembling cover, inspect O-rings for any
damage and replace as necessary.
2. Remove spring (3) and poppet (4).
Figure 62

5-8-51
Cover Assembly
9 8 7 6 5 4
Reference
Description
Number
1 Cap
2 Spring
3 Check
4 Cap
5 Piston 3
6 Sleeve
2
7 Poppet
1
8 Spring WE1400502
9 Cap Figure 63
1. Loosen cap (1) and remove spring (2) and check (3).
• Tool: 8 mm ( )
Figure 64
2. Loosen cap (4) and remove piston (5).
• Tool: 10 mm ( )
Figure 65
3. Loosen cap (9) and remove spring (8) and poppet (7).
• Tool: 8 mm ( )
4. Remove sleeve from poppet bore by gently tapping it from
the right side.
IMPORTANT
Be careful not to damage the edges of the inner and Figure 66
outer surfaces of the sleeve.

5-8-52
Boom Load Holding Valve
IMPORTANT
When disassembling Boom Load Holding Valve, tag and
label each component so that all parts can be reassembled
in the proper order.
11 10 9 8, 14
6, 7
Overload Relief Valve 5
15 12 13 WE1400503
Figure 67
Reference Reference
Description Qty. Description Qty.
Number Number
1 Manifold 1 9 Spring; Pilot 1
3 Poppet 1 10 Spool; Pilot 1
4 Spring 1 11 Cover 1
5 Guide; Spring 1 12 O-ring 1
6 O-ring 1 13 O-ring 1
7 Backup Ring 1 14 O-ring 2
8 Cap 2 15 Bolt; Socket 4
1. Remove socket bolts (15) and remove cover (11).
• Tool: 8 mm ( )
IMPORTANT
When assembling cover, inspect O-rings for any
damage and replace as necessary.

5-8-53
2. Remove guide (5), spring (4) and poppet (3) from manifold
bore (1).
Figure 68
3. Loosen cap (8) and remove spring (9) and spool (10). 8
• Tool: 6 mm ( )
9
10
WE1400504
Figure 69

5-8-54
IMPORTANT
When disassembling Arm Regeneration Valve, tag and label
proper order.
Reference
Description 1 2 3 4 5 6 7
Number
1 Cap
2 Cap
3 Spring
4 Spring Guide
5 Spool
6 Sleeve
WE1400505
7 Piston
Figure 70
1. Cap (1), loosen cap (2) and remove guide spring (4).
• Cap (1) 2
– Tool: 10 mm ( ) 1
– Torque: 59 N.m (6 kg.m, 43.4 ft lb)

• Cap (2)
– Tool: 27 mm ( ) 3
– Torque: 98 N.m (10 kg.m, 72 ft lb)
4 FG003254
Figure 71
5
6
FG003255
Figure 72

5-8-55
Bucket Unity Check
IMPORTANT
When disassembling Arm Regeneration Valve, tag and label
proper order.
Reference
Description
Number
1 Cap
2 Check
3 Spring
Figure 73
1. Loosen cap (1) and remove check (2) and spring (3).
• Tool: 32 mm ( )
Figure 74

5-8-56
Foot Relief Valve
IMPORTANT
When disassembling foot relief valve, tag and label each
component so that all parts can be reassembled in the
proper order.
Reference
Description
Number
1 Cap
2 Poppet
3 Cap
4 Shim
5 Spring
Figure 75
1. Loosen cap (1) and remove poppet (2). 2

• Tool: 30 mm ( )
• Torque: 59 N.m (6 kg.m, 43 ft lb) 1
5
2. Loosen cap (3) and remove shim (4) and spring (5). 4
• Tool: 30 mm ( )
IMPORTANT WE1400506
Figure 76
Shim is necessary for correct pressure adjustment and
must not be left out.

5-8-57
Bypass Cut Valve (BC Valve)
IMPORTANT
When disassembling Center Bypass Valve, tag and label
proper order.
Reference
Description
Number
1 Cap
2 Spring
3 Spool
Figure 77
1. Loosen cap (1) and remove spring (2) and spool (3).
• Tool: 41 mm ( )
Figure 78

5-8-58
Check Valve - Locations
Cap Only B
Travel
D Option
Bucket
Boom 1
D Arm 2
A Cap Only
Dozer
F
Swing
Boom 2
D
Arm 1
Figure 79 WE1400507
Reference Reference
Number Number
A Main Relief Valve E Travel
B P2 F Swing
C Arm 2
Option, Bucket, Boom 1, Boom 2,
D
Arm 1

5-8-59
Check Valve
IMPORTANT
When disassembling Check Valves, tag and label each
component so that all parts can be reassembled in the
proper order.
A: Check Valve (Main Relief Valve)

1
Reference
Description
Number
1 Cap 2
2 Spring 3
3 Check
Loosen cap (1), remove spring (2) and check (3). 2
• Tool: 12 mm ( )
WE1400508
Figure 80
B: Check Valve (P2)

1
Reference
Description
Number
1 Cap
2
2 Spring 3
3 Check
Loosen cap (1), remove spring (2) and check (3).

2
• Tool: 12 mm ( )
3
WE1400509
Figure 81

5-8-60
C: Check Valve (Arm 2)
1
Reference
Description
Number
1 Cap
2
2 Spring 3
3 Check
Loosen cap (1), remove spring (2) and check (3). 2
• Tool: 12 mm ( ) 3
WE1400510
Figure 82
D: Check Valve (Option, Bucket, Boom 1, Boom 2, Arm 1)

1
IMPORTANT
Even though the valve caps look the same, they are 3
different, and cannot be interchanged.
2
Reference
Description
Number
1 Cap
2 Spring
3 Check
3
2 WE1400511
• Tool: 12 mm ( )
Figure 83
E: Check Valve (Travel)

1
Reference
Description
Number
2
1 Cap
2 Backup Ring 3
3 O-ring
• Tool: 36 mm ( )
• Torque: 98 N.m (10 kg.m, 72 ft lb) HAAA7950
Figure 84

5-8-61
F: Check Valve (Swing)
1
IMPORTANT
Even though the valve caps look the same, they are 3
different, and cannot be interchanged. 2
Reference
Description
Number
1 Cap
2 Spring
3 Check
3
2 WE1400512
• Tool: 12 mm ( )
Figure 85

5-8-62
REASSEMBLY
Caution on Assembly
Caution on Handling O-ring

1. Do not use O-ring which has any defect or scratches from
handling.
2. Apply grease or hydraulic oil to installation portion of O-ring
grooves and O-ring to ease installation.
3. Do not stretch O-ring beyond permanent set.
4. When installing O-ring, be careful not to twist it. (A twisted
O-ring, is very difficult to return to its original shape after
installing it. This could also cause a leak.)
Caution on Handling Spool

1. Rated torque must be kept because over torque of screw
portion, can cause a malfunction of spool.
2. Be careful that each spool, spring and spool end must be
reassembled like before disassembling.
Method of Painting the Adhesives (Screw Part and Arm

Screw Part of Parts Requiring the Adhesiveness)
NOTE: Male and female screw threads of parts which need
to adhere.
CAUTION
AVOID INJURY
When working with Loctite, work in a place that is well
ventilated.
1. Cleaning (removal of grease)

Remove grease with steam, acetate, etc. or clean with an
alkali cleanser.
2. Dry
Dry Loctite surface with moisture free air or naturally. If it is
not completely dried, the effect of Loctite is weakened.
3. Primer painting
Slightly spray Loctite Primer T effect promoter to Loctite
surface and leave it for three or five minutes to dry.
4. Loctite application
Lightly apply Loctite #274 or equivalent to two or three
threads of spool female inlet. Now, be careful not to touch
coated part to spring seat.

5-8-63
CLEANING AND INSPECTION
Cleaning
Clean all parts thoroughly using a suitable cleaning fluid and dry
them with moisture free compressed air. Put them on a clean
paper or a vinyl for inspection.
Inspection
Inspect all parts for scratches, notches and other defects.
1. Inspect load check seat surface of valve housing for
scratches, scores, dirt, notches and corrosion. Remove
small scratches with oilstone.
2. Inspect exterior surface of spool for scratches and notches.
Remove small scratches with oilstone.
3. Sliding parts must be moved lightly and foreign materials
must be removed in all grooves and passages.
4. Replace any springs that are damaged, heavy deformed or
worn.
5. If relief valve malfunction, inspect it using relief valve
maintenance procedure.
6. Replace all O-rings and backup rings with new.
7. After disassembling cap or plug, check whether there are
paint chips around body hole or plug. If paint chips
penetrate into valve, they can cause malfunction or valve
to leak.

5-8-64
TROUBLESHOOTING
Overall Control Valve

Problem Possible Cause Remedy
Spool does not move. Oil temperature is abnormally Remove part with resistance of oil
increased. leakage within pipeline.
Pollution of operation oil. Replace operation oil and wash circuit at
same time.
Overly tighten pipe port joint. Check Torque.
Valve housing is skewed in loading. Loosen and confirm loading bolt.
Pressure is too high. Check pressure of pump and cylinder
port.
Spool is bent. Replace valve assembly.
Return spring is damaged. Replace damaged part.
Spring or cap is not in line. Loosen cap to release load.
The temperature distribution in Warm up entire circuit.
valve is inconsistent.
The valve is clogged by dust. Remove (flushing) dust.
The pilot pressure is insufficient. Check pilot valve and pilot relief
pressure.
Load is not maintained. Oil is leaking from cylinder. Check chamber part of cylinder.
Oil is bypassed from spool. Check groove of spool.
Oil is leaking from overload relief Wash valve housing seat part and relief
valve. valve seat part.
Oil is leaking from antidrift valve. Disintegrate antidrift valve and wash
seat part of each part. In event there is
grooves on seat part, replace poppet or
wrap poppet and seat part. In event of
having malfunction in antidrift valve
spool, spool and sleeve make pair that
both shall be replaced.
When spool is shifted to up The load check valve has dust. Disintegrate check valve and wash.
position from neutral, load is The poppet or seat part of check Replace poppet or wrap poppet and seat
dropped. value has groove. part.

5-8-65
Relief Valve
Press does not increase. Main poppet, sleeve or pilot poppet Replace relief valve.
are stuck open and valve seat part
has dust.
Unstable relief pressure. The seat part of pilot poppet has
groove.
Piston or main poppet gets stuck.
Abnormal relief pressure. Abrasion of seat part by dust.
Locking screw and adjustment Reset pressure and tighten locking
equipment are loosened. screw with regular Torque.
Oil leakage. Damage to relief valve seat part. Replace relief valve.
Each part is stuck with dust.
The O-ring is worn out. Replace adjustment equipment or O-ring
of loading part.
Overall Oil Pressure

Oil pressure condition is Breakdown of pump. Check pressure or replace pump.
bad or not operate at all. Breakdown of relief valve. Replace relief valve.
Breakdown of cylinders. Repair or replace.
Pump load pressure is significant. Check circuit pressure.
Valve has crevice. Replace valve assembly.
Spool does not make full stroke. Check operation of spool.
Tank surface is too low. Add operation oil.
Filter in circuit is clogged. Wash or replace filter.
Circuit pipeline is tightened. Check pipeline.

5-8-66
START-UP PROCEDURES
1. Before operating machine, make sure that oil passages
and hydraulic oil are clean.
2. Relief valve pressure should not be raised above specified
pressure setting.
3. The difference between main relief valve setting pressure
and overload relief valve setting pressure should not be
over 20 bar (20 kg/cm2 (290 psi)).
4. Before operating machine, the hydraulic system must be
fully warmed up. If machine is operated with cold hydraulic
oil and valve, be careful of the following, to prevent spool
sticking because of heat shock.
NOTE: Do not operate main relief valve or overload
relief valve suddenly and continuously.
Cycle oil through all actuators and warmed up
cold hydraulic oil in the lines and components
uniformly.
NOTE: Slight or compound work should not be
suddenly operated at cold weather because
heat is developed partly at all the orifices.

5-8-67
5-8-68
Swing Device
Edition 1
DX210WA Swing Device

5-9-1
MEMO
Swing Device DX210WA

5-9-2
Table of Contents
Swing Device
General ...........................................................5-9-5
Specification .............................................................. 5-9-5
Swing Motor ......................................................... 5-9-5
Swing Reduction Gear ......................................... 5-9-5
Pinion Gear .......................................................... 5-9-5
Parking Brake....................................................... 5-9-5
Overview ................................................................... 5-9-6
Parts List ................................................................... 5-9-8
Swing Motor ......................................................... 5-9-8
Swing Reduction Gear ....................................... 5-9-10
Swing Device...................................................... 5-9-12
Hydraulic Motor .................................................. 5-9-13
Valve Casing ...................................................... 5-9-14
Schematic of Operation of Reactionless Valve .. 5-9-18
Brake Part .......................................................... 5-9-19
Cautions for Operation ............................................ 5-9-21
Inspection ........................................................... 5-9-21
Direction of Rotation........................................... 5-9-21
External Load at the End of Shaft ...................... 5-9-22
Hydraulic Oil and Temperature Range............... 5-9-22
Filter ................................................................... 5-9-23
Installation and Piping ........................................ 5-9-23
Oil Filling and Air Ventilation .............................. 5-9-23
Instructions before Starting to Operate .............. 5-9-23
Precaution ....................................................5-9-24
Tools for Disassembly and Assembly ..................... 5-9-24
Tightening Torque ................................................... 5-9-24
Removal .......................................................5-9-26
Installation ....................................................5-9-30
Completing work ...........................................5-9-31

5-9-3
Section View .................................................5-9-32
Disassembly .................................................5-9-34
Swing Motor ............................................................ 5-9-34
Swing Reduction Gear ............................................ 5-9-39
Reassembly ..................................................5-9-43
Swing Motor ............................................................ 5-9-43
Swing Reduction Gear ............................................ 5-9-49
General Instructions ................................................ 5-9-57
Examination of Hydraulic Motor .............................. 5-9-57
Troubleshooting....................................................... 5-9-58
Maintenance Instructions..............................5-9-61
Replacement Standard of Worn Parts..................... 5-9-61
Standard of Sliding Surface Correction ................... 5-9-61

5-9-4
SAFETY INSTRUCTIONS
WARNING
machine. Read and understand the Operation and
or serious injury.
GENERAL
Specification
Swing Motor
Type Axial Piston

Displacement 128 cm3 (0.004 ft3)
Crossover Relief Valve Setting 265 bar (270 kg/cm2, 3,840 psi) @250 L/min
Max. Supply Flow 201 L/min (44 U.S. gal)
Motor Shaft Speed 1,570 rpm
Motor Shaft Torque 539 N.m (55 kg.m, 398 ft lb)
Accessory Valves Swing Reactionless Valve
Swing Reduction Gear
Drive Type 2 - Stage Planetary Gear

Reduction Ratio 21.58
Max. Output Speed 72.7 rpm
Max. Output Torque 11,640 N.m (1,187 kg.m, 8,586 ft lb)
Pinion Gear
Type Spur Gear

Gear P.C.D D 156 mm
No. of Teeth 13
Module 12
Parking Brake
Spool Cracking 13 bar (13 kg/cm2, 185 psi)

Time Delay 5 sec

5-9-5
Overview
Swing device consists of a swing motor, swing reduction gear.
Swing motor includes mechanical parking valve, relief valve,
makeup valve and time delay valve.
PA C PB DB
A
Air Breather
B
Oil Level Gauge
PG
SH
Dr
WE1400041
Figure 1
Port Name Size

A High-pressure (Right) 22.2 x 47.6 Flange
B High-pressure (Left) 22.2 x 47.6 Flange
C Make Up PF 1, O-ring
DB Motor Drain PF 1/2, O-ring
SH Brake Signal PF 1/4, O-ring
PG Brake Release PF 1/4, O-ring
Pa Pressure Gauge PF 1/4, O-ring
Pb Pressure Gauge PF 1/4, O-ring
Air Breather PT 1/2
Oil Level Gauge PT 1/4
Dr Oil Drain PT 1/2

5-9-6
SH
RED
PG
DB
265 bar
265 bar
C
PA PB
A B WE1400030
Figure 2

5-9-7
Parts List
Swing Motor
110
109
102 205
103
105 209
104
208
101
206
107 112 207
213
108 203
113
310
202
309
308
201
307
305
306 303
302
311 214
212
210 314
211
210
400 312
406
301
Figure 3 WE1400042

5-9-8
Reference Reference
Number Number
101 Valve; Casing 211 Spring
102 Plug 212 Ring; Snap
103 Spring 213 Plate, Valve
104 Plunger 214 Ring; Snap
105 Valve; Swing Reactionless 301 Case
107 Valve, Relief 302 Seal, Oil
108 Bearing; Ball 303 Bearing; Roller
109 Bolt; Socket 305 Plate; Separation
110 Plug 306 Plate; Friction
112 O-ring 307 O-ring
113 Pin; Spring 308 O-ring
201 Shaft; Drive 309 Piston; Brake
202 Plate; Shoe 310 Spring; Brake
203 Piston & Shoe Assembly 311 Plug; PT
205 Block, Cylinder 312 Gauge Assembly, Level
206 Ball; Thrust 314 Bolt, Socket
207 Plate; Retainer 400 Valve, Brake
208 Collar 406 Bolt M6 x 1.0 x 70
209 Roller * Seal Kit; Swing Motor
210 Washer
*: 112, 302, 307, 308

5-9-9
600
608 602
708
607 802
606
604
601 605
603 801
606
510
504
702
511
509 505
512
508
700 501
704 511
705
503
707
706
701 506
703
706
507
502
WE1400043
Figure 4

5-9-10
Reference Reference
Number Number
501 Case, Gear Box 604 Ring, Inner
502 Shaft, Pinion 605 Bearing, Needle
503 Bearing, Roller; Spherical 606 Washer, Thrust; No.1
504 Bearing, Roller; Spherical 607 Plate; Thrust
505 Seal, Oil 608 Screw
506 Cover 700 Carrier Assembly; No.2
507 Screw 701 Carrier; No.2
508 Washer, Thrust; No.3 702 Gear, Sun; No.2
509 Bolt M16 x 2.0 x 30 703 Gear, Planetary; No.2
510 Plug; PT 704 Pin; No.2
511 Plug 705 Bushing
512 Pin, Parallel 706 Washer, Thrust; No.2
600 Carrier Assembly; No.1 707 Pin, Spring
601 Carrier; No.1 708 Washer, Thrust
602 Gear, Sun; No.1 801 Gear, Ring
603 Gear, Planetary; No.1 802 Bolt, Socket

5-9-11
Swing Device
2 3
WE1400044
Figure 5
Reference Reference
Number Number
1 Socket Bolt 3 Air Breather Assembly
2 Level Gage Assembly

5-9-12
Theory of Operation
Hydraulic Motor
As shown in the figure below, the high-pressure oil entering the
cylinder block through valve plate (112) inlet side port exerts
pressure on the piston, generating axial force F. The force F is
divided into the two vectors of force F1 which is perpendicular to
the swash plate (103) and F2 which is perpendicular to the shaft,
with the shoe (104-1) as the medium. With the piston and the
medium, the force F2 is transmitted to the cylinder block (108)
and generates rotational torque to the output shaft. On the
cylinder block, 9 pistons are arranged equidistantly, and
rotational torque is transmitted to the output shaft by the multiple
pistons connected to the inlet side of the high-pressure oil in
consequences.
Reversing the direction of oil flow will reverse the direction of
rotation of the output shaft.
Theoretical output torque T is calculated with the formula below;
Pxq
T=
2xπ
P: effective differential pressure (kg/cm2)

q: volume per rotation (cc/rev)
103 112
Low Pressure Hyd. Oil High Pressure Hyd. Oil
Outlet Port Inlet Port
104-1 104 108
EX1301620
Figure 6 Operation Diagram of Motor

5-9-13
Valve Casing
1. Anticavitation check valve
Since the system using this type of motor has no valve
which has counterbalance function, the motor may rotate
exceeding the feed oil flow.
To prevent cavitation, suck in deficient oil through the
check valve.
Control Valve Control Valve
EX1301686
Figure 7
2. Relief valve
Lets assume that port P is pressurized from the tank
pressure. Initially, ports P and R are at tank pressure.
321 302 h g
R Port
P Port
A1 m 301 A2 n 401
EX1301621
Figure 8
When the two forces; the force defined by the product of

the area (A1) of plunger (301) receiving pressure and
pressure P1; and the force defined by the product of spring
(321) force (Fsp) and pressure-receiving area (A2) of
plunger (301) by the pressure Pg in the chamber g;
become the same, the relief valve starts to function.

5-9-14
Here, the Pg is the pressure in the chamber g which is
pressurized by the oil through the orifice m, and when it
reaches the pressure defined by the spring (321) pressing
the piston (302), the piston starts to move to the left.
P1 x A1 = Fsp + Pg x A2
Fsp + Pg x A2
P1 =
A1
321 g
R Port
P Port
A1 301 A2
Figure 9 EX1301687
3. Chamber h acts as a damping chamber by the orifice (n)

formed on the side of the piston (302).
By this, the pressure in the chamber g increases smoothly
until piston (302) reaches the end of the adjustment plug
(401).
321 302 h g
R Port
P Port
n 401
Figure 10 EX1301688

5-9-15
When the piston (302) reaches the end of the adjustment
plug (401), it cannot move further to the left, thus, the
pressure in chamber g becomes equal to Ps and the force
of the spring (321) becomes Fsp' (Figure 11).
Consequently, the pressure P varies as illustrated in
(Figure 11).
The pressure Ps at the final stage is expressed with the
equation below;
Ps x A1 = Fsp' + Ps x A2
Fsp'
Ps =
A1 - A2
302 g
R Port
P Port
Pressure: Ps 401
Pressure
Ps
P1
Time
Operational Diagram
EX1301689
Figure 11 Relief Valve

5-9-16
4. Reactionless valve
When the direction switching valve of swing motor I
switched, high-pressure oil is supplied to the port A (or port
B) of the hydraulic motor. Then, the poppet of the
reactionless valve moves to the right, blocks the bypass
route and drives the rotating body (1, Figure 12).
Then, when the direction switching valve returns to neutral
position, the ports at both sides of the hydraulic motor are
blocked, but the rotating body would maintain its rotation
because of inertia and the momentum of inertia is
transmitted to the hydraulic motor through the reduction
gear, generating brake pressure at the port B (or port A)
which stops the rotating body and tries to reverse the
direction of rotation.
By this brake pressure, the swing motor first stops and
then tries to reverse its direction of rotation and the
pressure at the port B tries to switch the poppet to the left,
but the action is delayed by the orifice at the port A. Now, a
bypass route is formed connecting the ports A and B
through which the high-pressure oil flows from port B to the
port A (2, Figure 12).
And, the poppet on the port B side moves to the left until it
blocks the bypass route (3, Figure 12).
As described above, in the process of reverse pressure
generation at the port B, the high-pressure oil is bypassed
to the port A to prevent reverse rotation and stop the swing
motor right away.
Motor Inlet
A Port Bypass Motor Outlet
B Port
(1)
Orifice Poppet Bypass
(2)
(3)
EX1301726
Figure 12 Principle of Operation of Reactionless Valve

5-9-17
Schematic of Operation of Reactionless Valve
1st 2nd

A B A B
Swing Swing Stop (Start of Stop)
3rd 4th
By Pass
A B A B
Swing Stop (before the Stop) Swing Stop (Complete of Stop)
EX1301690
Figure 13

5-9-18
Brake Part
The cylinder block (108) is connected with the driveshaft (102)
by spline joint, and rotation of the separation plate (110) in
circumferential direction is restricted by the circular arc grooved
on the casing (115). When the friction plate (109), engaged with
the outer circumference of the cylinder with gears, is pressed to
the casing (115) by the brake spring (118) with the separation
plate (110) and brake piston (119) as the media. Friction force is
generated between the friction plate and casing, separation
plate and brake piston. This friction force restricts and brakes
the driveshaft.
When brake release pressure is applied to the oil chamber
formed between the brake piston and casing and this pressure
overcomes the spring force, the brake piston moves and the
friction plate is separated from the casing, and the brake is
released.
Oil Pressure
Spring Force
118
119
Oil Chamber
Valve Casing
110
109 108
102
EX1401272
Figure 14 Operation Diagram of Brake

5-9-19
1. Parking brake operating
Parking Brake Spring
Parking Brake Piston
Oil Chamber SH
PG
Separation Plate PG DB
Friction Plate
SH WE1400028
Figure 15
2. Parking brake release
Parking Brake Spring
Parking Brake Piston
Oil Chamber
SH
PG
Separation Plate PG DB
Friction Plate
SH WE1400029
Figure 16

5-9-20
Cautions for Operation
Inspection
Please check the followings before installing a new motor:
1. Check if there is any part damaged or missing (during
transportation).
2. Check if there is any loose joint.
3. Check that flange surfaces and the drain port cover are
properly assembled and there is no dust or other particle in
the motor.
Direction of Rotation
The relationship between the directions of oil flow and shaft
rotation is presented in Figure 17 and Table.
The direction of rotation differs by the direction of the slope of
casing.
Be careful for the direction of swing which is differentiated by the
shape of casing and direction of flange.
Normal Direction Reverse Direction

Figure 17 WE1400045
Direction of the Rotation of the

Classification Inlet Outlet Shaft Seen at the End of the
Shaft
Normal Direction A B Right (Clockwise)
Reverse Direction B A Left (Counterclockwise)

5-9-21
External Load at the End of Shaft
In principle, the end of the motor shaft must be free of any
external radial or thrust load.
Hydraulic Oil and Temperature Range

1. Oil type
The recommended oil is mineral type hydraulic oil added
with extreme pressure additive, foam suppressor,
antioxidant, and desiccant, having high viscosity index.
2. Optimal viscosity and temperature range of hydraulic oil
(Figure 18)
Maximum viscosity range is 10 - 1000 cSt, however,
recommended range is 10 - 200 cSt to obtain optimal
efficiency.
Temperature range is restricted between -25 - 100°C to
protect oil seals and O-rings. The highest recommended
temperature is 60°C or lower to prevent degeneration of
the oil and seals.
Higher Limits of Viscosity

1000
750
500
400
300
Higher Temperature Limit

200
Low Temperature Limit
150
100
75
Viscosity in cSt
50
40
Optimum Working Range
30
25
20
15
10
9 Low Viscosity Limit
8
7
6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 C
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 F FG018906
Figure 18 Optimum Viscosity and Temperature Range
3. Other types of oils than mineral oils

Please contact us to use phosphoric acid ester,
water-glycol, or fatty acid ester oils.

5-9-22
Filter
Dust or metal particles in hydraulic oil accelerate wear of sliding
surfaces or can cause sticking. Install 10 μm filter in the oil circuit
to remove particles from the oil.
Regarding contamination, NAS Class 9 or lower or 2 - 4 mg/
100 cc in Millipore Filter contamination rating is recommended.
Installation and Piping

1. In principle, the motor shaft should face downward.
2. The deviation of centerline from the driven part must be
0.05 mm or less.
3. The tightening torque of the bolts used in mounting the
motor to bracket must be according to the specifications on
the outline drawings.
4. The casing must be always filled with oil.
The position of the oil drain of the motor must be as shown
in (Figure 19) to allow the casing be full of oil.
5. The maximum allowable pressure in the casing is 3 bar,
however, 2 bar or less is recommended.
6. Clean the pipeline and perform flushing.
7. Avoid excessive force at pipe joints. Figure 19 WE1400046
8. Drain pipe must be the same or larger than the port size of
the motor, and as short as possible.
Oil Filling and Air Ventilation

1. Starting operation, fill the casing with oil through drain port.
In the hydraulic motor, there are high-speed sliding motion
parts, such as bearing, piston, shoe and spherical bushing.
If oil is not fully filled, these sliding parts can cause sticking
or damage.
2. Air inside the hydraulic oil circuit or motor can cause
malfunction or damage, thus, must be removed
completely.
Instructions before Starting to Operate

Figure 20 WE1400047
1. Check if there is any loose joint or other trouble in the
pipeline.
2. Check that direction of rotation is correct.
3. Check oil leaks from the hydraulic motor.
4. Check if abnormal vibration occurs during rotation or
operating direction switching valve.
5. Check if the oil temperature rise too fast.
6. Check that actual pressure is about the same as the
setting value.

5-9-23
PRECAUTION
Tools for Disassembly and Assembly

Tables 1 and 2 and Figure 21 presents the tools required for
disassembly and reassembly. Since different bolts and plugs are
used in different types, check and prepare necessary tools.
Table 1
Name Size Application Part Tool (mm)
Hex Bolt M6 Brake Valve (10)
Hex Socket Head Bolt M20 Valve Casing (17)
Plug M30 RO Plug (14)
Hex Socket Head Bolt M12 Casing (10)
Relief Valve M33 Relief Valve (41)
Table 2
Specification
Size
Tools
for stop ring For ø45 shaft
Pliers For ø100 hole
for lock ring
For ø58 hole
Driver Flat tip, 2 pcs.
Steel Rod Approximately 10 x 8 x 200. 1 pc.
Hammer Plastic and metal hammers, 1 each
Torque adjustment range
• for 100 ~ 450 kg.cm
Torque Wrench
• for 400 ~ 1,800 kg.cm
• for 1,200 ~ 4,800 kg.cm
Slide Hammer Bearing Pliers -
Brake Piston Puller See next page
Tightening Torque
Table 3 presents the tightening torque of the bolts used in the
hydraulic motor. Observe the specified torque when tightening
the bolts.
Table 3
Reference Tightening Torque

Bolt Size Type
No. N.m kg.m ft lb
102 M30 Ro Plug 220.6 ±24.5 22.5 ±2.5 162.7 ±18.1
107 M33 Relief Valve 176.5 ±9.8 18 ±1 130.2 ±7.2
109 M20 Hex Socket Head Bolt 431.5 ±64.7 44 ±6.6 318.3 ±47.7
314 M12 Hex Socket Head Bolt 98 ±0.9 10 ±0.1 72 ±0.7
406 M6 Hex Bolt 11.8 ±2 1.2 ±0.2 8.7 ±1.4

5-9-24
2 x o9
2 x o7
o40
M10
(Effective Screw for Length : 20)
100
150
o11
M10
M10
123: T3 x 63
169
240
EX1301624
Figure 21 Tools for Brake Piston Disassembly

5-9-25
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Park the machine on flat level ground.

2. Extend the boom and arm, as shown in Figure 22 and
lower the boom until the attachment is 10 cm above the
ground.
3. Stop the engine.
10 cm
WE1400049
Figure 22

5-9-26
(Figure 23)
LOCK
WARNING WARNING
DO NOT OPERATE
or maintenance
ON OFF

O O
switch.
WE1401161
Figure 24

OFF
(Figure 25)
ON
Figure 25 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 26

5-9-27
WARNING
doing any work.
Figure 27
14. Remove hoses and adapters from swing device.
NOTE: Attach an identification tags to the removed hoses for reassembling.
After disconnecting hoses, plug them to prevent dirt or dust from entering.
Disconnect the hoses from the bottom to top of swing device.
DB
C
Dr(RG)
PG
A Sgr
B
SH
Figure 28 WE1400050

Port Name
A Main Port (from MCV "As") SAE 3/4", D20 8 63.7 6.5 47.0
B Main Port (from MCV "Bs") SAE 3/4", D20 8 63.7 6.5 47.0
C Make-up Port (from MCV "Rs") 1 7/16"-12UN-2B 41 169.5 17.3 125.1
Drain Port
DB PF 1/2 27 93.1 9.5 68.7
(Connect with Center Joint)
Brake Release Port
PG PF 1/4 19 39.2 4 28.9
(from Control Valve "Pg")
Brake Release Signal
SH PF 1/4 19 39.2 4 28.9
(from MCV "Pal")
Sgr Grease Inlet Port PF 1/4 19 39.2 4 28.9
N Nut PF 1/2 27 93.1 9.5 68.7
Dr (RG) Drain (Reduction Gear) PF 1/2 27 93.1 9.5 68.7

5-9-28
• Fitting
Size Torque
Port Name
C Adapter PF 1 UNF 1 7/16-12 41 205.8 21 151.8
DB Tee PF 1/2 PF 1/2 24 93.1 9.5 68.7
PG Adapter PF 1/4 PF 1/4 19 39.2 4 28.9
SH Elbow PF 1/4 PF 1/4 19 39.2 4 28.9
Sgr Adapter PT 1/4 PF 1/4 19 19.6 2 14.5
Dr (RG) Adapter PT 1/2 PF 1/2 27 49.0 5 36.2
1B, ID: 24.99, W: 3.53
A, B O-ring
(2180-1026D2)
1B P29 1B F-16
C O-ring
(S8000291) (S8030161)
1B P18
DB O-ring
(S8000181)
1B P11
PG, SH O-ring
(S8000111)
15. Install the eyebolts (M10 x 1.5, depth 18 mm) (Figure 29).
16. Attach a nylon sling onto the eyebolt.
Figure 29 WE1400051
17. Remove bolts and washers (1, Figure 30) (11 ea).
• Tool: 30 mm ( )
18. Remove plugs (2, Figure 30) (2 ea).
19. Install the back bolt to the plug position to ensure that
frame and swing device can be separated.
20. Hoist and remove swing device from the frame. 1
NOTE: When hoisting the swing device one part of 2
swing device will contact with the main frame. Figure 30 WE1400052
Hoist the swing device a little and push to the
front side while hoisting slowly.

5-9-29
21. Wind wire rope around the swing device, lift it up with a
crane and wash with flushing oil.
After washing, dry with compressed air.
• Weight: about 253 kg (558 lb)
WE1400053
Figure 31
INSTALLATION
WARNING
SERIOUS INJURY

2. When installing the hoses, install the drain hose first.
3. When installing the swing device, slightly move the end of
bucket to align it with the swing bearing gear if the swing
device does not fit the gear.

5-9-30
COMPLETING WORK
IMPORTANT
If air is not vented from system, it will cause damage to
swing motor and bearings.
1. Disconnect drain hose and fill swing motor case with

hydraulic oil.
2. Connect drain hose.
3. Start engine and set throttle at "LOW IDLE" and swing Figure 32 WE1400054
upper structure slowly two full revolutions to left and right.
4. Stop engine and check hydraulic oil level. Fill hydraulic oil
tank to "H" mark on sight gauge.
5. Check for oil leaks and clean all fill and venting locations.

5-9-31
SECTION VIEW
312
102
103
104
105
512
107
109
311
802
112 310 101 205 110 204 108 210 212 213 113
309
308 211
307 210
305
209
306
400
203
208
202
406
303
206
201 207
214 301
302
608
607 314
606 602
603 708
605 701
604 706
601 704
801 705
512 703
702 707
509 803
508 504
510 505
511
501 503
506
507
502
Figure 33 WE1400048

5-9-32
Reference Reference
Number Number
101 Valve; Casing 314 Bolt, Socket
102 Plug 400 Valve, Brake
103 Spring 406 Bolt M6 x 1.0 x 70
104 Plunger 501 Case, Gear Box
105 Valve; Swing Reactionless 502 Shaft, Pinion
107 Valve, Relief 503 Bearing, Roller; Spherical
108 Bearing; Ball 504 Bearing, Roller; Spherical
109 Bolt; Socket 505 Seal, Oil
110 Plug 506 Cover
112 O-ring 507 Screw
113 Pin; Spring 508 Washer, Thrust; No.3
201 Shaft; Drive 509 Bolt M16 x 2.0 x 30
202 Plate; Shoe 510 Plug; PT
203 Piston & Shoe Assembly 511 Plug
204 Piston 512 Pin, Parallel
205 Block, Cylinder 601 Carrier; No.1
206 Ball; Thrust 602 Gear, Sun; No.1
207 Plate; Retainer 603 Gear, Planetary; No.1
208 Collar 604 Ring, Inner
209 Roller 605 Bearing, Needle
210 Washer 606 Washer, Thrust; No.1
211 Spring 607 Plate; Thrust
212 Ring; Snap 608 Screw
213 Plate, Valve 700 Carrier Assembly; No.2
214 Ring; Snap 701 Carrier; No.2
301 Case 702 Gear, Sun; No.2
302 Seal, Oil 703 Gear, Planetary; No.2
303 Bearing; Roller 704 Pin; No.2
305 Plate; Separation 705 Bushing
306 Plate; Friction 706 Washer, Thrust; No.2
307 O-ring 707 Pin, Spring
308 O-ring 708 Washer, Thrust
309 Piston; Brake 801 Gear, Ring
310 Spring; Brake 802 Bolt, Socket
311 Plug; PT 803 Magnet
312 Gauge Assembly, Level

5-9-33
DISASSEMBLY
Swing Motor
Please use the following procedures for the inspection and
repair of the motor.
Numerals given in parentheses following the parts names
indicate the parts number shown by the parts list.
1. Wind the wire rope around motor, Lift up the motor with a
crane and clean the motor with cleaning oil. After cleaning,
dry with compressed air.
2. Drain the oil out of the casing (301).
3. Point the end of the driveshaft downward and fix it on a
disassembly table for easy disassembling. Before 101
disassembling make a match mark on motor casing (301)
and valve casing (101).
301
FG022402
Figure 34
4. Remove bolts (406) (3 ea) with brake valve (400).

• Tool: 10 mm ( )
301
400
406 WE1400016
Figure 35
5. Remove relief valve (107) from valve casing (101).

• Tool: 41 mm ( ) 101
107
FG022404
Figure 36

5-9-34
6. Remove RO plug (102) and take out spring (103) and
plunger (104) from valve casing (101).
• Tool: 14 mm ( )
101
102 104
103
FG022405
Figure 37
7. Remove swing reactionless valve assembly (105) from

valve casing (101).
105
101
WE1400017
Figure 38
8. Remove hex socket bolts (109) and disassemble valve 109

casing (101) from casing (301). When loosening bolts, the
valve casing will be raised by brake springs (310).
101
• Tool: 17 mm ( )
301
310
WE1400018
Figure 39
9. Remove brake springs (310) from the brake piston (309).

310
309
FG022408
Figure 40

5-9-35
10. Disassemble brake piston (309) from casing (301) by using
the special tool for removing the brake piston.
309
Lift it up straight by using the bolt hole in the brake piston.
301
FG022409
Figure 41
11. After placing the motor horizontally, take out cylinder block 301
(205) from casing (301).
201
205
WE1400019
Figure 42
12. Remove piston assembly (203), retainer (207), thrust ball

(206). When taking out the cylinder block, be careful not to 203
pull out roller (209). Be careful not to damage the sliding 207
parts of the cylinder block, thrust ball and shoe.
205
WE1400020
Figure 43
206
208
209
205
WE1400021
Figure 44

5-9-36
13. Pull out friction plate (306) (2 ea) and separation plate
(305) (3 ea) from casing (301). 306
305
301
WE1400022
Figure 45
14. Remove shoe plate (202) from casing (301).

When removing the shoe plate (202), be careful not to 202
damage the sliding parts of the shoe plate (202).
301
FG022412
Figure 46
15. Remove driveshaft (201) with bearing (303) from casing

(301). 201
Be careful not to damage the roller bearing and oil seal
contact surface. If you beat a driveshaft (201) end with
plastic hammer, it is easy to be disassembled. 303
301
WE1400023
Figure 47

5-9-37
16. Do next step only if required.
Press
1) Remove roller bearing (303) from driveshaft (201).
Do not reuse the disassembling bearing. Drive Shaft
Ball Bearing
Hang bearing inner

race on the base
of press.
FG024770
Figure 48
2) Take out oil seal (302) from the casing (301) with a
jig. Do not reuse the disassembling oil seal (302). PRESS Oil Seal
Rod Casing
FG022415
Figure 49
3) Take out valve plate (213) and O-ring (112) from the
valve casing (101).
213
112
101
WE1400024
Figure 50
4) Take out ball bearing (108) from the valve casing

(101).
Do not reuse the disassembling ball bearing (108). 108
Disassembling is finished, check each component throughly.
101
FG022417
Figure 51

5-9-38
Please use the following procedures for the inspection and
repair of the reduction gear.
Numerals given in parentheses following the parts names
indicate the part number shown by the parts list.
1. Wind the wire rope around reduction gear outside , Lift it up
with a crane and clean the reduction gear with cleaning oil.
After cleaning, dry with compressed air.
2. Remove the PT plug (510) and drain out gear oil.
• Gear oil volume: about 4 L (1 U.S. gal)
510
FG022429
Figure 52
3. Remove No. 1 sun gear (602) from No. 1 carrier 602

subassembly.
No. 1 Carrier
FG022430
Figure 53
4. Remove No. 1 carrier subassembly.

No. 1 Carrier
sub-assembly
FG022431
Figure 54

5-9-39
5. Remove No. 2 sun gear (702) from No. 2 carrier
subassembly. 702
FG022441
Figure 55
6. Remove bolt (509) in No. 2 carrier.

• Tool: 24 mm ( ) 509
FG022451
Figure 56
7. Remove No.2 carrier subassembly from ring gear.

No. 2 Carrier
Sub-assembly
FG022452
Figure 57
8. Remove bolt (802) in ring gear (1 ea).

802
• Tool: 6 mm ( )
WE1400025
Figure 58

5-9-40
9. Remove ring gear (801) from casing (501).
801
501
FG022454
Figure 59
10. Remove pins (512) from casing (501).

512
501
FG022455
Figure 60
11. Remove bolt (507) from casing (501).

501
507
FG022456
Figure 61
12. Use a rollover machine to turn case over and place a jig on
JIG
driveshaft. Use a press to remove pinion shaft from case 501
(501).
FG022457
Figure 62

5-9-41
13. Remove bearing (504) from case (501). 504
501
WE1400026
Figure 63
14. Remove pinion shaft (502) from casing (501).
501
502
FG022462
Figure 64
15. Remove oil seal (505).

505
IMPORTANT
Do not reuse oil seal!
Disassembling is finished, check each component throughly.
FG022460
Figure 65

5-9-42
REASSEMBLY
Swing Motor
Use care with the following instructions.
A. After disassembly, make sure to repair damaged
parts and prepare the parts to be replaced.
B. Wash all the parts with clean washing fluid and dry
with compressed air.
C. Apply clean hydraulic oil on the sliding surfaces and
bearings.
D. Replace O-rings and oil seals, which is a principle.
E. Tighten screws, bolts and plugs at specified torque
using a torque wrench.
1. Place casing (301) on the work table with the valve casing
side downward. 301
FG022418
Figure 66
2. (This procedure applies when oil seal was disassembled

from the casing.) Insert oil seal (302) at the casing (301) 302
with a tool. (Be careful to note the direction of oil seal and
insert until fully seated in the casing.)
301
FG022419
Figure 67

5-9-43
3. This procedure is necessary when the ball bearing was
separated from the driveshaft.
Install the ball bearing (303) in the driveshaft (201) by
shrinkage fitting.
201
303
FG024760
Figure 68
4. Insert the driving shaft (201) with the ball bearing (303) in
the casing (301) with its output shaft facing upward and 201
use a hammer to tap the surface of the ball bearing into the
casing. At this point, apply grease to the lip of the oil seal
lightly and then insert it carefully so it may not be
303
damaged.
NOTE: Wrap a tape around the spline of the driving
shaft to prevent the damage of the spline 301
because of the lip.
Tap the surface of the external circumference
evenly until it reaches the end completely.
WE1400023
Figure 69
5. Assemble shoe plate (202) to casing (301).

202
When assembling the shoe plate (202), be careful not to
damage the sliding parts of the shoe plate (202).
301
FG022412
Figure 70

5-9-44
6. Insert roller (209) to cylinder block (205).
209
Make sure that cylinder block is assembled with all
component.
(washer (210), spring (211), ring snap (212))
(Be careful not to damage the sliding surface of the
cylinder block.
Insert roller to each hole one by one.)
205
FG022420
Figure 71
7. Place collar (208), thrust ball (206) to the cylinder block

(205).
206
208
205 FG022421
Figure 72
8. Assemble the retainer (207) with the piston sub assembly

(203) unit to the cylinder block (205). 206
208
209
205
WE1400021
Figure 73
207 203
205
WE1400020
Figure 74

5-9-45
9. Insert cylinder block (205) to driveshaft (201) by aligning
with the spline.
201
205
FG022410
Figure 75
10. Place casing (301) downward and assemble separation

plate (305) (3 ea) and friction plate (306) (2 ea) in 305
sequence.
306
(Assemble the parts of the friction plate cut-off with four
gears at the same phase up and down.)
(Assemble the parts of the separation plate cut-off with four
jaws at the same phase.)
301
FG022423
Figure 76
11. Mount O-ring (307, 308) to casing (301).

(Apply grease thinly on the O-rings to prevent being cut
308
during assembling the brake piston.)
307
301
FG022424
Figure 77
12. Assemble brake piston (309) to casing (301). If the piston

is difficult to assemble because of the restriction of the O-
ring; screw in two M8 bolts on the brake piston and tap 309
them gently with plastic hammer.
301
FG022409
Figure 78

5-9-46
13. Assemble brake springs (310) into brake piston (309).
310
Confirm the springs are fitted to the brake piston
completely.
309
FG022408
Figure 79
14. (This procedure applies when ball bearing (108) was

disassembled from the valve casing.)
Assemble of ball bearing (108). Insert it to valve casing 108
(101) while tapping it lightly.
Tap evenly on the outer diameter of the outer race with a
brass drift until it completely stops.
Do not use a steel punch or bar on the bearing since it can
101
chip or crack the race.
FG022417
Figure 80
15. Assemble valve plate (213) to valve casing (101) and

install O-ring (112).
Be careful to note the direction of the valve plate. 213
Mount the valve plate with its round part toward the
opposite side of the flange.
112
Coat lightly with grease.
101
WE1400024
Figure 81
16. Mount valve casing (101) to casing (301) and tighten hex
socket bolts (109) to specification. 109
Be careful to note the mounting direction of the valve 101

casing. (Reference to the drawing)
Be careful not to drop the valve plate or let the brake
springs pop out.
Tighten the bolts evenly.
• Tool: 17 mm ( )
301
• Torque: 431.5 N.m (44 kg.m, 318.3 ft lb) FG022426
Figure 82

5-9-47
17. Install plunger (104) and spring (103) to valve casing (101)
and tighten RO plug (102) with O-ring (106).
Confirm the smooth movement of the plunger before
installing the plug.
101
• Tool: 14 mm ( ) 102 104
• Torque: 220.6 N.m (22.5 kg.m, 162.7 ft lb) 103
FG022405
Figure 83
18. Install swing reactionless valve (105) to valve casing (101).

Confirm the spring in the swing reactionless valve (105).
105
101
WE1400017
Figure 84
19. Assemble relief valve (107) with O-ring to valve casing

(101).
101
• Tool: 41 mm ( )
107
FG022404
Figure 85
20. Assemble brake valve (400) to casing (301) and tightening

the hex bolts to specified torque.
• Tool: 10 mm ( )
The assembly is completed. 301
400
406 WE1400016
Figure 86

5-9-48
Assembly should be done in the reverse order of disassembly
described above, taking into consideration the following points:
A. Parts damaged during disassembly should be
repaired without fail and spare parts should be
prepared in advance.
B. Every part should be cleaned enough with cleaning
oil and dried with compressed air before starting
assembly.
C. Sliding parts and bearings should be applied clean
hydraulic oil before their assembly.
D. Seal parts of the O-ring and the oil seal should be
replaced according to the standards.
E. Use a torque wrench to tighten or engage bolts and
plugs in accordance with “Tightening Torque” on
page 5-9-24.
1. Install the bearing cover (506) and the taper roller bearing
(503) on the pinion shaft (502).
503
506
502
FG022461
Figure 87
2. Install the pinion shaft (502) and other associated parts.
IMPORTANT 501
Prior to assembling the pinion shaft,etc. 502

Apply grease slightly on the lip surface to prevent any
scratch when installing.
FG022462
Figure 88

5-9-49
3. Tighten screws (507) to assemble cover (506).
506
507
FG022463
Figure 89
4. Mount a casing (501) on a suitable work table or jig.
501
FG022464
Figure 90
5. Apply grease thinly on the outer circumference of the oil

seal (505) and insert it into casing (501) by using pressing 505
jig.
IMPORTANT
Do not reuse oil seal! 501
FG022465
Figure 91
6. Install the taper roller bearing (504) with a using of tool.
504
501
FG022466
Figure 92

5-9-50
7. Assemble pins (512) with casing (501).
512
501
FG022455
Figure 93
8. Apply sealant evenly to ring gear assembly of casing.
FG022467
Figure 94
9. Lift ring gear (801) with hoist, wipe its mating surface clean
with cloth, Match and align holes and attach to casing
(501).
801
501
FG022454
Figure 95
10. Tightening special bolts (802) with no Loctite applied.

802
• Tool: 6 mm ( )
WE1400025
Figure 96

5-9-51
11. Assemble bushing (705) and the washer (706) onto planet
gear No.2 (703) and arrange it on the pinhole of the carrier 706
No.2.
705
Turn over gear assembly (703, 705, 706) and insert it and
thrust washer (508) into No. 2 carrier.
703
Align bushing hole with carrier holes.
NOTE: Thrust washer (706) must be on both side of
gear. 706
EX1402253
Figure 97
12. Align spring pinhole in pin No.2 (704) with spring pinhole of
No. 2 carrier.
704
Insert no.2 pin (704) into carrier and No. 2 bushing.
NOTE: Pin No.2 may need to be gently tapped with a
508
soft faced hammer.
After all four No.2 are installed,align spring pin (707) with
carrier hole and drive it into position using a hammer.
703
707 EX1402256
Figure 98
13. Using a suitable lifting device, lower No. 2 carrier

subassembly into ring gear, making sure that planetary No. 2 Carrier
gears are engaged. Continue to lower carrier and engaging Sub-assembly
it onto splines of pinion shaft.
Make sure that carrier is resting on bearing.
NOTE: Make sure that carrier and driveshaft can rotate.
FG022452
Figure 99
14. After tightening the bolt (509), to attach carrier assembly 2

and use a torque wrench to tighten it up to the standard
509
torque.
• Tool: 24 mm ( )
• Torque : 279.5 N.m (28.5 kg.m, 206 ft lb)
FG022451
Figure 100

5-9-52
15. Install No. 2 sun gear (702) in No. 2 carrier.
702
FG022441
Figure 101
16. Assemble the following parts on the carrier No.1.

606
Reference 603
Description
Number 605
603 Planet Gear 604
604 Innerring 606
605 Needle Bearing
708
606 Thrust Washer No.1
708 Thrust Washer
WE1400027
Figure 102
17. Assemble the following parts.

608
Reference
Description
Number
607 Thrust Plate
608 Screw
607
• Torque (608): 29 N.m (3 kg.m, 21 ft lb)
FG022472
Figure 103
18. Install the carrier No.1 subassembly. Lift the carrier No.1
subassembly and turn it clockwise or counterclockwise No. 1 Carrier
gently for it to engage with the spline of the No.2 sun gear sub-assembly
(702) and the ring gear (801).
FG022431
Figure 104

5-9-53
19. Install No. 1 sun gear (602) in No. 1 carrier.
602
FG022473
Figure 105
20. Use a hoist to lift the prepared motor, wipe out the
assembly, and install the retaining ring (214) on the shaft
(201).
201
214
FG022474
Figure 106
21. Apply sealant evenly to ring gear assembly of motor.
FG022475
Figure 107
22. Put the motor on the reduction gear carefully as shown in

the figure.
The level gauge port and hole in the ring gear should be
alligned.
Level
Assemble the motor by turning it clockwise or Gauge
counterclockwise gently so that splines of the shaft shall be Port
engaged with the No.1 sun gear.
FG022497
Figure 108

5-9-54
23. Apply Loctite to socket bolts (314) (16 ea).
314
FG022498
Figure 109
24. Insert bolt into holes, and tighten with an impact wrench.
• Tool: 10 mm ( )
• Torque : 98 N.m (10 kg.m, 72 ft lb)
314
FG022499
Figure 110
25. Install the level gauge pipe sealed with teflon tape with a
pipe wrench.
Level Gauge
Pipe
FG022500
Figure 111

5-9-55
26. Fill with the correct gear oil and check the oil level with
stick level gauge.
• Gear oil volume: about 4 L (1 U.S. gal)
Assembly is done.
FG022501
Figure 112

5-9-56
TROUBLESHOOTING
General Instructions
This section provides the corrective actions against any
abnormality identified during hydraulic motor operation.
General instructions are as follows:
1. Think before taking action
Before taking any action, examine the characteristics of the
problem, and if there had been similar trouble before.
In addition, examine once again that cause of the problem
is the hydraulic motor.
2. Take care of foreign material
Foreign materials cause abnormal friction and wear. Take
care to avoid foreign materials during disassembly and
reassembly.
3. Parts handling
All the parts are precisely ground, thus, take utmost care
not to damage.
4. Take care not to damage O-rings and gasket surfaces.
It is highly recommended to replace with new O-rings after
disassembly.
Examination of Hydraulic Motor

It is very difficult to find out the cause of trouble in hydraulic oil circuit.
Check the items listed below, and examine the cause of the
hydraulic motor.
1. Check oil quality in the casing
Remove drain plug and check the oil in the casing.
If the oil contains many metal particles, the cause of
trouble may be a part in the hydraulic motor.
2. Abnormal noise
Check if the motor makes abnormal noise.
3. Pressure measurement of each parts
Before disassembly and inspection, measure the pressure
of each parts and examine the problem.
4. Measure the drain quantity of the motor
1) Lock the swing and supply high-pressure oil to the
motor, and normal drain quantity must be
approximately 25 LPM or less.
2) Normal drain quantity in normal swiveling must be 2
LPM of less.

5-9-57
Troubleshooting
1. Hydraulic motor fails to rotate
Symptom Possible Cause Corrective Action

Pressure does not rise 1. The setting of the relief 1. Set up with correct value
valve in the circuit is
incorrect.
2. Relief valve malfunction. 2.
1) Plunger sticks 1) Plunger sticks
2) Plunger orifice 2) Plunger orifice
clogged. clogged.
3. Plunger seat failure 3. Check the seat and replace
it if damaged.
Pressure rises up to normal level 1. Overloaded. 1. Remove load.
2. Sticking of moving parts 2. Check/repair piston, shoe,
cylinder block, and valve
plate.
3. Brake release pressure is 3.
not applied.
1) Check/repair the
circuit.
2) Check the brake
switching valve.
4. Brake piston is sticking. 4. Disassemble and check
5. Friction plate is sticking. 5. Disassemble and check
Replace the sticking part.
2. The direction of rotation is reverse.

Direction of rotation is reverse 1. Motor rotates in reverse 1. Referring to Figure 12,
direction. assemble correctly.
2. The inlet and outlet of 2. Correct the pipeline.
pipeline are reverse.

5-9-58
3. Rotating speed fails to reach setting value.

Rotating speed fails to reach 1. Insufficient incoming flow. 1. Check pump discharge
setting value rate, circuit to the motor.
2. Temperature is too high 2. Reduce the oil
and oil leaks too much. temperature.
3. Wear of damaged of sliding 3. Replace the damaged part.
parts
4. Insufficient brake torque

Insufficient brake torque 1. Friction plate is worn. 1. Disassemble and check.
Replace the part if
excessively worn.
2. Brake piston is sticking 2. Disassemble and check
3. Brake release pressure 3.
cannot be removed.
1) Check/repair the
circuit.
2) Check the brake
switching valve.
4. The spline of the friction 4. Disassemble and check
plate is damaged.
Replace the damaged part
5. Hydraulic motor slips excessively

Check the drain quantity of the motor.
Normal drain rate is 500 cc/min.

Excessive slip when external 1. Relief valve malfunction. 1. Same as subclause 1).
torque to drive the hydraulic
Same as subclause 1).
motor is applied.
2. Bad plunger seat 2. Replace the damaged part.

5-9-59
6. Oil leak
1) Leak at oil seal

Leak at oil seal 1. The lip is damaged by dust. 1. Replace the oil seal.
2. Worn or damaged shaft. 2. Change the relative
position of the lip and shaft,
or replace the lip.
3. Oil seal lip is overturned 3. Repair clogged pipeline.
because of excessively
high-pressure in the casing.
4. Rusted shaft. 4. Disassemble and correct it.
2) Oil leak at joint surface

Oil leak at joint surface 1. O-ring is missing. 1. Insert correctly and
reassemble
2. O-ring is damaged. 2. Replace.
3. Seal surface is damaged. 3. Disassemble and correct it
4. Loose or damaged bolt. 4. Tighten at specified torque
or replace the bolt

5-9-60
MAINTENANCE INSTRUCTIONS
Replacement Standard of Worn Parts

When a part is worn exceeding the criteria below, adjust or
replace the part. However, the criteria for parts with distinct
damage are not defined.
Standard Replacement
Item Corrective Action
Dimension (mm) Criteria (mm)
Clearance between the piston and Replace the piston or
0.025 0.055
cylinder block cylinder block
Clearance between the piston and Replace the piston or
0.05 0.2
shoe compressed part (δ) shoe assembly
Replace the piston or
Shoe thickness (t) 4.5 4.3
shoe assembly
Assembled height of the retainer Replace the retainer and
10.8 10.3
plate and spherical bushing (H-h) spherical bushing set
Friction plate thickness 3.5 3.1 Replace
H
h
t
Piston and shoe clearance between the piston and shoe ( ) Assembled height of the retainer and spherical bush (H-h)
Shoe thickness (t)
FG019002
Figure 113
Standard of Sliding Surface Correction

Correct or replace the part whose surface roughness of the
sliding face exceeds the following criteria.
Part Name Standard Roughness Roughness Requiring Correction

Shoe 0.8 - Z (Ra = 0.2) (Lapping) 3 - Z (Ra = 0.8)
Shoe Plate 0.4 - Z (Ra = 0.1) (Lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (Lapping) 12.5 - Z (Ra = 3.2)
Valve Plate 0.8 - Z (Ra = 0.2) (Lapping) 6.3 - Z (Ra = 1.6)
1)
NOTE: All the sliding surfaces must be lapped to make the
roughness below the standard roughness.
NOTE: 2)If the sliding surfaces of the retainer or spherical

bushing are excessively rough, replace the parts by
set unit.

5-9-61
5-9-62
Joystick Valve
(Work Lever)
Edition 1
DX210WA Joystick Valve (Work Lever)

5-10-1
MEMO
Joystick Valve (Work Lever) DX210WA

5-10-2
Table of Contents
Joystick Valve (Work Lever)

Safety Instructions ........................................5-10-5
General .........................................................5-10-5
Specifications .......................................................... 5-10-5
Overview ................................................................. 5-10-6
Parts List ................................................................. 5-10-8
Theory of Operation .............................................. 5-10-10
Section View ...............................................5-10-12
Removal .....................................................5-10-14
Installation ..................................................5-10-19
Completing work .........................................5-10-20
Tools and Torques......................................5-10-21
Disassembly ...............................................5-10-21
Reassembly ................................................5-10-25

5-10-3
5-10-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Max. Primary Pressure 50 kg/cm2 (50 bar, 711.1 psi)
Max. Back Pressure 3 kg/cm2 (3 bar, 42.7 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Continuous Rated Current of Switch 5A-125V/3A-250V
Internal Leakage
Oil Temperature 50 ±5°C
Neutrality 30 ~ 150 cc
At Work (15 kg/cm2) 30 ~ 400 cc
Performance
Port 1, 3 Port 2, 4
40 40
30 30
28 1.5 28 1.5
20 (20) 20 (20.5)
(17.5) 16.6 3 (19) 17 3
10 10
6.5 1 6.5 1 5.5 2
5.5 2
0 1 2 3 4 5 6 6.5 7 0 1 2 3 4 5 6 6.2 7 7.5 8
EX1401822
Figure 1

5-10-5
Overview
The remote control valve contains four push rods, spring
holders, spools and return springs, which are in the valve
casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
S1 S2
S3 S2 S1 S3
ingle
21.5 S
, 4)
(Port 2
gle
19 Sin 27
1 , 3) Do
(Port 24 ubl
e
A A
4 4
1 P 1 P
T T
2 3 2 3
LH RH
Push Button Switch

3 2 1 LH RH Center
6 5 4
1 - Red 2 - Blue 3 - Yellow
4 - Black 5 - Gray 6 - Green
View A
EX1401823
Figure 2

5-10-6
Push Button Switch

(LH)
Switch LH RH 1 Red 4 Block
S1 Rotating (CCW) Shear Close (RH)
S2 Rotating (CW) Shear Open 2 Blue 5 Gray
S3 Horn Button Breaker/Booster Button (Center)
3 Yellow 6 Green
EX1401824
Figure 3
Ports
P T
Port LH RH Size
1 Left Swing Bucket Crowd
2 Arm Dump Boom Down
3 Right Swing Bucket Dump
PF 3/8
4 Arm Crowd Boom Up
P Pilot Oil Inlet Pilot Oil Inlet
1 3 2 4
T Pilot Oil Return Pilot Oil Return
EX1301711
Figure 4

5-10-7
Parts List
28
24
18
25A
16 23
25B 17
36
12 18
16
22
32 11 17
15 35
25 8 12
14
20 11
13 10
34 8
5 7
30 21
6
4 33
5
131
19
27 9
4
1
9
26 SPOOL
2, 4
SPOOL
A
1, 3
29
37 : 24 ~ 28
3
EX1401825
Figure 5

5-10-8
Reference Reference
Number Number
1 Case 22 Plate, Swash
2 Plug 23 Nut
3 Bushing 24 Nut
4 Spool Handle Assembly (LH)
25
5 Shim Handle Assembly (RH)
6 Spring 25A Cap; Peanut
7 Seat; Spring 25B Cap; Round
8 Stopper 26 Bar; Handle
9 Spring 27 Pin; Spring
10 Stopper (1, 3) 28 Bellows
11 Spring 29 Bushing
12 Rod; Push 30 Connector Assembly
13 Spring 32 Switch Assembly
14 Seat; Spring 33 Spool Kit; 1, 3
15 Stopper (2, 4) 34 Spool Kit; 2, 4
16 Plug 35 Plug Kit; 1, 3
17 O-ring 36 Plug Kit; 2, 4
18 Seal; Rod Kit; Handle (LH)
37
19 Plate Kit; Handle (RH)
20 Boot 131 Spacer
21 Joint Assembly

5-10-9
Theory of Operation
Structure
The joystick valve contains four push rods, spring seat, spools
and return springs, which are in the valve casing. Moves the
spool of the main control valve by reducing the pressure of the
pilot pump from a first pressure to a second pressure.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
Function
1. Neutral position
1
When the joystick lever is in the neutral state, the spool is
pressed upward by the return spring and the spring seat.
The P-port is blocked by the lower part of the spool, and 2
the 4 operation ports are connected to the T-port by the
upperpart of the spool.
Reference 3
Description
Number
1 Swash Plate 4
2 Push Rod 5
3 Balance Spring
4 Return Spring
5 Spool
EX1301707
Figure 6
2. Half-operated state
When the joystick lever is moved, the push rod moves
downward, and the force thereof is transferred to the spool
through the spring seat and the control spring. When the
spool moves, the first pressure is transferred to the
operation ports through the spool.
When the lever spring stops in the halfway position, the
force of the compressed spring and the hydraulic pressure
caused by the second pressure applied upward because of
the difference in area of the upper and lower ends of the
spool create a state of equilibrium, and this pressure is
transferred to the spool of the control valve. That is, the
first pressure is transferred to the operation ports through
the spool as a hydraulic pressure (second pressure)
corresponding to the force of the compressed control
spring. EX1301708
Figure 7

5-10-10
3. Fully operated state
When the joystick lever is moved to its full extent, the lower
end of the push rod fully presses the spool seat to fully
compress the control spring.
The first pressure is transferred to the operation ports
through the spool, and the second pressure coming
through the spool overpowers the force of the control
spring, pushing the spool upward, and thus the spool is
restricted from movement by the push rod.
That is, when the joystick lever is fully pressed, the control
spring cannot perform its function and the spool is
restricted, making the first pressure and the second
pressure equal.
EX1301709
Figure 8

5-10-11
SECTION VIEW
25
27
28
26
24
20
23
12
21
11
22
18
131
16
19
15 10
29 17
14
8
13
7
5
6
4
30 9
1 3
2 EX1401826
Figure 9

5-10-12
Reference Reference
Number Number
1 Case 17 O-ring
2 Plug 18 Seal; Rod
3 Bushing 19 Plate
4 Spool 20 Boot
5 Shim 21 Joint Assembly
6 Spring 22 Plate, Swash
7 Seat; Spring 23 Nut
8 Stopper 24 Nut
9 Spring Handle Assembly (LH)
25
10 Stopper (1, 3) Handle Assembly (RH)
11 Spring 26 Bar; Handle
12 Rod; Push 27 Pin; Spring
13 Spring 28 Bellows
14 Seat; Spring 29 Bushing
15 Stopper (2, 4) 30 Connector Assembly
16 Plug 131 Spacer

5-10-13
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

ground as shown in Figure 10 before lowering the bucket
WE1400302
Figure 10

5-10-14
(Figure 11)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF

O O

switch.
WE1401161
Figure 12

OFF
(Figure 13)
ON
Figure 13 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 14

5-10-15
WARNING
doing any work.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 15
EX1402442
12. Remove screws (1, Figure 16) (3 ea), remove upper cover
(2) from bracket, and disconnect the connector of harness
which connect with switches.
• Tool: Phillips screwdriver 1
1
2
EX1401964
Figure 16 Stand RH
13. Remove screw (1, Figure 17) and bolts (2) (2 ea).
• Tool: 13 mm ( ), phillips screwdriver 1

14. Remove upper cover (3) from bracket, and disconnect the
connector of harness which conncet with switches.
2
3
WE1400303
Figure 17 Stand LH

5-10-16
15. Remove screws (1, Figure 18) with mounting plate (2) from
control stand bracket. 4
Remove bolts and washers (3, Figure 18) (4 ea), and
disconnect the harness connector of joystick valve.
Separate joystick valve (4, Figure 18) from control stand.
1
Left side is same.
• Tool: 5 mm ( ), phillips screwdriver 3

2
Figure 18 Stand RH EX1401966
3 2
1
WE1400304
Figure 19 Stand LH

5-10-17
16. Remove hoses and adapters from joystick valve.
After disconnecting hoses from joystick valve, plug them to prevent dirt or dust from entering.
4 4
1 P 1
P
T 3 T
2 2 3
Left Hand Right Hand

Figure 20 EX1401968

Port Name
to Control Valve "XBs"
1 PF 3/8 22 49 5 36.2
(Joint Adapter Top)
2 to Joint Block Ass'y "2" PF 3/8 22 49 5 36.2
Left to Control Valve "XAs"
3 PF 3/8 22 49 5 36.2
Hand (Joint Adapter Bottom)
P from P Block PF 3/8 22 49 5 36.2
T to T Block (Drain) PF 3/8 22 49 5 36.2
Right 3 to Joint Block Ass'y "6" PF 3/8 22 49 5 36.2
Hand 4 to Joint Block Ass'y "3" PF 3/8 22 49 5 36.2
P from P Block PF 3/8 22 49 5 36.2
T to T Block (Drain) PF 3/8 22 49 5 36.2
• Fitting
Size Torque
Port Name
1, 2, 3, 4,
Adapter PF 3/8 PF 3/8 22 49 5 36.2
Left/Right P, T
Hand 1, 2, 3, 4,
O-ring 1B, P14 (S8000141)
P, T
* A: Valve Side, B: Hose Side

5-10-18
17. Remove joystick valve from control stand.
EX1401969
Figure 21
INSTALLATION
WARNING
SERIOUS INJURY

2. Keep the assembly angle when installing the hoses to
joystick valve.

5-10-19
COMPLETING WORK
1. Start engine and set throttle at "LOW IDLE".
HAOB290L
Figure 22
3. Slowly cycle boom, arm, bucket cylinders and swing motor

about five times without a load to vent air from pilot lines.
Do this for five minutes.
WE1400305
Figure 23

5-10-20
TOOLS AND TORQUES
Reference Torque
Description Tool
Number N.m kg.m ft lb
2 Plug 36.3 3.7 27 PT1/8 ( )
22 Swash Plate 162.8 16.6 120 27 mm ( )
23 Hex Nut 162.8 16.6 120 22 mm ( )
24 Nut 162.8 16.6 120 22 mm ( )
DISASSEMBLY
1. Remove lead wire from bushing (29).
FG000804
Figure 24
2. Remove lever assembly from case (1).
FG000805
Figure 25
3. Remove hex nut (23) and swash plate (22) from case.
FG000806
Figure 26

5-10-21
4. Remove joint assembly (21) from case.
FG000807
Figure 27
5. Remove plate (19) from case (1).
FG000808
Figure 28
6. Remove plug kit assembly, stopper (10), and spring (11)

from case (1).
FG000809
Figure 29
FG000810
Figure 30

5-10-22
FG000811
Figure 31
7. Remove four spool kit assemblies from case (1).
FG000812
Figure 32
FG000813
Figure 33
8. The bushing (3) and plug cannot be removed from case

(1).
FG000814
Figure 34

5-10-23
FG000815
Figure 35
FG000816
Figure 36
FG000817
Figure 37

5-10-24
REASSEMBLY
1. Install four plugs (2) into case (1).
FG000815
Figure 38
FG000817
Figure 39
2. Install bushing (3) into case (1) using jig.
Figure 40 FG000814
FG000816
Figure 41

5-10-25
FG000818
Figure 42
3. Take care when assembling spool kit assemblies (1 and 3,

2 and 4). They should be assembled in same way).
The assembly order is; spool (4), shim (5), spring (6),
spring seat (7), and stopper (8).
FG000819
Figure 43
FG000812
Figure 44
4. Install spring (9) into case (1).
FG000820
Figure 45

5-10-26
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
FG000821
Figure 46
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (2) into plug (16) in proper order.
FG000822
Figure 47
FG000810
Figure 48
7. Assemble four springs (11) and stoppers (10) and insert

assembled set in case (1) to form a plug kit assembly.
NOTE: Pay attention to measurement specifications of
stoppers (1 and 3, 2 and 4).
FG000809
Figure 49

5-10-27
FG000811
Figure 50
FG000823
Figure 51
8. Install plate (19) into case (1).
FG000808
Figure 52
9. Install joint assembly (21) into case (1).
FG000807
Figure 53

5-10-28
10. Install wash plate (22) and hex nut (23) into case (1).
FG000806
Figure 54
11. Insert bar and tighten it with a spanner to check balance of

joint assembly.
FG000824
Figure 55
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 56
13. Install lever assembly into case (1).
FG000805
Figure 57

5-10-29
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG000826
Figure 58
FG000827
Figure 59
15. Install lead wire terminal into connector terminal pressing

them together.
FG001097
Figure 60

5-10-30
16. Assemble connector assembly (30), and connect it to lead
wire terminal, and properly route wiring.
FG000828
Figure 61
FG000829
Figure 62

5-10-31
5-10-32
1Gear Pump
(Brake and Steering)
Edition 1
DX210WA Gear Pump (Brake and Steering)

5-11-1
MEMO
Gear Pump (Brake and Steering) DX210WA

5-11-2
Table of Contents
Gear Pump (Brake and Steering)

General .........................................................5-11-5
General Description................................................. 5-11-5
Specification ............................................................ 5-11-5
Overview ................................................................. 5-11-6
Parts List ................................................................. 5-11-7
Removal .......................................................5-11-8
Installation ..................................................5-11-12
Completing Work ........................................5-11-13
Single Gear Pump ......................................5-11-14
Disassembly .......................................................... 5-11-14
Reassembly........................................................... 5-11-16

5-11-3
5-11-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This gear pump is installed onto the main pump PTO (Power
Take-Off). It is driven by the main pump to discharge oil.
This discharged oil is passed through the priority valve and is
delivered to the steering valve for steering operation. It is also
delivered to the brake supply valve, passing through the brake
filter for brake operation.
Also, as this pump is a fixed displacement type, not a variable
displacement type, it discharges a fixed amount of oil to the
brake side and steering side.
Specification
Clockwise
(Looking on Driveshaft)
Displacement 34.55 cc/rev / 11.23 cc/rev
Inlet Pressure Range for Pump 0.7 ~ 3 bar (0.7 ~ 3 kg/cm2, 10.1 ~ 43.5 psi)
Max. Continuous Pressure (Rated) 260 bar (265 kg/cm2, 3,771 psi)
Max. Intermittent Pressure 280 bar (286 kg/cm2, 4,061 psi)
Max. Peak Pressure 300 bar (306 kg/cm2, 4,351 psi)

5-11-5
Overview
Inlet
Outlet (Steering)
Outlet (Brake)
WE1400308
Figure 1

Steering Brake
Port Name Size
Inlet Hydraulic Oil Inlet ø30.5
Outlet
Hydraulic Oil Outlet PF 1/2 O-ring
(Steering) Main Pump
Outlet
Hydraulic Oil Outlet PF 1/2 O-ring
(Brake)
Inlet WE1400309
Figure 2

5-11-6
Parts List
11
15
2
18
23
17
9
6
17
23
25
26
12
14
3
16
27
19
19
10
7
20 24
21 13
4
22
5
8
16
22
WE1400310
Figure 3
Reference Reference
Number Number
1 Body 15 Washer
2 Body 16 Seal
3 Cover; Rear 17 Seal
4 Cover; Front 18 Seal; Standard
5 Plate; Thrust 19 Seal
6 Plate; Thrust 20 Seal; Shaft
7 Gear; Drive 21 Ring
8 Gear; Drive 22 Ring; Back-up
9 Shaft; Drive 23 Ring; Antiextrusion
10 Gear; Driven 24 Bearing; Sleeve
11 Bolt; Socket M14 x 2.0 x 65 25 Hub
12 Bolt M10 x 1.5 x 90 26 Pin; Dowel
13 Screw; Grub 27 Bush; Steel
14 Washer, Spring * Seal Kit
*: 16, 17, 18, 19, 20, 23

5-11-7
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.
1. Make the machine swing about 135° leftward on the flat

ground as shown in Figure 4 before lowering the bucket on
the ground and then stop engine.
WE1400312
Figure 4

5-11-8
(Figure 5)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF

O O

switch.
WE1401161
Figure 6

OFF
(Figure 7)
ON
Figure 7 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 8

5-11-9
WARNING
doing any work.
EX1402442
12. Open the right side door.
WE1400313
Figure 10

5-11-10
13. Remove hoses and adapters from gear pump.
NOTE: Attach identification tags to the removed hoses
for reassembling.
PS
After disconnecting hoses from gear pump, plug
them to prevent dirt or dust from entering.
Disconnect the hoses from the bottom to top of PB
gear pump. S
Figure 11 WE1400314

Port Name
S from Main Suction Pipe SAE 1 1/4", D30.5 8 63.7 6.5 47.0
Dummy 13/16"-16UN-2B 24 55.9 5.7 41.2
PS
to Priority Valve "P" 13/16"-16UN-2B 24 55.9 5.7 41.2
PB to Brake Filter "IN" 13/16"-16UN-2B 24 55.9 5.7 41.2
• Fitting
Size Torque
Port Name
Adapter PF 1/2 UNF 13/16-16 27 93.1 9.5 68.7
PS
Tee UNF 13/16-16 UNF 13/16-16 29 55.9 5.7 41.2
PB Elbow PF 1/2 UNF 13/16-16 27 93.1 9.5 68.7
ID: 37.69, W: 3.53,
S O-ring
1B (2180-1026D23)
1B, P18 1B, F-08
PS, PB O-ring
(S8000181) (S8030081)
14. Remove bolts (1, Figure 12) (2 ea) and washers with gear
pump (2) from main pump.
• Tool: 10 mm ( )
1
Figure 12 WE1400315

5-11-11
15. Remove gear pump from main pump.
• Pump weight: about 16 kg (35.3 lb)
WE1400316
Figure 13
INSTALLATION
WARNING
SERIOUS INJURY

5-11-12
COMPLETING WORK
HAOB290L
Figure 14
3. Slowly operate the steering wheel and brake pedal about

five times.
Figure 15 WE1400317
WE1400318
Figure 16

5-11-13
SINGLE GEAR PUMP
Disassembly
1. Clean exterior of pump.
FG001072
Figure 17
2. Remove clamp bolts.
FG001074
Figure 18
3. Cover sharp edges of driveshaft with adhesive tape and

coat shaft end extension with clean grease, to avoid any
damage to lip of shaft seal when removing mounting
flange.
FG001073
Figure 19

5-11-14
4. Remove mounting flange taking care to keep flange as
straight as possible during removal.
If mounting flange is stuck, tap around edge with rubber
mallet to break it away from body.
NOTE: Make sure that while removing mounting flange,
shaft and other components remain in position.
FG001075
Figure 20
5. Remove retaining ring, if replacement is necessary.
FG000834
Figure 21
6. Remove shaft seal taking care not to damage surface of

shaft hole, if replacement is necessary.
FG000835
Figure 22
7. Pull drive gear up to facilitate removal of front plate.
FG001076
Figure 23

5-11-15
8. Remove driving gear and driven gear, keeping gears as
straight as possible.
FG001077
Figure 24
9. Remove rear plate and end cover.
FG001078
Figure 25
Reassembly
1. Clean all components with care.
FG001078
Figure 26
2. Using a suitable driver, install shaft seal in mounting

flange.
FG000839
Figure 27

5-11-16
3. Install retaining ring in groove.
FG000840
Figure 28
4. Install O-ring on both sides of rear section of body.

NOTE: Coat O-rings with grease to hold O-rings in
body.
FG001079
Figure 29
5. Install rear section body on rear cover.
FG001080
Figure 30
6. Install seals in pressure plate (s) groove. Then install

backup ring in groove with seals. Coat seals with grease. Outlet Side
NOTE: The front and rear pressure plates and seals
and backup rings are the same.
Inlet Side
FG001401
Figure 31

5-11-17
7. Insert pressure plate assembly into body while keeping it
straight.
NOTE: Seal side should face to rear cover, opposite
side of gears.
NOTE: Pay attention to installation direction of seal.
FG001081
Figure 32
8. Install drive gear and driven gear.
FG001082
Figure 33
9. Insert pressure plate into body in proper direction.
FG001083
Figure 34
10. Locate mounting flange in right position.
FG001084
Figure 35

5-11-18
11. Tighten bolts with washer in a crisscross pattern to a
torque value of 45 N.m (4.59 kg.m, 33.2 ft lb).
FG001085
Figure 36
12. Check that pump rotates freely when driveshaft is turned

by hand. If not a pressure plate seal may be pinched.
FG000851
Figure 37

5-11-19
5-11-20
Brake System
Edition 1
DX210WA Brake System

5-12-1
MEMO
Brake System DX210WA

5-12-2
Table of Contents
Brake System
General .........................................................5-12-6
Hydraulic Circuit ...................................................... 5-12-7

5-12-3
5-12-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-12-5
GENERAL
General Description
Oil from the gear pump, which is connected to the main pump
PTO (Power Take-Off), passes through the brake filter and is
supplied to the brake supply valve.
This oil is also collected in the accumulator and is also supplied to
the brake pedal valve to build up the brake operating pressure.
When an operator operates the brake pedal valve during machine
operation, pressure already built in the brake pedal valve is
transferred to the shuttle valve which then passes it to the front
axle and rear axle through the center joints (ports 6 and 7) in
order to apply it to the brake system for braking and stopping the
machine.
Brake Pedal Valve
Accumulator
Front Axle
BR1
BR2
A1 P1
P2
A2 P2
AC
AB ACC A
Shuttle ACC B
Valve B1 Brake
B2 Supply
Valve P1
67
Brake Filter
6
Gear Pump
7
Main Pump
Center Joint
Rear Axle
EX1402421
Figure 1

5-12-6
Hydraulic Circuit
3
T GP P1
1
3.5 bar
C1 4
C6 C3
PSA 2x0.7 L
103 bar
125 bar 30bar
2 C4 ACC A
C2 160 bar ACC B
C5
PSD
10
5
Release Cruise G1 AC AB
W BL1 65 bar
4.6 bar Front Rear Low
BR1 T1 Axle Axle Pressure
Warning
P1
6
A2 A1
Release Cruise
B2 S1 B1 W BL2
4.6 bar
BR2 T2
P2
65±4 bar
Auto Ram
Operate
Rear Axle Front Axle

Brake Brake
7
Chock
9 3 3 1 1 3 3 1 1 3 3 1 3 1 8
8 8 1 1 2 2 8 8 4 4 8 8 2 4 4
4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
Steer
Cylinder
Chock
EX1402420
Figure 2
Reference Reference
Number Number
1 Gear Pump 6 Shuttle Valve
2 Brake Filter 7 Center Joint
3 Brake Supply Valve 8 Front Axle
4 Accumulator 9 Rear Axle
5 Brake Pedal Valve 10 Main Pump

5-12-7
A brake pump (1, Figure 2) supplies pressurized fluid to the
hydraulic brake system. Force on the brake pedal (5, Figure 2)
moves two spools in the brake valve (5, Figure 2). The spools
are proportional. The farther the brake pedal is pushed, the
greater amount of fluid that passes through each spool. One
spool ports fluid to brake pistons in the front axle (8, Figure 2).
The other spool ports fluid to brake pistons in the rear axle (9,
Figure 2). Pressure on the brake pistons applies pressure to the
brake disks, and this stops axle shaft and wheel rotation. The
brake hydraulic system also contains five accumulators (4,
Figure 2). The accumulators hold a volume of pressurized fluid
large enough to allow the brakes to be applied five times with full
pressure, after the engine has been turned off. The hydraulic
brake system includes a cruise release sensor. Pressing the
brake pedal (5, Figure 2) will build up the brake pressure.

5-12-8
Brake Filter
Edition 1
DX210WA Brake Filter

5-13-1
MEMO
Brake Filter DX210WA

5-13-2
Table of Contents
Brake Filter
General .........................................................5-13-5
Specification ............................................................ 5-13-5
Overview ................................................................. 5-13-6
Parts List ................................................................. 5-13-6

5-13-3
5-13-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This filter is to remove foreign materials in oil in the brake piping
in order to prevent deterioration of the brake operation
performance due to foreign materials.
Specification
160 bar
Max. Working Pressure
(163 kg/cm2, 2,364 psi)
Temperature Range -20 ~ 120°C
Bypass Setting Pressure 3.5 bar (3.5 kg/cm2, 50.8 psi)
Weight 1.3 kg (2.9 lb)
Filtration Rating 10 μm
Element Replacement Interval 1,000 hr

5-13-5
Overview
No Name Size
Inlet
1 Inlet/Outlet PF 1/2
Outlet
WE1400330
Figure 1
Parts List
Reference
Description
Number
4
1 Element, Brake Filter
2 O-ring
3 O-ring 3
4 By-pass Valve
2 1
WE1400331
Figure 2

5-13-6
Brake Supply Valve
Edition 1
DX210WA Brake Supply Valve

5-14-1
MEMO
Brake Supply Valve DX210WA

5-14-2
Table of Contents
Brake Supply Valve

General .........................................................5-14-5
Specification ............................................................ 5-14-5
Overview ................................................................. 5-14-6
Parts List ................................................................. 5-14-7
Cautions for Disassembly and Reassembly..5-14-10
Tools and Torque .......................................5-14-11
Removal .....................................................5-14-12
Installation ..................................................5-14-16
Completing Work ........................................5-14-17
Troubleshooting ..........................................5-14-18
How to Check Brake Pressure ...................5-14-19

5-14-3
5-14-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This valve receives hydraulic oil from the brake gear pump to
build up certain pressure in the accumulator and pass oil to the
brake pedal valve.
Also, if pressure built in the gear pump is over the preset level
(157 bar (160 kg/cm2, 2,276 psi)), high pressure oil is drained
and returned to the tank.
Specification
Max Working Pressure 206 bar (210 kg/cm2, 2987 psi)
Rated Flow 16.5 L/min (4.4 U.S. gal/min)
Relief Setting Pressure 157 ±2 bar (160 ±2 kg/cm2, 2,276 ±28 psi)
Cut in - 101 bar (103 kg/cm2, 1,465 psi)
Unloading Pressure
Cut out - 123 bar(125 kg/cm2, 1,778 psi)
Weight 4 kg (9 lb)

5-14-5
Overview
2 5, 5A
6
C
D
S
P
C
A
2
C
4, 4A
C
AC
C
B
3
S
C
P
AC
C4
T
G1 4, 4A AB
C3
P1
1 AC
C A GP
A PS
WE1400363
Figure 1
No. Part Name Quantity Remark

1 Manifold Block 1
2 Relief Valve 1 C2
3 Logic Valve 1 C1
4 Check Valve 3 C3, C4, C5
5 Unloading Valve 1 C6
Port Name Size T GP P1

P1 In (Brake Pump)
T Out (Tank)
PF 1/2 103 bar
C1
ACC A Accumulator 125 bar
ACC B Accumulator C6 PSA

AB to Rear Axle C3
PF 3/8 160 bar ACC A
AC to Front Axle C4
PSD Pressure Switch PF 1/4

C2 C5
ACC B
PSD
G1 AC AB
WE1400362
Figure 2

5-14-6
Parts List
2 5, 5A
6
C
D
S
P
C
A
2
C
4, 4A
C
AC
C
B
3
S
C
P
AC
C4
T
G1 4, 4A AB
C3
P1
1 AC
C A GP
A PS
WE1400363
Figure 3
Reference Reference
Number Number
1 Manifold Block 4, 4A Check Valve
2 Relief Valve 5, 5A Unloading Valve
3 Logic Valve

5-14-7
Theory of Operation
Functions
This brake supply valve assembly package has functions as
below:
1. Prevents overload on brake pump saving energy.
2. Performs a function as a safety device of the brake control
device.
3. Supplies brake control pressure.
Functions of Each Valve
Valve No. Valve Name Valve Functions

C1 Logic Valve Remote controlled by set values of unloading valve (C6).
Performs functions as a safety device that prevent the
C2 Relief Valve destructions and damages of the system resulting from overload
or abnormal pressure within the brake control system.
Prevents reverse flows of the pressure and oil created by the
C3 Check Valve
brake control system.
Prevents damages in the pressure and oil that are compressed in
C4, C5 Check Valve
the accumulator installed at the ACC'A and ACC'B Ports.
Keeps the pump moving under no load by bypassing discharged
C6 Unloading Valve pressure and oil to the tank from the pump when the brake
control system is overloaded.
Detailed Functions and Application of Brake Supply Valve

1. Prevents overload on brake pump saving energy.
The pressure and oil flows discharged by the brake pump
is supplied to the brake control device through valves. As
the engine revolution (rpm) of the vehicle goes up, the
revolution of the brake pump goes up increasing the
amount of pressure and oil discharge. This valve package
prevents energy loss by reducing loss in sources of power
and fluid energy.
In case the pressure of the brake control system exceeds
the set pressure value of the unloading valve (C6), the pilot
spool in the unloading valve is operated to bypass oil flows
on the drain line of the logic valve (C1) to the "T" line. This
releases the spool in the logic valve to bypass the pressure
and oil discharged by the pump to the tank, allowing the
pump to move under no load.
If the pressure value of the brake control system goes
below a set pressure value, the pilot spool of the unloading
valve closes. This will make the drain line have oil flows
and the spool in the logic valve closes. Then, the pressure
and oil flows discharged by the pump are supplied into the
brake control device.

5-14-8
Cut-out is when the pressure and oil flows discharged by
the pump are bypassed, and cut-in is when they are
supplied to the brake control device.
The default setting of the unloading valve is as below:
Set Pressure
Oil Flow
Cut-in Cut-out
16.5 L/min 101 ±3 bar (103 ±3 kg/cm2, 1,465 ±42 psi) 123 ±3 bar (125 ±3 kg/cm2, 1,778 ±42 psi)
2. Performs a function as a safety device of the brake control

device.
An overload within the brake control device created by
external force can cause an abnormal rise in pressure
resulting in damages or breakage on all brake control
devices. However, the relief valve (C2) is installed to
prevent these troubles. In case the brake pressure
exceeds a set pressure value of the relief valve, the relief
valve operates to maintain the set pressure value. That is,
the valve returns any excess pressure over a set pressure
value to the tank to cut off an abnormal rise of pressure
caused by overloads inside the system, preventing
damages and breakage on all devices in the system.
The default setting of the relief valve is as below:
Oil Flow Set Pressure

157 ±3 bar
16.5 L/min
(160 ±3 kg/cm2, 2,275 ±42 psi)
3. Supplies brake control pressure.

Stepping on the brake pedal, the compressed pressure in
the accumulator is reduced below a cut-in set point and the
pilot spool in the unloading valve closes, resulting in oil
flows on the drain line of the logic valve. This oil flow keeps
the spool in the logic valve closed.
The pressure and oil flows discharged by the pump are
then supplied to the accumulator and the brake control
device. In case the pressure value exceeds the cut-out set
point of the unloading valve, the logic valve and the
unloading valve operates to bypass the pressure and the
oil flows discharged by the pump to the tank, allowing the
pump move with no load and preventing pressure surges
in the brake system. Check valves (C4, C5) maintain brake
control functions of each brake without affecting the other
brake on the other side as each brake circuit is separated.

5-14-9
CAUTIONS FOR DISASSEMBLY
AND REASSEMBLY
1. Clean up the surrounding area to remove any foreign
substances before disassembly and reassembly.
2. Make sure to observe the assembly torques and tools
specified in table when disassembling and re-assembling
parts.
3. Follow the directions described in the above drawing for
disassembly and re-assembly.
4. Be careful not to let any contaminants go into the package
when re-assembling.
5. Make sure to clean parts before re-assembly after
disassembly.
6. Wrap the screw thread with seal tapes (teflon tapes) 3 ~ 4
times when re-assembling the PT series plugs.

5-14-10
TOOLS AND TORQUE
The assembly torque of each part in the brake supply valve
assembly package is described in <Table 1>. Observe the
specified torque values using the right tool.
1. Disassembly, re-assembly of brake supply valve assembly
package, and necessary tools.
Disassembly
Assembly
FG007444
Figure 4
Assembly Torque Assembling Tools

No. Part Name Screw Spec
N.m kg.m ft lb
1 Logic valve M20 ∗ 1.5 44 ±4.9 4.5 ±0.5 32.5 ±3.6 Torque Wrench/32 mm Hex. Socket
2 Relief valve UNF7/8-14" 44 ±4.9 4.5 ±0.5 32.5 ±3.6 Torque Wrench/1" Hex. Socket
3∗ 3 Check Valve UNF7/8-14" 44 ±4.9 4.5 ±0.5 32.5 ±3.6 Torque Wrench/1" Hex. Socket
4 Unloading Valve M20 ∗ 1.5 44 ±4.9 4.5 ±0.5 32.5 ±3.6 Torque Wrench/32 mm Hex. Socket
5∗ 3 PT 1/4" Plug PT 1/4-19" 49 5.0 36.2 Torque Wrench/6 mm Wrench Socket
6∗ 6 PT 1/8" Plug bolt PT 1/8-28" 27.5 2.8 20.3 Torque Wrench/5 mm Wrench Socket
7∗ 3 PF 1/4" Plug PF 1/4-19" 24.5 ±2.5 2.5 ±0.25 18 ±1.8 Torque Wrench/19 mm Hex.Socket

5-14-11
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1400415
Figure 5

5-14-12
(Figure 6)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF
4. Operate the joystick levers and brake pedal several times

to release the remaining pressure in the hydraulic piping.
O O

switch.
WE1401161
Figure 7

OFF
(Figure 8)
ON
Figure 8 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 9

5-14-13
WARNING
doing any work.
EX1402442
12. Open the left side door.
Figure 11 WE1400416
13. Disconnect the harness connector.
WE1400417
Figure 12

5-14-14
14. Remove hoses and adapters from brake supply valve.
NOTE: Attach identification tags to the removed hoses ACC A ACC B
for reassembling.
After disconnecting hoses from brake supply
valve, plug them to prevent dirt or dust from
entering.
Disconnect the hoses from the bottom to top of
AC PSD
brake supply valve. AB
P1 T
Figure 13 WE1400418

Port Name
T to Oil Cooler Pipe PF 1/2" 27 93.1 9.5 68.7
P1 from Brake Filter "OUT" 13/16"-16UN-2B 24 55.9 5.7 41.2
AB to Brake Pedal Valve "P2" 11/16"-16UN-2B 21 38.2 3.9 28.2
AC to Brake Pedal Valve "P1" 11/16"-16UN-2B 21 38.2 3.9 28.2
ACC A to Accumulator RH (Front Axle) 11/16"-16UN-2B 21 38.2 3.9 28.2
ACC B to Accumulator LH (Rear Axle) 11/16"-16UN-2B 21 38.2 3.9 28.2
PSD Pressure Switch PF 1/4"
• Fitting
Size Torque
Port Name
T Adapter PF 1/2" PF 1/2" 27 93.1 9.5 68.7
P1 Adapter PF 1/2" UNF 13/16-16 27 93.1 9.5 68.7
AB Adapter PF 3/8" UNF 11/16-16 22 49.0 5 36.2
AC Elbow PF 3/8" UNF 11/16-16 22 49.0 5 36.2
ACC A,
Adapter PF 1/2" UNF 11/16-16 27 93.1 9.5 68.7
ACC B
PSD Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
1B, P18
T O-ring
(S8000181)
1B, P18 1B, F-08
P1 O-ring
(S8000181) (S8030081)
1B, P14 1B, F-06
AB, AC O-ring
(S8000141) (S8030061)
ACC A, 1B, P18 1B, F-06
O-ring
ACC B (S8000181) (S8030061)
1B, P11
PSD O-ring
(S8000111)

5-14-15
15. Remove bolts (1, Figure 14) (2 ea) and washers with brake
1
supply valve (2) from main frame. 2
• Tool: 17 mm ( )
Figure 14 WE1400419
16. Remove brake supply valve from main frame.

• Valve weight: about 4 kg (8.8 lb)
Figure 15 WE1400420
INSTALLATION
WARNING
SERIOUS INJURY

2. When installing the hose, be install the drain hose first.

5-14-16
COMPLETING WORK
HAOB290L
Figure 16
3. Slowly push brake pedal about five times without a load to

vent air from brake lines.
WE1400317
Figure 17

5-14-17
TROUBLESHOOTING
Symptom Checkpoints Descriptions Remedy
Unable to supply 1. Foreign materials, 1. Disassemble the logic valve and check Remove foreign
pressure to brake contaminants in the if any foreign materials or materials and clean
logic valve. contaminants such as sludge is lodged the contaminated
between spool and body. area
2. Foreign materials, 2. Disassemble the logic valve and check Remove foreign
contaminants in if any foreign materials or materials and clean
relief valve contaminants such as sludge is lodged the contaminated
between poppet and body. area.
3. Discharge pressure 3. Install a pressure gauge at the "G1" Locate cause of
and its amount port to measure pressure value problems and
pumped by brake discharged by brake pump: correct.
pump
– Under low engine rpm operations
– With unloading valve fully closed
– Set point: 157 ±2 bar
(160 ±2 kg/cm2, 2,276 ±28 psi)
Brake light is on 1. Cut-in of the 1 Check cut-in pressure of the unloading Readjust the
unloading valve valve (C6). pressure value.
– Install a pressure gauge at the
"G1" port to measure cut-in
pressure.
– Set point: 101 ±2 bar
(103 ±2 kg/cm2, 1,465 ±28 psi)
2. Pressure switch 2. If there is no problem with the above Locate cause of
checkpoint 1 but the brake light is still problems and
on, check the connection of the correct.
pressure switch.
– Set point: 65 bar
(66 kg/cm2, 943 psi) ±10%
3. Contamination in 3. Check the element screen inside Clean the filter and
brake filter brake filter if it is contaminated by replace.
foreign materials.
4. Foreign materials, 4. Refer to the above descriptions 1 and Remove foreign
contaminants in the 2 for checkpoints "Unable to supply materials and
logic valve and the pressure to brake." clean the
relief valve contaminated area.
Cut-in and cut-out 1. Damages in O-ring 1. Disassemble each check valve (C3, Replace check
cycles are too fast and backup rings C4, C5) and check up on O-ring and valve.
installed in check backup rings if damaged
valve
2. Leakage in foot 2. Remove hydraulic hoses installed at Replace foot brake
brake valve outlets (Ports BR1, BR2) of foot brake valve.
valve to check leakage:
– With the brake pedal unpressed
(Neutral)
– Set point: Refer to "Foot brake
valve leakage control."

5-14-18
HOW TO CHECK BRAKE PRESSURE
Install a pressure gauge as below:
Ports Screw Specification Remark

GP PF1/4" O-ring Boss
G1 PF1/4" O-ring Boss Remove pressure switch.
Check pressure values as below:
Unloading Valve Operations

Ports
Cut-in Cut-out
Within 157 bar (160 kg/cm 2,276 psi)
2, Within 8.8 bar (9 kg/cm2, 128 psi)
GP
approximately approximately
G1 101 ±3 bar (103 ±3 kg/cm2, 1,465 ±42 psi) 123 ±3 bar (125 ±3 kg/cm2, 1,778 ±42 psi)

5-14-19
5-14-20
1Brake Pedal Valve
Edition 1
DX210WA Brake Pedal Valve

5-15-1
MEMO
Brake Pedal Valve DX210WA

5-15-2
Table of Contents
Brake Pedal Valve

General .........................................................5-15-5
Specification ............................................................ 5-15-5
Overview ................................................................. 5-15-6
Section View .................................................5-15-9
Removal .....................................................5-15-10
Installation ..................................................5-15-15
Completing Work ........................................5-15-16
Disassembly ...............................................5-15-17
Reassembly ................................................5-15-17
Reassembly of the Lower Part .............................. 5-15-17
Reassembly of the Upper Part .............................. 5-15-19
Assembly of Pedal Plate ....................................... 5-15-22

5-15-3
5-15-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This pedal valve is designed for heavy-duty brake pedal valve of
driving excavator.
It is hydraulic operated and contains an operation brake function
to fix pedal with ratch while the machine stops.
Specification
103 ±2 ~ 125 ±2 bar
Supply Pressure (105 ±2 ~ 127 ±2 kg/cm2,
1,494 ±29 ~ 1,813 ±29 psi)
Flow Rate 22.5 L/min (5.9 U.S. gpm)
80 ±3 bar
Secondary Pressure
(81 ±3 kg/cm2, 1,160 ±21.7 psi)
Operation Angle 20°
Weight 4 kg (8.8 lb)

5-15-5
Overview
T1 BL1
P1
BR1
T2
BL2
P2
BR2
WE1400364
Figure 1
Hydraulic Circuit
Port Size
T1, T2, P1, P2, BL1, BL2,
PF 3/8
BR1, BR2
BL1
BR1 T1
P1
BL2
T2
BR2
P2
WE1400366
Figure 2

5-15-6
Theory of Operation
Brake valve is a reducing valve. Pressure to main pressure (P
port) flows in the valve and reduced set pressure flows to the
axle brake by way of the brake port (BR port) to stop the
machine.
When the brake pedal is depressed, the spool in the valve is
moved downward, connecting the port P1 and BR1 and the port
P2 and BR2 to form the oil passage.
Then, oil is passed to the front and rear axle through this
passage and center joint to operate the brake.
1. In Neutral Position
A. P port spool (3) blocks main pressure to P1 port.
B. T and BR ports are connected, which is the tank
BL1
pressure.
T1
BR1
P1
T1
BL1
P1
BL2
BR1
T2
BR2
P2
WE1400369
Figure 3
2. During Operation
BL1
A. Operation of pedal causes action of main spring (13) T1
BR1
and spool (3). The load of spring (13) generates P1
pressure B port seating pressure.
B. P and BR ports are connected and pressure is 13
generated, which moves to orifice to act pilot 3
pressure to the floor of spool (3).
T1 BL2
BL1 T2
C. If pilot pressure is higher than pressure set to spring BR2
P2
(13), spool (3) moves up and pressure decreases.
P1
D. If pilot pressure is lower than pressure set to spring BR1
(13), spool (3) moves down to close T port and
pressure increases.
E. Operation angle of pedal changes load of spring (13) WE1400370
and thus the second pressure of BR port. Figure 4

5-15-7
Refer to the Curve
90
P1, P2 ports: Supply pressure
Secondary Pressure (bar)

80
T1, T2 ports: Tank port 70
60
BR1, BR2 ports: Brake supply port
50
BL1, BL2 ports: Brake pressure sensor location 40
30
20
10
2 4 6 8 10 12 14 16 18 20 22
Operation Angles
WE1400367
Figure 5

5-15-8
SECTION VIEW
T1
BL1
P1
BR1
T2
BL2
P2
BR2
WE1400368
Figure 6

5-15-9
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1400421
Figure 7

5-15-10
(Figure 8)
LOCK
WARNING
WARNING
or maintenance
ON OFF
IMPORTANT
Operate the joystick levers and brake pedal valve
several times to release the remaining pressure in the
hydraulic piping.

O O

switch.
WE1401161
Figure 9

OFF
(Figure 10)
ON
Figure 10 EX1401760

5-15-11
3
5 8
1 2
7 6
4
EX1401809
Figure 11
WARNING
doing any work.
EX1402442
11. Stow the front upper window (1, Figure 13) in the cabin
ceiling.
1
12. Remove lower window (2) from cabin in direction of the
arrow.
WARNING
2
Never have wet hands when handling a window. Never
drop window or let it come into contact with other WE1400422
Figure 13
parts of machine.
Figure 14 WE1400423

5-15-12
• Tool: 19 mm ( ) 1 2
WE1400424
15. Disconnect the harness connector (2 ea).
WE1400425
Figure 16
16. How to disconnect the harness connector.
WE1400426
Figure 17

5-15-13
17. Remove hoses and adapters from brake pedal valve.
T1
NOTE: Attach identification tags to the removed hoses BL1
for reassembling.
After disconnecting hoses from brake pedal
BR1 P1
valve, plug them to prevent dirt or dust from
entering.
BL2 T2
brake pedal valve.
BR2
P2
WE1400427
Figure 18 Bottom of Floor Plate

Port Name
T1 to Oil Tank PF 3/8" 22 49.0 5 36.2
T2 to Oil Tank PF 3/8" 22 49.0 5 36.2
P1 from Brake Supply Valve "AC" 11/16"-16UN-2B 22 38.2 3.9 28.2
P2 from Brake Supply Valve "AB" 11/16"-16UN-2B 22 38.2 3.9 28.2
to Shuttle Valve "A1"
BR1 PF 3/8" 22 49.0 5 36.2
(Center Joint)
to Shuttle Valve "A2"
BR2 PF 3/8" 22 49.0 5 36.2
(Center Joint)
• Fitting
Size Torque
Port Name
T1, T2 Adapter PF 3/8" PF 3/8" 22 30.8 3.14 22.7
P1, P2 Adapter PF 3/8" UNF 11/16-16 22 30.8 3.14 22.7
BR1, BR2 Elbow PF 3/8" PF 3/8" 22 30.8 3.14 22.7
BL1, BL2 Reducer PF 3/8" 1/2-20 UNF-2A 22 30.8 3.14 22.7
T1, T2,
1B, P14
BR1, BR2, O-ring
(S8000141)
BL1, BL2
1B, P14 1B, F-06
P1, P2 O-ring
(S8000141) (S8030061)
* A: Opposite side of hose, B: Hose Side

5-15-14
18. Remove bolts (1, Figure 19) (4 ea) and washers with brake
pedal valve (2) from floor plate.
• Tool: 13 mm ( )
2
WE1400428
Figure 19
19. Remove brake pedal valve from floor plate.

• Valve weight: about 5 kg (11 lb)
WE1400429
Figure 20
INSTALLATION
WARNING
SERIOUS INJURY


5-15-15
COMPLETING WORK
HAOB290L
Figure 21
3. Slowly push brake pedal several times and wait for 5

minutes without a load to vent air from brake lines.
WE1400317
Figure 22

5-15-16
DISASSEMBLY
Disassembly shall be made in the reverse order of reassembly.
REASSEMBLY
Reassembly of the Lower Part
4 3 2 1 5 6 7
FG003651
Figure 23
Reference Reference
Number Number
1 Lower Part 5 O-ring
2 Spool 6 Spring Guide
3 Lower Spring 7 Upper Spring
4 Plug
1. Insert spool (2) and lower spring (3) in lower part (1).
CAUTION
AVOID INJURY
Take care to prevent dust or foreign substances
entering valves after washing.
FG003652
Figure 24

5-15-17
2. Install plug (4) on lower part (1).
• Tool: 19 mm ( )
• Torque: 137.3 ~ 161.8 N.m
(14 ~ 16.5 kg.m, 101.3 ~ 119.3 ft lb)
FG003653
Figure 25
3. Install O-ring (5).
FG003654
Figure 26
4. Install spring guide (6) and upper spring (7).
FG003655
Figure 27

5-15-18
Reassembly of the Upper Part
1 2 3 4 5
6 7 8 9 10
FG003656
Figure 28
Reference Reference
Number Number
1 Upper Part 6 Spool
2 Oil Seat 7 Spring Retainer
3 Plain Washer 8 Main Spring
4 Retaining Ring 9 Holder
5 Drive Bearing 10 Rubber Cover
1. Install oil seal (2), plain washer (3), retaining ring (4), and
drive bearing on lower part (1).
Tools: Drive bearing jig and retaining ring pliers.
CAUTION
AVOID INJURY
Use a jig to press and push bearing.
Never remove the dry bearing.
FG003657
Figure 29

5-15-19
2. Insert spool into the lower part.
CAUTION
AVOID INJURY
Take care to prevent dust or foreign substances
entering valves after washing.
FG003658
Figure 30
3. Assemble the upper and lower parts.
CAUTION
AVOID INJURY
Do not forget to install O-ring.
FG003659
Figure 31
4. Connection of the upper and lower parts.
• Tool: 6 mm ( )
• Torque: 24.5 ~ 29.4 N.m

(2.5 ~ 3.0 kg.m, 18.1 ~ 21.7 ft lb)
FG003560
Figure 32

5-15-20
5. Assemble spring retainer (7) and main spring (8).
FG003662
Figure 33
6. Install holder (9).
FG003663
Figure 34
7. Install rubber cover (10).
FG003664
Figure 35

5-15-21
Assembly of Pedal Plate
1 2 3 4
5 6 7 8 9 10 11 12 10
Figure 36 FG003665
Reference Reference
Number Number
1 Rubber Pedal 7 Ratch Lock Pin
2 Lock Plate 8 Retaining Ring
3 Pedal 9 Pedal Lock Pin
4 Retaining Ring 10 Hexagon Bolt
5 Ratch 11 Pedal Plate
6 Ratch Spring 12 Double Torsion Spring

5-15-22
1. Install pedal plate.
• Tool: 6 mm ( )
• Torque: 24.5 ~ 29.4 N.m

(2.5 ~ 3.0 kg.m, 18.1 ~ 21.7 ft lb)
FG003666
Figure 37
2. Use a ø12 round rod to place pedal elements (2, 3) and

double torsion spring (11) on pedal plate (12) and use a
hammer to push the round rod into lock pin (9).
• Tools: ø12 round rod and plastic hammer
FG003667
Figure 38
3. Install the lock pin retaining ring at the end of lock pin (9).
• Tools: Shaft retaining ring flyer
CAUTION
AVOID INJURY
When removing lock pin, remove the retaining ring
first.
FG003668
Figure 39

5-15-23
4. Install ratch spring (6) on ratch (5).
CAUTION
AVOID INJURY
Apply grease to the inside of ratch spring.
FG003669
Figure 40
5. Use ratch lock pin (7) to install the ratch assembly in pedal
plate (11).
CAUTION
AVOID INJURY
When removing lock pin, remove the retaining ring
first. (Damage to pedal plate)
FG003670
Figure 41
6. Install retaining ring.

• Tool: Driver
FG003671
Figure 42

5-15-24
FG003672
Figure 43
7. Apply grease to the area of lock plate (2) which ratch

contacts.
FG003673
Figure 44
8. Use a driver to install rubber pedal (1) on the pedal

assembly.
FG003674
Figure 45

5-15-25
FG003675
Figure 46
FG003676
Figure 47
9. Install pedal angle adjustment bolt (10).
• Tool: 13 mm ( )
FG003677
Figure 48
FG003678
Figure 49

5-15-26
Accelerator Pedal Valve
Edition 1
DX210WA Accelerator Pedal Valve

5-16-1
MEMO
Accelerator Pedal Valve DX210WA

5-16-2
Table of Contents
Accelerator Pedal Valve

General .........................................................5-16-5
Specification ............................................................ 5-16-5
Overview ................................................................. 5-16-6
Section View ...............................................5-16-10
Removal .....................................................5-16-12
Installation ..................................................5-16-16
Completing Work ........................................5-16-17
Tools ...........................................................5-16-18
Disassembly ...............................................5-16-18
Assembly ....................................................5-16-20

5-16-3
5-16-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Supply Pressure 40 bar (40 kg/cm2, 569 psi)
Flow Rate 8 ~ 27 L/min (2 ~ 7 U.S. gpm)
12 ~ 40 bar
Secondary Pressure
(12 ~ 40 kg/cm2, 171 ~ 569 psi)
Operation Angle 25°
Weight 5 kg (11 lb)

5-16-5
Overview
T A
WE1400471
Figure 1
Hydraulic Circuit
Port Size
P, T, A PF 1/4
T
A
P
Figure 2 WE1400472

5-16-6
Theory of Operation
Function
It is used to reduce the primary pressure delivered from the pilot
gear pump to the secondary pressure level to control the control
valve travel spool.
1. Neutral position
While the accelerator valve is in the neutral position, the
spring seat (6), spool (3) and push rod (12) have been
pushed upwards by the spring (8).
The oil with the primary pressure flowed into the
accelerator valve through the port (P).
Keeps blocked by the spool (3).
The operating port (A) are connected to the port (T).
14
12
T
A
6 P
8
T Port
P Port
3
A Port WE1400468
Figure 3

5-16-7
2. Fine control
Moving the pedal (14) forces the push rod (12) to move
downwards, and the moving rod pushes down the spring
seat (6), spring (5), and spool (3).
Once the spool (3) is moved as much as a specified
distance, the oil with the primary pressure begins to flow
into the operating port(A) through the spool (3).
Stopping the pedal (14) in the fine control process,
balances the force of the spring (5) and the secondary
pressure by the pushing force of hydraulic pressure acting
on the spool (3).
This secondary pressure is transferred to the control valve
travel spool.
14
12
T
A
6 P
T Port
P Port
3
A Port WE1400469
Figure 4

5-16-8
3. Full control
Moving the pedal (14) to the full forces the push rod (12) to
move downwards and the moving rod pushes down the
spring seat (6), spring (5) and spool (3), by which the
spring (5) is fully compressed.
The primary pressure is delivered to the operating port(A)
through the spool (3) while the delivered secondary
pressure pushes up the spool (3). However, as the spool
(3) is fixed to the push rod (12) and thus cannot move.
14
12
T
A
P
6
T Port
P Port
3
A Port WE1400470
Figure 5

5-16-9
SECTION VIEW
23
15, 16
14
19
17
22
20
18 24
10
21 25
12
9
13
6
11
7 5 2
8
4
3
1
EX1400473
Figure 6

5-16-10
Reference Reference
Number Number
1 Body 13 Plate
2 Plug 14 Pedal
3 Spool 15 Hook
4 Spring Seat 16 Screw
5 Spring 17 Bushing
6 Spring Seat 18 Guide Pin
7 Stopper 19 Snap Ring
8 Spring 20 Wrench Bolt
9 Plug 21 Dust Seal
10 Oil Seal 22 Pin
11 O-ring 23 Pedal Cover
12 Push Rod

5-16-11
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1400421
Figure 7

5-16-12
(Figure 8)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF

O O

switch.
WE1401161
Figure 9

OFF
(Figure 10)
ON
Figure 10 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 11

5-16-13
WARNING
doing any work.
EX1402442
12. Stow the front upper window (1, Figure 13) in the cabin
ceiling.
1
13. Remove lower window (2) from cabin in direction of the
arrow.
WARNING
2
Never have wet hands when handling a window. Never
drop window or let it come into contact with other WE1400422
Figure 13
parts of machine.
Figure 14 WE1400423
• Tool: 19 mm ( ) 1 2
WE1400424

5-16-14
16. Remove hoses and adapters from accelerator pedal valve.
T
for reassembling.
After disconnecting hoses from accelerator P
pedal valve, plug them to prevent dirt or dust
from entering.
accelerator pedal valve.
A
WE1400458
Figure 16 Bottom of Cabin

Port Name
A to Solenoid Valve "TS" PF 1/4" 19 39.2 4 28.9
P from Solenoid Valve "P1" PF 1/4" 19 39.2 4 28.9
T to T Block PF 1/4" 19 39.2 4 28.9
• Fitting
Size Torque
Port Name
A Elbow PF 1/4" PF 1/4" 19 39.2 4 28.9
P, T Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
1B, P11
A, P, T O-ring
(S8000111)
17. Remove screws (1, Figure 17) (2 ea) with hook (2) from
accelerator pedal.
1
• Tool: Screw Driver
18. Remove bolts (3, Figure 17) (3 ea) and washers with
2
accelerator pedal valve (4) from floor plate.
• Tool: 5 mm ( )
3
4
Figure 17 WE1400459

5-16-15
19. Remove accelerator valve from floor plate.
WE1400460
Figure 18
INSTALLATION
WARNING
SERIOUS INJURY
1. Perform installation in the reverse order to removal. 205 mm

3. The distance of rod must be 205 mm when assembling rod
Rod
(Figure 19).
4. After assembling, pour grease to grease nipple (Figure 19).
Nipple
WE1400461
Figure 19

5-16-16
COMPLETING WORK
HAOB290L
Figure 20
3. Slowly push accelerator pedal about five times without a

load to vent air from pilot lines.
WE1400462
Figure 21

5-16-17
TOOLS
Reference
Description Tool
Number
2 Plug 5 mm ( )
9 Plug 21 mm ( )
19 Retaining Ring Plier ( )
DISASSEMBLY
1. Remove retaining ring (19) with guide pin (18) and bushing
(17). (Figure 22)
WE1400474
Figure 22
1. Disassemble plug kit (ll) from the body (1).
FG007509
Figure 23
FG007510
Figure 24

5-16-18
2. Disassemble spool kit (l) from the body (1).
FG007511
Figure 25
3. Disassemble spring (8) from the body (1).
FG007512
Figure 26

5-16-19
ASSEMBLY
1. Assemble plug (2) in the body (1).
FG007513
Figure 27
2. Assemble spring (8) in the body (1).
FG007512
Figure 28
3. Assemble spool kit (l).

Assemble spring seat (l-4), spring (l-5), spring seat (l-6)
and stopper (l-7) at spool (l-3) in the order.
Figure 29
4. Assemble spool kit (l) in the body (1).
FG007511
Figure 30

5-16-20
5. Assemble plug kit (ll)
Assemble seal (ll-10), dust seal (ll-13), O-ring (ll-11), push
rod (ll-12) in plug (ll-9) in the order.
Figure 31
6. Assemble plug kit (ll) in the body (1).
FG007510
Figure 32
FG007509
Figure 33
7. Assemble retaining ring (19) with guide pin (18) and

bushing (17). (Figure 34)
WE1400474
Figure 34

5-16-21
5-16-22
Accumulator
(Brake and Pilot)
Edition 1
DX210WA Accumulator (Brake and Pilot)

5-17-1
MEMO
Accumulator (Brake and Pilot) DX210WA

5-17-2
Table of Contents
Accumulator (Brake and Pilot)

Specifications .......................................................... 5-17-7

5-17-3
5-17-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-17-5
GENERAL
General Description
The accumulator is a gas-charged storage device designed to
hold a reserve quantity of hydraulic fluid under pressure. 1
Accumulators are used in hydraulic circuits in much the same
way that condensers (or capacitors) are used to collect, store 2
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference 3
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
3 Diaphragm 4
4 Fluid Valve
ARS1790L
Accumulators are solidly constructed to resist the high operating Figure 1

pressures of the fluids they contain. There are only three main
moving parts: a plug at the top allows precharging or expelling
gas from the compressible, precharged upper chamber; a valve
assembly at the bottom of the accumulator for passing hydraulic
fluid in and out, and an elastic diaphragm to separate the two
chambers. The flexible diaphragm changes shape to conform to
the changing pressures and volumes of the two fluids in the
upper and lower chambers.
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber 0 bar (0 psi,

empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas (usually nitrogen) is
introduced through the port at the top of the accumulator,
the diaphragm expands to maximum size. The valve button 1 2 3
in the center of the diaphragm pushes into the fluid
opening in the bottom chamber, sealing off the lower valve.
If the pressure of the gas charge exceeds system oil
pressure, no fluid enters the accumulator. The button also
keeps the diaphragm from protruding into the lower valve
opening.
NOTE: Precharge pressure is referred to as the "P1"
pressure. The accumulator manufacturer's "P1" 4 5 6
ARS1800L
rated pressure should be stamped or marked on
the accumulator's rating plate. Annual checks of Figure 2
actual precharge pressure should be made by
tapping a hydraulic pressure gauge (and 3-way
adapter coupling) into the valve on the bottom
of the accumulator. When hydraulic fluid is

5-17-6
pushed out the lower valve opening by the
pressure of the gas charge on the other side of
the diaphragm - and there is no
counterpressure from system oil - the valve
button on the bottom of the diaphragm
eventually seals off the lower oil passage. Just
after the needle on the gauge reaches its
highest point (when there is 0 bar (0 psi)
resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to the "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
Specifications
System Charge Pressure Working Pressure Volume
10 bar 80 bar
Pilot
(10 kg/cm2, 145 psi) (82 kg/cm2, 1,160 psi) 750 cc
30 bar 210 bar (45.77 in3)
Brake
(31 kg/cm2, 435 psi) (214 kg/cm2, 3,046 psi)

5-17-7
5-17-8
Steering System
Edition 1
DX210WA Steering System

5-18-1
MEMO
Steering System DX210WA

5-18-2
Table of Contents
Steering System
General .........................................................5-18-6

5-18-3
5-18-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-18-5
GENERAL
General Description
Turning the steering wheel causes hydraulic oil to be sent from
the steering gear type pump to the steering valve which directs
oil to the steering cylinders.
Front Axle
8
9
Steering Cylinder 9 8
LS
L
R
T
P
Center Joint
Steering Valve
LS
P
CF
EF
Priority Valve Gear Pump
Main Pump
EX1402435
Figure 1

5-18-6
Hydraulic Circuit
5
Left Turn Right Turn
L Steering Valve R
225 bar 3
3 3 1 1 1 1 3 3 1 1 3 3 1 3 1
8 8 2 2 8 8 4 4 8 8 2 4 4
4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
1
Chock
Front Axle
175 bar
Steer
Cylinder
Chock
P T LS
4
3 bar
2 CF EF
LS
P 6
EX1402434
Figure 2
Reference Reference
Number Number
1 Steering Valve 4 Gear Pump
2 Priority Valve 5 Front Axle
3 Center Joint 6 Main Pump

5-18-7
Theory of Operation
1. Neutral
L R
175 bar
CF
P T LS
LS
Priority Valve
LS Connected to Tank Neutral Position (LS Line is Opened)
T P
WE1400376
Figure 3
• Function : To feed oil from the steering gear pump to the steering cylinder of front axle for steering
operation.
• Configuration: Pump, priority valve, steering unit (neutral position spring, spool and sleeve, gerotor,
makeup check, etc.).
Operation
When handle is not operated, the spool and sleeve are stopped by the neutrally-positioned spring.
The oil passage of the spool and sleeve blocks the pump, cylinder in/out and gerotor in/out.
LS pressure transmits the steering load to the priority valve and the pressure is transferred to the T-port by
the internal oil passage.
When the LS pressure joins the T-port, the pressure of the pump activates the spool of the priority valve to
switch over to the left, and then the pump oil joins the front.

5-18-8
2. Right (left) turn
L R
175 bar
CF
P T LS
LS
Priority Valve
T P Steering Position (LS Line is Closed)
WE1400377
Figure 4
Operation
When the steering wheel turns, the neutrally-positioned spring connecting the spool and the sleeve is
depressed downwards and begins to turn, creating a rotational angle.
The difference in the rotational angles between the spool and the sleeve serves to connect the oil passage
of the LS to the pump, which transfers the priority spool to the right.
This in turn blocks the oil flow from joining the front, and the oil is carried to the steering unit.
The pump oil of the steering unit joins the entry of the gerotor by the internal oil passage of the spool and sleeve.
Then, the oil from the gerotor is carried to the cylinder by the internal oil passage of the spool and sleeve for
steering operation.
Oil returned from the steering cylinder is carried to the tank by the oil passage of the spool and sleeve.

5-18-9
5-18-10
Steering Valve
Edition 1
DX210WA Steering Valve

5-19-1
MEMO
Steering Valve DX210WA

5-19-2
Table of Contents
Steering Valve
General .........................................................5-19-6
Specifications .......................................................... 5-19-7
Overview ................................................................. 5-19-8
Gerotor Operation ................................................. 5-19-10
Relief Valve ........................................................... 5-19-10

5-19-3
5-19-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-19-5
GENERAL
General Description
The steering unit consists of the direction control section (A,
Figure 1) and the pump or oil control section (B).
These two sections operate together to forward hydraulic oil to
the steering cylinder of front axle.
The hydraulic oil from the priority valve flows into the direction
control section of the steering unit.
When the steering wheel is activated, the hydraulic oil in the
direction control section is channeled to the steering cylinder.
The oil control section is fitted with a small hydraulic pump which
controls the hydraulic oil fed to the steering cylinder.
When the steering wheel turns rapidly, more hydraulic oil is fed
to the steering cylinder.
The increased flow of hydraulic oil enables the main valve spool
to move farther, and the increased movements of the spool
make the hydraulic oil from the priority valve or the gear pump
carried to the steering cylinder for faster steering operation.
Direction Control Section (A)
P
Section (B)
Oil Control
WE1400383
Figure 1

5-19-6
Specifications
General
Type Load Sensing Non Reaction
Rated Displacement 315 cc/rev (19 in3 /rev)
Max. Pressure ON P - Port
175 bar (179 kg/cm² (2,538 psi))
(Relief Valve Setting)
Max. Pressure ON T - Port 20 bar (20 kg/cm² (290 psi))
Max. Pressure ON L, R - Port
225 bar (229 kg/cm² (3,263 psi))
(Shock Valve Setting)
Rated Oil Flow 32 L/min (8.5 U.S. gpm)
Weight 6.3 kg (13.9 lb)
Operating Condition
Max. Pump Discharge Flow 40 L/min (10.6 U.S. gpm)
Max. Pump Pressure 175 bar (179 kg/cm² (2,538 psi))
Hydraulic Oil ISO VG 46 WR or SIMILAR
Hydraulic Oil Temperature -20 ~ 90°C

5-19-7
Overview
LS
Spline
L R
T P
WE1400384
Figure 2
Spline Specification
Dia. Pitch 16/32
NO of Teeth 12
Pitch Dia. ø19.05
Pressure Angle 30 Degree
Over Pin Dia. Max. 15.128
Pin Dia. ø3

L R
Port Name Size 225 bar
P Pressure PF 1/2
T Drain PF 1/2
L Left Turn PF 1/2
R Right Turn PF 1/2
LS Load Sensing PF 1/4
175 bar
P T LS
WE1400385
Figure 3

5-19-8
Theory of Operation
Neutral Operation
Figure 4
With the steering wheel in the neutral position (wheels turned

neither right nor left), the spool (2, Figure 4) and sleeve (1) are
stationary at the position where the center pin (4) becomes
centered in the spool space by the centering springs (3). Oil flow
through the load sensing line (LS), port L, port R, and port T are
bypassed to the tank line and the oil supply (P) is blocked by the
directional spool in the steering unit. Even if an external force is
applied to the steering cylinder, the steering unit is protected
because the oil path is blocked by the directional spool.
Right Turn
The spool (2, Figure 4) is engaged with the spline of the steering
shaft. When the steering wheel is turned to the right, the spool
turns. The sleeve (1) is connected to the spool (2) by centering
springs (3). When spool turns, the sleeve turns. The sleeve
turning angle is about 10° less than the spool turning angle.
This allows the longitudinal slots in the spool to align with the
ports in the sleeve. Oil from port P on the steering unit travels
through the control spool and is directed to port R which directs
the oil to the steering cylinders. The amount of flow metered to
port R is controlled by the amount of steering wheel rotation.
Excess oil flow through port P that is not metered to port R, is
directed by the spool to port T and is then directed through the
oil cooler and into the tank.
Left Turn
The spool (2, Figure 4) is engaged with the spline of the steering
shaft. When the steering wheel is connected to the spool (2) by
centering springs (3). When the spool turns, the sleeve turns.
The sleeve turning angle is about 10° less than the spool turning
angle. This allows the longitudinal slots in the spool to align with
the ports in the sleeve. When the steering wheel is turned to the
left, oil from port P on the steering unit is directed through the
control spool in the steering unit, out port L and into the steering
cylinders. The amount of oil flow metered to port L is controlled
by the amount of steering wheel rotation. Excess oil flow through
port P that is not metered to port L, is directed by the spool to
port T and is then directed through the oil cooler and into the
tank.

5-19-9
Gerotor Operation Inner Gear
If the engine or pump is not operating, the steering unit works as
a manual pump when the steering wheel is turned. The gerotor Outer Gear
will work when the input torque to the steering wheel is less than Pin
117.7 N.m (12 kg.m, 87 ft lb). If the necessary input torque is
greater than this, the gerotor will not function. When the steering
wheel is turned, the gerotor creates a vacuum that draws oil
from port T. The gerotor pumps this oil through the control spool Drive
and into the steering cylinders. Return oil flows back to the spool
and is used to lubricate the steering unit. The return oil then WL1300660
flows back into the tank line and is recirculated back to the Figure 5
gerotor and the steering cylinders.
Relief Valve
The main relief valve is built into the steering valve. When
abnormal pressure is generated during steering operation, the
pump oil is returned to the tank line by the relief valve to prevent
failure or breakdown of the hydraulic pump.
Figure 6

5-19-10
Priority Valve
Edition 1
DX210WA Priority Valve

5-20-1
MEMO
Priority Valve DX210WA

5-20-2
Table of Contents
Priority Valve
General .........................................................5-20-6
Overview ................................................................. 5-20-6
Removal .......................................................5-20-8
Installation ..................................................5-20-12
Completing Work ........................................5-20-13

5-20-3
5-20-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-20-5
GENERAL
Overview
CF
EF P LS
WE1400387
Figure 1
Port Name Size

P Pressure In
EF Drain PF 1/2
CF Pressure Out
LS Load Sensing PF 1/4
Hydraulic Circuit to Steering Valve to Oil Tank

CF EF
LS
WE1400388
Figure 2

5-20-6
Theory of Operation
While the engine is stopped, the spool of the priority valve is
moved to the left by force of the spring.
In this state, the port EF is closed and the port CF is open.
When the engine is started and the steering valve is in the
neutral position, pressure at the port CF is increased to
overcome force of the spring of the priority valve.
Then, the spool is moved to the right, resulting in oil delivery to
the port EF through the spool.
The priority valve is a dynamic type. Oil (at the port CF)
discharged from the pump passes through the dynamic orifice
line in the priority spool and returns back to the tank through the
steering valve. (steering in the neutral position)
When oil from the pump is supplied to the port EF through the
priority spool, pressure in the line between the ports P and EF is
dropped, which is proportional to the oil flow.
LS
EF CF
WE1400386
Figure 3

5-20-7
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1400408
Figure 4

5-20-8
(Figure 5)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF
4. Operate the joystick levers, pedals and steering wheel

several times to release the remaining pressure in the
hydraulic piping.
O O

switch.
WE1401161
Figure 6

OFF
(Figure 7)
ON
Figure 7 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 8

5-20-9
WARNING
doing any work.
EX1402442
cover (2) on bottom of main frame. 1 2
• Tool: 19 mm ( )
WE1400409

5-20-10
13. Remove hoses and adapters from priority valve.
NOTE: Attach identification tags to the removed hoses EF
for reassembling. P
After disconnecting hoses from priority valve,
plug them to prevent dirt or dust from entering.
priority valve.
CF
LS
WE1400410
Figure 11

Port Name
P from Steering Pump 13/16"-16UN-2B 24 55.9 5.7 41.2
to Oil Cooler Pipe PF 1/2" 27 93.1 9.5 68.7
EF
from Steering Valve "T" PF 1/2" 27 93.1 9.5 68.7
CF to Steering Valve "P" 13/16"-16UN-2B 24 55.9 5.7 41.2
LS from Steering Valve "LS" 9/16"-18UNF-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
P, CF Adapter PF 1/2" UNF 13/16-16 27 93.1 9.5 68.7
EF Tee PF 1/2" PF 1/2" 22 93.1 9.5 68.7
LS Adapter PF 1/4" UNF 9/16-18 19 39.2 4 28.9
1B, P18 1B, F-08
P, CF O-ring
(S8000181) (S8030081)
1B, P18
EF O-ring
(S8000181)
1B, P11 1B, F-04
LS O-ring
(S8000111) (S8030041)
* A: Opposite side of hose, B (C): Hose Side

14. Remove bolts (1, Figure 12) and washers with priority
valve (2) from bracket.
2 1
• Tool: 13 mm ( )
Figure 12 WE1400411

5-20-11
15. Remove priority valve from bracket.
WE1400412
Figure 13
INSTALLATION
WARNING
SERIOUS INJURY


5-20-12
COMPLETING WORK
HAOB290L
Figure 14
3. Slowly turn the steering wheel to the right and left about
five times without a load to vent air from pilot lines.
WE1400318
Figure 15

5-20-13
5-20-14
Dozer Joystick Valve
Edition 1
DX210WA Dozer Joystick Valve

5-21-1
MEMO
Dozer Joystick Valve DX210WA

5-21-2
Table of Contents
Dozer Joystick Valve

General .........................................................5-21-5
Specifications .......................................................... 5-21-5
Overview ................................................................. 5-21-6
Parts List ................................................................. 5-21-8
Tools ...........................................................5-21-11
Removal .....................................................5-21-12
Installation ..................................................5-21-16
Completing work .........................................5-21-16
Disassembly ...............................................5-21-17
Reassembly ................................................5-21-20

5-21-3
5-21-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Supply Pressure 40 bar (40 kg/cm2, 569 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Oil Temperature -20 ~ +90°C
Performance
28 + 30
Operating Torque (kg.cm)
Secondary Pressure
Secondary Pressure
(kg/cm2)
(kg/cm2)
16.6促3
5促1 Operating Torque

2.4促1.5
0 1促5 4 6 6.5促0.5
Push-rod Stroke (mm)
EX1403270
Figure 1

5-21-5
Overview
The pilot valve is a valve that controls the spool stroke, direction,
etc of a main control valve.
This function is done by providing the spring at one end of the
main control valve spool and applying the output pressure
(secondary pressure) of the pilot valve to the other end.
15
M10 x 1.25
P
1 2
EX1403271
Figure 2
Port Size
1, 2, P, T PF 1/4 O-ring

5-21-6
Hydraulic Circuit
T P
1 2
FG007451
Figure 3

5-21-7
Parts List
23
20
22
16
21
14
19
15
18
17
5-5
6-1
5-1 6-4
6
6-2
5 5-4
6-3
4
5-3
5-2 2
3 1
Figure 4 EX1403272
Reference Reference
Number Number
1 Body 6-3 O-ring
2 Plug 6-4 Rod; Push
3 O-ring 14 Cover
4 Spring 15 Bolt
5 Spool Kit 16 Guide
5-1 Seat; Spring 17 Pin
5-2 Spool 18 Bolt
5-3 Seat; Spring 19 Nut
5-4 Spring 20 Lever
5-5 Stopper 21 Pin; Spring
6 Plug Kit 22 Boot
6-1 Plug 23 Bushing
6-2 Seal; Rod * Seal Kit; Dozer Joystick
*: 3, 6-3

5-21-8
Theory of Operation
Function
It is used to reduce the primary pressure delivered from the pilot
gear pump to the secondary pressure level to control the control
valve dozer spool.
1. Neutral position
While the dozer valve is in the neutral position, the spring
seat (5-1), spool (5-2) and push rod (6-4) have been
pushed upwards by the spring (4).
The oil with the primary pressure flowed into the dozer
valve through the port P.
Keeps blocked by the spool (5-2).
The operating ports (1 and 2) are connected to the port T.
T P
6-4
5-1
T
4
1 2
5-2 P
1 2
Figure 5 EX1403273

5-21-9
2. Fine control
Moving the lever (20) forces the push rod (6-4) to move
downwards, and the moving rod pushes down the spring
seat (5-1), spring (5-3), and spool (5-2).
Once the spool (5-2) is moved as much as a specified
distance, the oil with the primary pressure begins to flow
into the operating port through the spool (5-2).
Stopping the lever (20) in the fine control process,
balances the force of the spring (5-3) and the secondary
pressure by the pushing force of hydraulic pressure acting
on the spool (5-2).
This secondary pressure is transferred to the control valve
dozer spool.
20
T P
6-4
5-1
T
5-3
1 2
5-2 P
1 2
EX1403274
Figure 6

5-21-10
3. Full control
Moving the lever (20) to the full forces the push rod (6-4) to
move downwards and the moving rod pushes down the
spring seat (5-1), spring (5-3) and spool (5-2), by which the
spring (5-3) is fully compressed.
The primary pressure is delivered to the operating port
through the spool (5-2) while the delivered secondary
pressure pushes up the spool (5-2). However, as the spool
(5-2) is fixed to the push rod (6-4) and thus cannot move.
20
T P
6-4
5-1
T
5-3
1 2
P
5-2
1 2
EX1403275
Figure 7
TOOLS
Reference
Description Tool
Number
2 Plug 10 mm ( )
15 Socket Bolt 5 mm ( )
18 Bolt 2.5 mm ( )
19 Nut 8 mm ( )

5-21-11
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1400302
Figure 8

5-21-12
(Figure 9)
LOCK
WARNING
WARNING
DO NOT OPERATE
or maintenance
ON OFF
4. Operate the joystick levers, dozer lever and pedals several

times to release the remaining pressure in the hydraulic
piping.
O O

switch.
WE1401161
Figure 10

OFF
(Figure 11)
ON
Figure 11 EX1401760

3
5 8
1 2
7 6
4
EX1401809
Figure 12

5-21-13
WARNING
doing any work.
Figure 13
12. Remove screw (1, Figure 14) and bolt (2) (2 ea).
• Tool: 13 mm ( ), phillips screwdriver

1
13. Remove upper cover (3) from bracket, and disconnect the
connector of harness which connceted with switches.
2
3
WE1400389
Figure 14 Stand LH
14. Remove bolts and washers (1, Figure 15) (2 ea), separate
dozer lever (2) from stand bracket.
• Tool: 10 mm ( )
2
Figure 15 WE1400390

5-21-14
15. Remove hoses and adapters from dozer valve.
NOTE: Attach identification tags to the removed hoses T
for reassembling.
After disconnecting hoses from dozer valve, plug
them to prevent dirt or dust from entering. P
1 2
WE1400391
Figure 16

Port Name
to Control Valve "XAd"
1 PF 1/4" 19 39.2 4 28.9
(Joint Adapter Top)
to Control Valve "XBd"
2 PF 1/4" 19 39.2 4 28.9
(Joint Adapter Bottom)
P from P Block PF 1/4" 19 39.2 4 28.9
T to T Block (Drain) PF 1/4" 19 39.2 4 28.9
• Fitting
Size Torque
Port Name
1, P, T Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
2 Elbow PF 1/4" PF 1/4" 19 39.2 4 28.9
1, 2, P, T O-ring 1B, P11 (S8000111)

16. Remove dozer joystick valve from control stand.
EX1403106
Figure 17

5-21-15
INSTALLATION
WARNING
SERIOUS INJURY

2. Keep the assembly angle when installing the hoses to
dozer valve.
COMPLETING WORK
HAOB290L
Figure 18
3. Slowly push and pull dozer lever as shown in Figure 19

about five times without a load to vent air from pilot lines.
4. Check the function of operation.
• Push: Dozer blade down
• Pull: Dozer blade up
Figure 19 WE1400392

5-21-16
DISASSEMBLY
1. Disassemble boot(22) and bushing(23) from the body(1).
Figure 20
2. Disassemble guide(16) and pin(17) from the cover(14).
FG003783
Figure 21
3. Disassemble cover(14) from the body(1).
FG003786-1
Figure 22
Figure 23

5-21-17
Figure 24
4. Disassemble plug kit (II) from the body (1).
FG003787
Figure 25
5. Disassemble spool kit (I) from the body (1).
FG003788
Figure 26
6. Disassemble spring (4) from the body (1).
FG003789
Figure 27

5-21-18
7. Disassemble plug (2) from the body (1).
Figure 28
Figure 29

5-21-19
REASSEMBLY
1. Assemble plug (2) in the body (1).
Figure 30
Figure 31
2. Assemble spring (4) in the body (1).
FG003789
Figure 32
3. Assemble spool kit (I).

Assemble spring seat (I-7), spring (I-8), spring seat (I-5)
and stopper (I-9) at spool (I-6) in the order.
FG003791
Figure 33

5-21-20
4. Assemble spool kit (I) in the body (1).
FG003788
Figure 34
5. Assemble plug kit (II)

Assemble rod seal (II-11), o-ring (II-12), push rod (II-13)
and plug (II-10) in the order.
FG003792
Figure 35
6. Assemble plug kit (II) in the body (1).
FG003787
Figure 36

5-21-21
7. Assemble cover(14) in the body(1) with wrench bolt.
Figure 37
Figure 38
8. Assemble wrench bolt(15) in the body(1) with torque

wrench.
FG003786-1
Figure 39
9. Assemble socket bolt(18) and nut(19) in the guide(16).
FG007458
Figure 40

5-21-22
10. Assemble guide(16) and lever(20) with spring pin(21).
FG003794
Figure 41
FG003794-1
Figure 42
11. Assemble guide(16) in the cover with pin(17).
FG003783
Figure 43
12. Adjust the clearance of lever(20) with wrench and spanner.
FG003795
Figure 44

5-21-23
13. Assemble boot(22) and busshing(23) in the body(1).
Figure 45
FG003781-1
Figure 46

5-21-24
1SolenoidValve
(3 Functions)
Edition 1
DX210WA Solenoid Valve (3 Functions)

5-22-1
MEMO
Solenoid Valve (3 Functions) DX210WA

5-22-2
Table of Contents
Solenoid Valve (3 Functions)

General .........................................................5-22-5
Specification ............................................................ 5-22-5
Overview ................................................................. 5-22-6
Parts List ................................................................. 5-22-8
Tools and Torque .......................................5-22-10

5-22-3
5-22-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This 3-solenoid valve has functions as below.
1. Cuts off pilot pressure.
2. Controls driving speed. (Inching Mode)
3. Performs a ram lock function. (Locking chocking cylinder)
Specification
Pressure (Max.) 69 bar (70 kg/cm2, 996 psi)
Flow (Max.) 23 L/min (6.1 U.S. gal)
Leakage below 40 ml/min
Solenoid Coil
Rated Voltage DC 24 V
Operation Voltage Range 20 ~ 30 V
Surge Absorber Built in

5-22-5
Overview
C3
C2
C1
C4
PB
CT P3
S
PS
P2
P
IC
C5
CH
T
WE1400206
Figure 1
Reference Reference
Number Number
C1 Ram Lock C3 Pilot Cut-off
C2 Inching Mode

5-22-6
CH IC PB PS
C5
C4
C1 C2 C3
P1
P2 P3 GTS
WE1400207
Figure 2
Port Name Size

P1 Pilot Filter
T Drain PF 1/2
PS Pilot Inlet Pressure
PB Accumulator
PF 3/8
P2 Transmission Control Valve
P3 Swing Motor Parking Brake Release
CH Ram Lock
PF 1/4
IC Inching Mode (Low Travel)
GTS Transmission Pressure Warning

5-22-7
Parts List
C3
C2
C1
C4
3
C5
Figure 3
WE1400208
Reference Reference
Number Number
1 Body 3 Check Valve
2 Spool, Solenoid 4 Coil 24 V

5-22-8
Theory of Operation
Functions of 3 Solenoid Valve

This solenoid valve has functions as below:
1. Performs a ram lock.
2. Controls driving speed.
3. Cuts off pilot pressure.
Application by Function of Each Solenoid Valve
No. Valve Function Application Remark

Used to absorb vibration from the front axle depending on
road conditions when the vehicle is moving while it keeps
C1 Performs a ram lock. Ram lock
the front axle stable to increase operation convenience
when the vehicle is working.
Converts to low-speed driving (below 5 km/h).
C2 Controls driving speed. During the excavation work to cross mudslide covered the Inching
rise (travel) improves the gradability.
Supplies the pressure and oil flows discharged by the pilot
C3 Cuts off pilot pressure. pump to the solenoid valve that supplies pilot pressure
and the remote control valve, to drive each device.
Detailed Function and Application Descriptions by Solenoid Valve

1. C1 performs ram lock.
Ram lock is a function to absorb vibration from the front
axle depending on road conditions when the vehicle is
moving while it keeps the front axle stable to increase
operation convenience when the vehicle is working.
A. How the ram lock function "ON" works
When (C1) goes "OFF", it blocks the flow path between
both ram cylinders enabling the oil flow in the cylinders
to remain steady. And this activates ram lock.
B. How ram lock "OFF" works
If (C1) is turned "ON", it connects the flow path
between both ram cylinders allowing load on them
and the strokes of the cylinders are adjusted based
on their loads.
2. C2 controls driving speed.
Travel speed has to be controlled by low speed under 5 km/h
for specific work mode. This function fixes the displacement
of travel motor regardless travel load or speed.
3. C3 cuts off pilot pressure.
(C3) transmits the pressure and oil supplied from the pilot
pump to solenoid valve that supplies pilot pressure, the
breaker valve package, and remote control valve (dozer,
arm/swing, boom/bucket). Pull down the cut-off lever on
the left-hand side of the driver's seat to give electric signals
of the limit switch enabling the valve to supply pilot
pressure into the system.

5-22-9
TOOLS AND TORQUE
The assembly torque of each part in the Solenoid Valve
Package is described in the table below.
Observe the specified torque values using the right tool.
2-1
Disassembly
2-2
Assembly
2-3
C3
C2
C1
C4
3 C5
3
WE1400209
Figure 4
Torque
No. Part Name Screw Spec Tools
N.m kg.m ft lb
Torque Wrench/19 mm
2-1 Coil Lock Nut UNF1/2-20" 2.9 ±0.2 0.6 ±0.02 4.3 ±0.14
Hex. Socket
Torque Wrench/1"
2-3 Solenoid Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket
Torque Wrench/1"
3 Check Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket

5-22-10
AND REASSEMBLY
substances before disassembly and re-assembly.
specified in table of page 5-22-10 when disassembling and
re-assembling parts.
4. Disassembly and re-assembly of solenoid valve
A. Disassemble the valve by turning (2-1) coil lock nut in
the disassembly direction.
CAUTION
AVOID INJURY
Do not damage the tube and retainer of Solenoid
Valve when disassembling the coil lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not work.
B. After disassembling coil lock nut, take out (2-2) coil

using your hand.
C. Then, disassemble (2-3) Solenoid valve by turning it
in the disassembly direction.
D. Identify problems and re-assembling solenoid valve
and coil.
E. Avoid using excessive torque in re-assembling
solenoid valve and coil.
CAUTION
AVOID INJURY
Excessive use of torque will result in defects on
solenoid valve.

when re-assembling.
disassembly.

5-22-11
TROUBLESHOOTING
Solenoid Foreign Disassemble valve and check if any foreign materials Remove foreign
valve will materials, or contaminants such as sludge lodged in between materials and clean
not contaminants in case and spool. the contaminated
function valve area.
properly Damages in Disassemble valve and check if the tube and retainer Replace valve.
tube and area is deformed (dented, contracted).
retainer
Breaking of wire, Disassemble valve and check resistance of coil. Replace coil.
short circuiting,
• Condition: 26.7Ω @ 14°C
thermal
reactions in coil • Breaking of wire: The resistance of coil is ∞
(infinite).
• Short circuiting: The resistance is low or
excessive.
Disassemble valve and check if the molded area of
coil is melted by thermal reactions.
Connection to Check if the terminals of the cap housing (with a lead Replace faulty
terminal in coil) and the housing (facing housing) are connected housing and
connector properly. terminal.
No pilot Pilot pressure Remove the adaptor and hydraulic hoses at the "PS" Refer to the above
pressure port and install a pressure gauge to check discharge checkpoints and
pressure value at the pilot pump with (C3) solenoid descriptions for
operated. "Solenoid valve"
Pilot relief valve Check operation of the relief valve installed on the Remove foreign
pilot line. materials and
replace relief valve.
• Check if pressure is bypassed by foreign
materials.
Pilot pump Check pilot pump operation. Replace pilot pump
Pilot filter Check if the mesh screen of pilot filter is Clean affected parts
contaminated by foreign materials. and replace filter.
Actuator Pilot system Check pilot system according to the above Locate cause of
will not checkpoints and descriptions for "No" pilot pressure. problems in pilot
function system and correct.
properly Solenoid valve Install a pressure gauge at each valve outlet (Ports Refer to the above
CH, IC, PS) and operate solenoid valve to check checkpoints and
discharge pressure value. descriptions for
"Solenoid valve"
Main control Check if the main control valve for each device is Follow descriptions
valve working properly. to correct.
Devices Check if the device is working properly. Follow descriptions
to correct.
How to Check Pilot Pressure
Where to Install Pressure Gauges Screw Specification Remark

CH, IC PF1/4" O-ring boss Solenoid Valve "ON"
PS PF1/2" O-ring boss Solenoid Valve "ON"
• Pilot pressure: 40 bar (40 kg/cm2, 580 psi)

5-22-12
1SolenoidValve
(5 Functions)
Edition 1

5-23-1
MEMO

5-23-2
Table of Contents
Solenoid Valve (5 Functions)

General .........................................................5-23-5
Specification ............................................................ 5-23-5
Overview ................................................................. 5-23-6
Parts List ................................................................. 5-23-8
Tools and Torque .......................................5-23-11

5-23-3
5-23-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This 5-solenoid valve has functions as below.
1. Supplies pressure to breaker.
2. Drives forward.
3. Drives backward.
4. Boosts main pressure.
5. Controls cruise driving.
Specification
Pressure (Max.) 69 bar (70 kg/cm2, 996 psi)
Flow (Max.) 23 L/min (6.1 U.S. gal)
Leakage below 40 ml/min
Solenoid Coil
Rated Voltage DC 24 V
Operation Voltage Range 20 ~ 30 V
Surge Absorber Built in

5-23-5
Overview
C1 C7
C6 C2
C5 C5
C2 C6
C7 C1
HO TS
PL
PA R
R PB
PB AR
R P
PL P
P1 HO
TS
T
WE1400210
Figure 1
Reference Reference
Number Number
C1 Breaker C2 Main Pressure Boost
C6 Drive Forward C7 Cruise Control
C5 Drive Backward

5-23-6
C1 C6 C5 C2 C7
P1
HO PAR PBR PL TS
WE1400211
Figure 2
Port Name Size

P1 Pilot Filter
PF 1/2
T Drain
P Pilot Inlet Pressure
PL Main Pressure Boost
PAR Drive Forward
PF 1/4
HO Pilot Supply to Breaker, Two-way
TS Cruise Control
PBR Drive Backward

5-23-7
Parts List
C7
1
C2
C5
C6
C1
Figure 3 WE1400212
Reference Reference
Number Number
1 Body 3 Coil 24 V
2 Spool, Solenoid

5-23-8
Theory of Operation
Functions of 5 Solenoid Valve

This solenoid valve package has functions as below:
1. Supplies pressure to breaker.
2. Boosts main pressure.
3. Drives forward.
4. Drives backward.
5. Controls cruise driving.
Application by Function of Each Solenoid Valve
No. Valve Function Application Remark

Used to supply pilot pressure to the option spool of
C1 Operation of breaker main control valve that supplies pressure to the
breaker (shear).
Used to increase set pressure of the main relief valve Pressure
C2 Main pressure boost
to boost excavation power temporarily. boost
Driving forward or Used to drive vehicles forward or backward by
C5 and C6
backward operating the travel spool of the main control valve.
C7 Cruise control Used to reduce driver fatigue in long-haul operations.
Detailed Functions and Application of Each Solenoid Valve

1. Operation of breaker
The (C1) solenoid valve starts to operate when the breaker
of the joystick is switched on and supplies pilot pressure to
option spool of the main control valve. The option spool is
converted by the pilot pressure, supplies the pressure and
oil flows discharged by the pump into the breaker to enable
the vehicle to perform a breaker operation.
2. Main pressure boost
This is a function that increases the pressure of the main
relief valve to boost excavation power temporarily.
When the pressure boost switch on the lever is turned on
by the signals of the EPOS controller, this solenoid valve
for pressure boost is turned "ON" for operation increasing
the set pressure of the main relief valve from 323 bar
(330 kg/cm2, 4,693 psi) approx. to 343 bar (350 kg.cm2,
4,978 psi) approx., to boost excavation power.
In addition, this solenoid valve can be operated by
selecting a mode on the switch (operation/parking/driving).
The default pressure in the relief valve is 343 bar (350 kg.cm2,
4,978 psi) in the driving mode.

5-23-9
3. Control of driving forward or backward
The incoming pressure and oil flows from the pilot pump is
supplied via (C7) to the solenoid valve (C5 and C6) that
controls driving directions- forward and backward driving.
The position of the lever - Forward driving, Backward
driving, Gear shift - directs this pressure and oil flows to
activate (C5 and C6) and then the travel spool of the main
control valve.
This incoming pressure and oil flows from the main pump
make the travel motor rotate in the right or reverse
direction changing driving directions of the vehicle.
When the vehicle runs forward, forward driving solenoid
valve (C6) operates, while backward solenoid valve (C5)
operates when the vehicle runs backward.
4. Cruise control
This cruise control function is used to reduce driver fatigue
in long-haul operations. Pushing the cruise switch will run
the vehicle with the lever on "F" without pushing the
accelerator pedal. The driving speed can be controlled with
the engine control dial.
Also, the vehicle can be set to run at a constant speed by
adjusting the engine control dial.
When the vehicle runs uphill or downhill, its speed may
change. However, this is not a malfunction but this
happens due to changes in load. Pushing the brake pedal
will automatically stop cruise driving at a traffic signal or
roadblock. Cruise driving can also be released by moving
the lever to "N". If the engine noise is too loud, adjust the
engine control dial to low speed.
With Automatic Low Speed switched "ON", the engine
slows down to the set speed in 4 minutes or so after the
cruise driving function is released (after the pedal is
pressed).
If the cruise driving function operates again, the engine
speed goes up to the original speed right away.

5-23-10
TOOLS AND TORQUE
The assembly torque of each part in the Solenoid Valve
Package is described in the table below.
Observe the specified torque values using the right tool.
2-1
Disassembly
2-2
Assembly
2-3
C2 C7
C5
C6
C1
WE1400213
Figure 4
Torque
No. Part Name Screw Spec Tools
N.m kg.m ft lb
Torque Wrench/19 mm
2-1 Coil Lock Nut UNF1/2-20" 2.9 ±0.2 0.6 ±0.02 4.3 ±0.14
Hex. Socket
Torque Wrench/1"
2-3 Solenoid Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket

5-23-11
AND REASSEMBLY
substances before disassembly and re-assembly.
specified in table of page 5-23-11 when disassembling and
re-assembling parts.
4. Disassembly and re-assembly of solenoid valve
A. Disassemble the valve by turning (2-1) coil lock nut in
the disassembly direction.
CAUTION
AVOID INJURY
Do not damage the tube and retainer of Solenoid
Valve when disassembling the coil lock nut.
In case the tube and retainer gets damaged
(dented, deformed), solenoid valve will not work.
B. After disassembling coil lock nut, take out (2-2) coil

using your hand.
C. Then, disassemble (2-3) Solenoid valve by turning it
in the disassembly direction.
D. Identify problems and re-assembling solenoid valve
and coil.
E. Avoid using excessive torque in re-assembling
solenoid valve and coil.
CAUTION
AVOID INJURY
Excessive use of torque will result in defects on
solenoid valve.

when re-assembling.
disassembly.

5-23-12
TROUBLESHOOTING
Solenoid Foreign Disassemble valve and check if any foreign materials Remove foreign
valve will materials, or contaminants such as sludge lodged in between materials and clean
not contaminants in case and spool. the contaminated
function valve area.
properly Damages in Disassemble valve and check if the tube and retainer Replace valve.
tube and area is deformed (dented, contracted).
retainer
Breaking of wire, Disassemble valve and check resistance of coil. Replace coil.
short circuiting,
• Condition: 26.7Ω @ 14°C
thermal
reactions in coil • Breaking of wire: The resistance of coil is ∞
(infinite).
• Short circuiting: The resistance is low or
excessive.
Disassemble valve and check if the molded area of
coil is melted by thermal reactions.
Connection to Check if the terminals of the cap housing (with a lead Replace faulty
terminal in coil) and the housing (facing housing) are connected housing and
connector properly. terminal.
No pilot Pilot pressure Remove the adaptor and hydraulic hoses at the "PL" Refer to the above
pressure port and install a pressure gauge to check discharge checkpoints and
pressure value at the pilot pump with (C2) solenoid descriptions for
operated. "Solenoid valve"
Pilot relief valve Check operation of the relief valve installed on the Remove foreign
pilot line. materials and
replace relief valve.
• Check if pressure is bypassed by foreign
materials.
Pilot pump Check pilot pump operation. Replace pilot pump
Pilot filter Check if the mesh screen of pilot filter is Clean affected parts
contaminated by foreign materials. and replace filter.
Actuator Pilot system Check pilot system according to the above Locate cause of
will not checkpoints and descriptions for "No" pilot pressure. problems in pilot
function system and correct.
properly Solenoid valve Install a pressure gauge at each valve outlet (Ports Refer to the above
HO, PL, PBR, PAR, TS) and operate solenoid valve checkpoints and
to check discharge pressure value. descriptions for
"Solenoid valve"
Main control Check if the main control valve for each device is Follow descriptions
valve working properly. to correct.
Devices Check if the device is working properly. Follow descriptions
to correct.
How to Check Pilot Pressure
Where to Install Pressure Gauges Screw Specification Remark

HO, PL, PBR, PAR, TS PF1/4" O-ring boss Solenoid Valve "ON"
• Pilot pressure: 40 bar (40 kg/cm2, 580 psi)

5-23-13
5-23-14
Gear Pump
(Rotating)
Edition 1
DX210WA Gear Pump (Rotating)

5-24-1
MEMO
Gear Pump (Rotating) DX210WA

5-24-2
Table of Contents
Gear Pump (Rotating)

General .........................................................5-24-5
Specification ............................................................ 5-24-5
Overview ................................................................. 5-24-6
Location................................................................... 5-24-6
Parts List ................................................................. 5-24-7
Single Gear Pump ........................................5-24-8
Disassembly ............................................................ 5-24-8
Reassembly........................................................... 5-24-10

5-24-3
5-24-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Clockwise
(Looking on Driveshaft)
Displacement 14.53 cm3/rev
Inlet Pressure Range for Pump 0.7 - 3 bar (0.7 - 3 kg/cm2, 10.1 - 43.5 psi)
Max. Continuous Pressure (Rated) 255 kg/cm2 (250 bar, 3,626 psi)
Max. Intermittent Pressure 286 kg/cm2 (280 bar, 4,061 psi)
Max. Peak Pressure 306 kg/cm2 (300 bar, 4,351 psi)
Weight 3 kg (6.6 lb)

5-24-5
Overview
Out
In
Figure 1 EX1403314

Inlet
Port Name Size
In Hydraulic Oil Inlet PF 3/4 O-ring
Out Hydraulic Oil Outlet PF 1/2 O-ring
Outlet
Figure 2 EX1301736
Location
Gear Pump
Engine
Figure 3
WE1400467

5-24-6
Parts List
14
5 13
4
13
7
11
10
14
9
14
10
4
6
9
2
12
EX1301309
Figure 4
Reference Reference
Number Number
1 Body 9 Seal
2 Front Cover 10 Seal
3 Rear Cover 11 Shaft Seal
4 Thrust Plate 12 Snap Ring
5 Driveshaft 13 Backup Ring
6 Driven Gear 14 Dowel Pin
7 Bolt * Gear Pump Seal Kit
8 Spring Washer

5-24-7
SINGLE GEAR PUMP
Disassembly
1. Clean exterior of pump.
FG001072
Figure 5
2. Remove clamp bolts.
FG001074
Figure 6
3. Cover sharp edges of driveshaft with adhesive tape and

coat shaft end extension with clean grease, to avoid any
damage to lip of shaft seal when removing mounting
flange.
FG001073
Figure 7

5-24-8
4. Remove mounting flange taking care to keep flange as
straight as possible during removal.
If mounting flange is stuck, tap around edge with rubber
mallet to break it away from body.
NOTE: Make sure that while removing mounting flange,
shaft and other components remain in position.
FG001075
Figure 8
5. Remove retaining ring, if replacement is necessary.
FG000834
Figure 9
6. Remove shaft seal taking care not to damage surface of

shaft hole, if replacement is necessary.
FG000835
Figure 10
7. Pull drive gear up to facilitate removal of front plate.
FG001076
Figure 11

5-24-9
8. Remove driving gear and driven gear, keeping gears as
straight as possible.
FG001077
Figure 12
9. Remove rear plate and end cover.
FG001078
Figure 13
Reassembly
1. Clean all components with care.
FG001078
Figure 14
2. Using a suitable driver, install shaft seal in mounting

flange.
FG000839
Figure 15

5-24-10
3. Install retaining ring in groove.
FG000840
Figure 16
4. Install O-ring on both sides of rear section of body.

NOTE: Coat O-rings with grease to hold O-rings in
body.
FG001079
Figure 17
5. Install rear section body on rear cover.
FG001080
Figure 18
6. Install seals in pressure plate (s) groove. Then install

backup ring in groove with seals. Coat seals with grease. Outlet Side
NOTE: The front and rear pressure plates and seals
and backup rings are the same.
Inlet Side
FG001401
Figure 19

5-24-11
7. Insert pressure plate assembly into body while keeping it
straight.
NOTE: Seal side should face to rear cover, opposite
side of gears.
NOTE: Pay attention to installation direction of seal.
FG001081
Figure 20
8. Install drive gear and driven gear.
FG001082
Figure 21
9. Insert pressure plate into body in proper direction.
FG001083
Figure 22
10. Locate mounting flange in right position.
FG001084
Figure 23

5-24-12
11. Tighten bolts with washer in a crisscross pattern to a
torque value of 45 N.m (4.59 kg.m, 33.2 ft lb).
FG001085
Figure 24
12. Check that pump rotates freely when driveshaft is turned

by hand. If not a pressure plate seal may be pinched.
FG000851
Figure 25

5-24-13
5-24-14
One Spool Valve
(Rotating)
Edition 1
DX210WA One Spool Valve (Rotating)

5-25-1
MEMO
One Spool Valve (Rotating) DX210WA

5-25-2
Table of Contents
One Spool Valve (Rotating)

General .........................................................5-25-5
Specification ............................................................ 5-25-5
Overview ................................................................. 5-25-6
Disassembly and Assembly..........................5-25-9
General Cautions .................................................... 5-25-9
Replacement of Spool ........................................... 5-25-10
Replacement of Main Relief Valve ........................ 5-25-12
Replacement of Overload Relief Valve ................. 5-25-13
Replacement of Sub-Block.................................... 5-25-15

5-25-3
MEMO

5-25-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Rated Pressure 83 bar (85 kg/cm2, 1,209 psi)
Rated Flow 50 L/min (13 U.S. gal)
Internal Leakage 100 cc/min at 68 bar (69 kg/cm2, 986 psi)
Main Relief Pressure Setting 78 bar (80 kg/cm2, 1,131 psi)
Overload Relief Pressure Setting 98 bar (100 kg/cm2, 1,421 psi)

5-25-5
Overview
4 1
5 T P 2
pa A B pb
2-PF 1/4 (Pilot Port) 3

EX1403307
Figure 1
Reference Reference
Number Number
1 Inlet Block 4 Main Relief Valve
2 Work Block 5 Overload Relief Valve
3 T Block

P
Port Name Size T
78 bar
P Pressure Input
PF 1/2
T Drain
A Attach Pressure In/Out
PF 3/8 pa pb
B Attach Pressure In/Out
A
Pa Pilot Pressure 98 bar
PF 1/4 B
Pb Pilot Pressure
EX1403308
Figure 2

5-25-6
Theory of Operation
In the Neutral Condition

The hydraulic oil, supplied to the P port under the neutral
condition, is to be flowed out to the tank passage through the
"One Spool Valve".
A B T
pa pb
pa pb A
B
EX1403309
Figure 3
Spool Operation
1. When Pilot Pressure "Pa" is impressed
When pilot pressure is impressed at the "Pa" port, the
pressured oil flowed from the P port is to be discharged to
the A port through the load check poppet and the spool, as
the hydraulic oil passage for bypass is blocked.
P
A B T
pa pa pb
pb
A
B
EX1403310
Figure 4

5-25-7
2. When Pilot Pressure "Pb" is impressed
When pilot pressure is impressed at the "Pb" port, the
pressured oil flowed from the P port is to be discharged to
the B port through the load check poppet and the spool, as
the hydraulic oil passage for bypass is blocked.
P
A B T
pb pa pb
pa
A
B
EX1403311
Figure 5

5-25-8
DISASSEMBLY AND ASSEMBLY
General Cautions
It is the principle that disassembly and assembly of this valve
should carried out by the manufacturer. In case disassembly
and assembly is inevitably required elsewhere, the following
cautions must be observed.
1. This valve is precisely processed and the gaps among
each part are extremely tiny. This, disassembly and
assembly should be performed very carefully so that any
foreign material such as dust or sand can not intrude into
the valve.
2. For disassembly, a technician should start disassembly
after fully understanding the structure of the valve with
structural drawings and reference drawings.
3. When the valve needs to be removed from a machine, be
sure to put caps on each port and to wash the exterior of
the assembly after checking the caps on each port again
before assembling.
4. In case the disassembled parts need to be placed
unassembled for a while, they must be treated with rust
prevent oil and sealed to prevent rusting.
5. Do not hold a pilot cap, a relief valve and a overload relief
valve when this valve needs to be moved.
6. Even in case disassembly and assembly is not peformed
smoothly, do not hit or treat any part of the product roughly.
7. After disassembly, attach ID tags to each part for accurate
assembly.
8. For O-rings and back up-rings, it is the principle to use the
new ones. And be sure not to damage one during
assembly. (Apply a small portion of grease on the parts for
smooth assembly.)
9. Fasten bolts, overload relief valves and main relief valves
with the specified standard torque.
10. As various tests (relief characteristics test, leakage test,
operational test, etc.) are essential after disassembly and
assembly, do not disassemble this valve if those tests are
not available.
11. Be careful not to damage the O-ring contacting parts of this
valve for preventing oil leakage.
12. Be cautious about safety during operation as this valve
assembly is heavy.

5-25-9
Replacement of Spool
CAUTION
AVOID INJURY
For replacement of a spool, it must be replaced with a sub-
assembly of spool.
CAUTION
AVOID INJURY
During assembly operation of a spool sub-assembly, be
careful so that a foreign material can not intrude into the
sub-assembly.
1. Removing Pilot Cap

Unfasten the two bolts for the pilot cap with a L-wrench
(5mm) and remove the cap along with the washer.
(You can remove either of them.)
Figure 6
Figure 7

5-25-10
2. Removing Spool
After fixing the main body and removing the return spring
and the spring seat first, pull the spool in the horizontal
direction (parallel to the spool hole) to remove it from the
main body.
Too much impressed force for disassembly may damage
the spool. When the spool is stuck, therefore, push it back
smoothly and try to pull the spool while rotating it.
While removing the spool, check which end has the mark.
Figure 8
3. Assembling Spool
Insert the spool into the fixed main body. (Overloaded
force may damage the main body or the spool. When the
spool is stuck, pull it back and press it smoothly while
rotating it.)
Check the direction of the mark, identified during the
disassembly operation.
Assemble the spring seat and the spring.
Figure 9
Figure 10
4. Assembling Pilot Cap (on Return Spring Side)

Cover the pilot cap on the return spring of the spool,
previously assembled to the main body, and fasten it with
two bolts at the specified standard torque using a torque
wrench (5mm). Check if there is the O-ring on the
contacting surface.
Figure 11

5-25-11
Replacement of Main Relief Valve
CAUTION
AVOID INJURY
Be careful not to damage the seat of the removed main
relief valve.
CAUTION
AVOID INJURY
As the main relief valve is a very important part, related to
performance and safety, and hard to be set for the pressure
again, be sure to replace it with an assembly if needed, not
disassembling it.
CAUTION
AVOID INJURY
During assembly of a main relief valve, be careful so that a
foreign material cannot intrude into the main frame.
1. Removing Main Relief Valve

Fix the main body and remove the main relief valve by
unfastening the hexagon bolt with a spanner (3 0mm).
The spanner should hold the bolt as deeply as possible.
Figure 12
Figure 13

5-25-12
2. Assembling Main Relief Valve
Fasten the main relief valve to the main body at the
specified standard torque using a torque wrench (30mm).
Check if there is the O-ring on the contacting surface.
Figure 14
Replacement of Overload Relief Valve
CAUTION
AVOID INJURY
As the removed overload relief valves may have different
setting values for each position, identify them for the
original position with tags for accurate assembly.
CAUTION
AVOID INJURY
As the overload relief valve is a precision part, be cautious
about damage or intrusion of foreign materials.
CAUTION
AVOID INJURY
As the overload relief valve is a very important part, related
to performance and safety, and hard to be set for the
pressure again, be sure to replace it with an assembly if
needed, not disassembling it.
CAUTION
AVOID INJURY
During disassembly of a overload relief valve, be careful not
to damage the return cap by the spanner.

5-25-13
1. Removing Overload Relief Valve
Fix the main body and remove the overload relief valve by
unfastening the hexagon bolt with a spanner (22mm). The
spanner should hold the bolt as deeply as possible.
Figure 15
Figure 16
2. Assembling Overload Relief Valve

Fasten the overload relief valve to the main frame at the
specified standard torque using a torque wrench (22mm).
Check if there is the O-ring on the contacting surface.
Figure 17

5-25-14
Replacement of Sub-Block
CAUTION
AVOID INJURY
During assembly of the sub-block assembly, be careful so
that a foreign material cannot intrude into the main body.
1. Installation of Surface Plate

Install a surface plate on a workbench for replacement of
the sub block assembly.
Figure 18
2. Removing Sub-Block Assembly

Place the main frame on the surface plate, installed on the
workbench.
Remove the assembly by unfastening the four nuts, fixing
it, with a spanner or a hexagon wrench (13 mm).
Figure 19
3. Replacing Block Assembly

Replace the faulty assembly with a new one and assemble
the new one in order.
Figure 20

5-25-15
4. Assembling Nuts
Arrange the main frame and fasten the four nuts at the
specified standard torque with a torque wrench (13 mm).
Before completely fastening the nuts, check if each sub-
lock is properly arranged based on the surface plate.
Figure 21

5-25-16
1Lower Structure and
Chassis
Swing Bearing
Edition 1
DX210WA Swing Bearing

6-1-1
MEMO
Swing Bearing DX210WA

6-1-2
Table of Contents
Swing Bearing
General ...........................................................6-1-6
General Description................................................... 6-1-6
Parts List ................................................................... 6-1-6
Maintenance Guidelines .................................6-1-7
Disassembly ...................................................6-1-8
Reassembly ..................................................6-1-10

6-1-3
6-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

6-1-5
GENERAL
General Description
The swing bearing, which connects the upper structure with the
lower structure, consists of a inner ring, outer ring and ball
bearings. During swing movement, power from the swing motor
is transferred to the pinion by planetary gears connected to
gears on the inner ring, which is fixed in the undercarriage. Ball
bearings turn the outer ring.
Parts List
2 6
FG1301305
Figure 1
Reference Reference
Number Number
1 Outer Ring 5 Ball
2 Inner Ring 6 Retainer
3 Tapered Pin 7 Seal
4 Plug

6-1-6
MAINTENANCE GUIDELINES
Operating Recommendation
The service life of the swing bearing may be extended if a daily
effort is made to equalize usage over both ends of the
excavator. If the excavator is used in the same operating
configuration day in and day out (for example, with the travel
motors always under the counterweight, or with the attachment
over one side of the machine more than the other), the bearing's
service life could be reduced. Repositioning the excavator
during the work shift, to work the opposite end of the bearing,
will provide a more even and gradual rate of wear and extended
service life. EX1302041
Figure 2
Measuring Swing Bearing Axial Play

Regular checks of bearing displacement must be made at least
twice a year. Use a dial indicator. With the arm cylinders fully
retracted and the bucket cylinders fully extended, position the
arm tip pin height is flush with the boom foot pin height.
(Figure 3)
Push the attachment against the ground to lift up the excavator
above the ground and take measurements at 4 points, 90° apart, The height as the
boom foot pin height.
around the circumference of the bearing.
Record and keep all measurements. Play in the bearing should WE1400394
increase minimally from one inspection to the next. Figure 3 Measurement (h1)
Eventually, however, as the bearing begins to approach the limit

of its service life, clearance increases become much more
pronounced and the actual measured play in the bearing could
exceed twice the value that was measured when the machine
was new.
Measuring Bearing Lateral Play

When vertical checks are made, the side to side play in the
bearing can be checked by fully retracting the arm and bucket WE1400393
cylinders and extending the tip of the bucket as far forward as it Figure 4 Measurement (h2)
will go. With the excavator parked on a flat, level surface and the
bucket tip just off the ground, push against the bucket sideways
to take up all the lateral clearance in the bearing. (Less than 100
lb of force must be required to move the bucket over all the
way.) Check lateral play in both directions and record the values.
When the bearing is beginning to approach the end of its service
life, the measured lateral clearance should start to show
increase in value.

6-1-7
DISASSEMBLY
1. Remove tip of tapered pin (3, Figure 5) using grinder and
tap lightly to remove debris.
Figure 5
2. Remove plug (4, Figure 6) using a M10 x P 1.5 bolt.
Figure 6
3. Lift outer ring and check that inner ring can move freely.
See Figure 7, if not, replace seal (7, Figure 8).
• Weight: 280 kg (617 lb)
Figure 7
4. Turn inner ring and use magnet bar (C, Figure 8) to

remove steel balls (5).
Figure 8

6-1-8
5. Turn inner ring and use wire (D, Figure 9) to remove
retainers (6).
Figure 9

6-1-9
REASSEMBLY
1. Clean (degrease) the seal groove for the outer and inner
seals (7).
Apply instant glue to seal (7).
Install both seals respectively into position.
Figure 10
2. Hoist the outer race by crane horizontally and match it with

the inner race coaxially.
Rotating the outer race, insert balls (5), support (6) into the
plug (4) hole one by one with a round bar.
Figure 11
Figure 12
3. Top plug (4) into outer race (1) and then, drive pin (3) into
the pinhole.
Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.
Figure 13

6-1-10
Front Axle
Edition 1
DX210WA Front Axle

6-2-1
MEMO
Front Axle DX210WA

6-2-2
Table of Contents
Front Axle
General ...........................................................6-2-5
Specification .............................................................. 6-2-5
Parts List ................................................................... 6-2-6
Lubrication and Maintenance .........................6-2-7
Oil Change ........................................................... 6-2-7
Oil Change Interval............................................... 6-2-8
Oil Level Check .................................................... 6-2-8
Brake .................................................................... 6-2-8
Brake Wear Measurement..............................6-2-9
Lining Wear Measurement of Multi-disc Brake... 6-2-10
Disassembly .................................................6-2-11
Steering ................................................................... 6-2-11
Output...................................................................... 6-2-15
Planetary Carrier ................................................ 6-2-16
Brake/Hub .......................................................... 6-2-17
Knuckle Housing ................................................ 6-2-20
Differential - Input .................................................... 6-2-23
Differential .......................................................... 6-2-24
Input ................................................................... 6-2-26
Pivot Bearing ........................................................... 6-2-28
Reassembly ..................................................6-2-29
Differential - Input .................................................... 6-2-29
Determine Thickness of the Shim to Obtain a Correct
Contact Pattern .................................................. 6-2-29
Adjust Rolling Moment of Drive Pinion Bearing.. 6-2-31
Differential .......................................................... 6-2-33
Adjust Backlash of Bevel Gear Set and Bearing
Rolling Moment of Differential Bearing............... 6-2-36
Backlash and Contact Pattern Check................. 6-2-38
Input Flange ............................................................ 6-2-41
Output...................................................................... 6-2-42
DX210WA Front Axle

6-2-3
Preassemble Axle Housing ................................ 6-2-43
Knuckle Housing ................................................ 6-2-44
Hub..................................................................... 6-2-50
Multi-Disc Brake ................................................. 6-2-52
Planetary Carrier ................................................ 6-2-59
Pivot Bearing ........................................................... 6-2-61
Steering ................................................................... 6-2-62
Steering Setting and Checking........................... 6-2-68
Oil Drain Oil Filling................................................... 6-2-71
Front Axle DX210WA

6-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Type Fully Floating Planetary Drive
Overall Reduction Ratio 16 : 1
Differential Oil Volume 11 L (3 U.S. gal.)
Hub Oil Volume Per Each 2.5 L (0.6 U.S. gal.)
Circle Diameter 335 mm
Wheel Bolt
No. of Bolt/Thread 10 ea/M22 X 1.5
Type Wet Disc
Brake
Operating Pressure 80 bar (77 kg/cm2, 1,138 psi)
Travelling 16,200 kg (35,715 lb)
Axle Loading
Working 39,250 kg (86,531 lb)
Rated Pressure 170 bar (173 kg/cm2, 2466 psi)
Steering
Relief Pressure 225 bar (229 kg/cm2, 3263 psi)
DX210WA Front Axle

6-2-5
Parts List
270
510
90 30
80
540
10
275 391
130 630 280
502 501
40 392
393
396
160
214
210
200 230 320
232
390
120 130
135
205
239 238
256 258
Figure 1 WE1400361
Reference Reference
Number Number
10 Ring; Cassette 280 Disc; I.clutch A = 3.0
30 Bearing; Roller 280 Disc; I.clutch A = 2.5
40 Bearing; Roller 320 Washer; Thrust S = 1.5
80 Hub 320 Washer; Thrust S = 1.7
90 O-ring 320 Washer; Thrust S = 2.0
120 Carrier; Disk 320 Washer; Thrust S = 2.2
160 Ring; Gear 320 Washer; Thrust S = 2.7
200 Piston 320 Washer; Thrust S = 3.0
205 Pin; Cylindrical 390 Carrier Assembly; Planet
210 U-ring 390 Carrier Assembly; Planetary Gear
214 Ring; Support 391 Carrier; Planet
230 U-ring 392 Gear; Planet
232 Ring; Support 393 Bearing; Roller
238 Spring; Compression 396 Ring; Retaining
239 Spring; Compression 501 Plug; Screw
256 Screw 502 O-ring
258 Sleeve; Spring 510 Screw; Hex
270 Disc; O.clutch 630 Screw; Cap
275 Disc; I.clutch A = 2.5 540 Bolt, Wheel; M22 x 1.5 x 48
280 Disc; I.clutch A = 2.0
Front Axle DX210WA

6-2-6
LUBRICATION AND MAINTENANCE
Oil Change
A horizontal installation position of the axle in every direction is
precondition for an oil change according to specifications!
Place vehicle in a horizontal position!
Carefully clean all drain, filler and control plugs prior to opening!
Drain oil only right after a longer travel period!
4
5
1
2
WE1400329
Figure 2
Reference Reference
Number Number
Oil Drain Hole Oil Filler/Oil Check Hole
1 3
(M36 x 1.5 Axle Drive Housing) (M36 x 1.5 Axle Drive Housing)
Oil Drain/Oil Filler Hole 4 Brake Connection Pipe
2
(M36 x 1.5 Output Units) 5 Brake Breather Valve
1. Oil drain from axle

Loosen oil drain plugs (1) and drain oil from axle.
2. Oil drain from outputs
WARNING
To avoid injury when opening the oil drain and oil filler
plug (2), due to a possible pressure build-up in the oil
system of the planetary carrier, bring drain hole to
topmost position (12 o’clock) and carefully unscrew oil
drain and oil filler plug (2).
Then bring drain hole to lowermost position (6 o’clock)
and drain oil from outputs.
DX210WA Front Axle

6-2-7
3. Oil filling of axle
Provide drain plug (1, with magnetic) with a new O-ring and
mount it.
• Torque (M36 x 1.5): 50 N.m (5.1 kg.m, 36.9 ft lb)
Fill up oil to the overflow of the filler hole (3).
• Filling volume: approximately 11 L (3 U.S. gal)
4. Check
Check oil level after some minutes and fill-up to the
specified level, until level remains constant.
Provide filling and checking plugs (3) with new O-ring and
mount them.
5. Oil filling of outputs
Position both oil drain and oil filler hole (2) (reference line
horizontally to road level) and fill oil up to overflow.
Filling quantity per output: approximately 2.5 L (0.6 U.S. gal)
Provide drain and filler plug (2) with new O-ring and mount it.
Oil Change Interval

First oil change after 500 operating hours, any further one after
2000 (i.e. after 2500/4500/6500 ....) operating hours, however,
at least once per year.
Oil Level Check

Check oil level every month, in particular, however, after putting a
vehicle into operation with new or repaired axles or axle parts.
Brake
The following oils are admissible for the pneumo-hydraulic
operated or accumulator operated brake actuation
1. Motor oils SAE 10 W acc. to specification MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF. oils type A, Suffix A, Dexron von II D
Front Axle DX210WA

6-2-8
BRAKE WEAR MEASUREMENT
WARNING
The measurement of wear on the multi-disc brake only
gives limited information on the total state of the plate pack.
Without disassembling the output.
Make measurement of lining wear at least once per year, in

particular, however, in case of a different braking behaviour, like:
• Brake noises
• Reduced braking power
• Different deceleration
• Different brake oil level
• Different braking pressure
CAUTION
AVOID INJURY
To avoid injury when opening the oil drain/oil filler plug (1),
due to a possible pressure build-up in the planetary carrier
bring drain hole to topmost position (12 o’clock) and
carefully unscrew oil drain and filler plug (1).
DX210WA Front Axle

6-2-9
Then turn output until oil filler/oil drain hole (1) is on 9 o’clock
position (Figure 3).
Sketches in Figure 4, Figure 5 are shown turned by 90° Legend
to Figure 3, Figure 4 and Figure 5
1
Reference
Description
Number
1 Oil Filler/Oil Drain Hole
Gauge Hole (ø = 10 mm) in Ring Gear - Oil Stand
2
9 o’clock Position
3 Dial Indicator with Solenoid Support 2
4 Planetary Carrier
5 Ring Gear
6 Piston
7 Plate Pack FG006855
Figure 3
X Piston Stroke
4 5 6 7
FG002281
Figure 4
Lining Wear Measurement of Multi-disc Brake
With unapplied brake, piston is in contact with ring gear by
compression spring return. See Figure 4.
• Get dial indicator (3) into touch with piston (6) through oil
filler/oil drain hole (1) and gauge hole (2).
• Apply pressure on brake and determine piston stroke (X,
see Figure 5) by means of dial indicator.
X
• Take limit value of piston stroke (at max. wear) from the
chart below. FG002282
Figure 5
Lined Piston Stroke with New Limit Value of Piston

Discs Discs Stroke (X) at Max. Wear
7 pcs. 1.2 ... 1.8 mm 6.5 mm
Make lining wear measurement on both outputs!

Then provide oil drain/filler plug with new O-ring and install it.
Front Axle DX210WA

6-2-10
DISASSEMBLY
Total view - axle installed on assembly truck.
WARNING
Secure axle by means of a support (arrow).
Figure 6
Steering
1. View - Steering installed in axle.
Figure 7
2. Loosen hex nuts on both tie rods.
Figure 8
WARNING
Drive out tie rod from bevel seat.
Use suitable mandrel (brass/aluminium).
Figure 9
DX210WA Front Axle

6-2-11
3. Warm up threaded joint area of piston rod/axial joint.
Disassembly is more difficult (thread/axial joint is installed
with locking compound/Loctite no. 243).
Figure 10
4. Separate both tie rods (assembly) from piston rod.
CAUTION
AVOID INJURY
If work is just to be done on sealing elements and/or
piston rod or guide, no disassembly of the steering
cylinder assembly is required and you may continue
with Figure 11.
Figure 11
5. Disassemble both elbows (see arrows) or screw necks,

depending on version.
Figure 12
Front Axle DX210WA

6-2-12
6. Loosen threaded joint of steering/axle drive housing.
Figure 13
7. Steering cylinder is fixed with locking compound -

disassembly is more difficult!
Heat up both application areas of locking compound (see
arrows) of the axle drive housing by means of a hot-air
blower.
Figure 14
8. Drive out steering cylinder assembly from axle drive

housing by means of a plastic/aluminium hammer.
Figure 15
9. Unsnap the circlip and remove flange.
Figure 16
DX210WA Front Axle

6-2-13
10. Unsnap retaining ring.
Figure 17
11. Drive the guide into the cylinder tube (direction of arrow)
until the circlip can be removed. (See Figure 19)
Figure 18
12. Unsnap circlip.
Figure 19
13. Drive out piston rod together with guide from cylinder tube.
Figure 20
Front Axle DX210WA

6-2-14
14. Pull off guide from piston rod.
Remove all sealing elements from piston, guide and
cylinder.
Figure 21
Output
1. Loosen screw plug and drain oil from the axle.
CAUTION
AVOID INJURY
Use suitable collecting basin - environmental
protection!
Figure 22
WARNING
To avoid injury due to a possible pressure build-up in
the oil system of the planetary carrier, bring oil filler
and control plug to 12 o’clock position and carefully
unscrew! use suitable mandrel (brass/aluminium).
Then bring drain hole to 6 o’clock position and drain
the oil! Figure 23
CAUTION
AVOID INJURY
Use suitable collecting basin - environmental
protection!
DX210WA Front Axle

6-2-15
CAUTION
AVOID INJURY
Following illustration shows the complete
disassembly of the output (Figure 25 ~ Figure 28)
- if work is required on the differential and/or pinion,
you may disassemble the output as one unit. as shown
on the adjacent photo.
2. Please take the required work steps (such as dismantling

the tie rod-, bearing pins ecc. ...) from chapters
• “Steering” on page 6-2-11 and
• “Knuckle Housing” on page 6-2-20.
WARNING
Pay attention to seal ring in the axle housing - risk of Figure 24
damage!
Planetary Carrier
1. Loosen both cylinder screws and separate planetary
carrier from hub.
Figure 25
2. Unsnap circlip.
Figure 26
Front Axle DX210WA

6-2-16
3. Pull off planetary gear by means of a two-armed puller.
Figure 27
4. Unsnap circlip and remove washer.

Then remove roller bearing, second circlip and washer
from planetary gear.
Figure 28
Brake/Hub
1. Unsnap retaining ring and remove both thrust washers.
Figure 29
2. Remove slotted nut mount (cylinder screw).
Figure 30
DX210WA Front Axle

6-2-17
3. Loosen slotted nut.
Figure 31
4. Press off ring gear with piston.

Pay attention to the releasing O-ring (arrow).
Figure 32
5. Loosen hex. screws, remove spring sleeves and

compression springs.
Figure 33
6. Press off piston from ring gear.
Figure 34
Front Axle DX210WA

6-2-18
7. Remove sealing elements (arrows) from ring gear.
Figure 35
8. Remove plate pack.
Figure 36
9. Remove O-ring (arrow) and lift-off disc carrier with lever,

then remove releasing O-ring.
Figure 37
10. Pull hub from hub carrier by means of pressure piece and
two armed puller.
CAUTION
AVOID INJURY
Pay attention to the releasing bearing inner ring.
Figure 38
DX210WA Front Axle

6-2-19
11. Lift-off shaft seal (arrow) with lever and remove both
bearing outer rings from hub.
Figure 39
12. Pull bearing inner ring from hub.
Figure 40
Knuckle Housing 7
1. Legend to the sketch.
Reference
Description
Number
1 Bearing Pin 6
3
2 Knuckle Housing
2 5
3 Axle Housing
4 Shim (Only on Lower Bearing Pin) 4
1
FG002333
5 O-ring
Figure 41
6 Sealing Cap
7 Taper Roller Bearing
2. Loosen threaded connection and remove upper bearing

pin.
WARNING
Remove lower bearing pin - by means of lifting device/
see Figure 42 - not before securing the knuckle
housing.
Figure 42
Front Axle DX210WA

6-2-20
3. Secure knuckle housing by means of lifting device and
dismantle lower bearing pin.
CAUTION
AVOID INJURY
Pay attention to releasing shim.
Figure 43
4. Remove bearing inner ring (7), O-ring (5), sealing cap (6)
and brake connection screw neck (8) from bearing pin (1).
Figure 44
5. Separate knuckle housing with double u-joint shaft from

axle housing.
WARNING
Pay attention to seal ring in the axle housing - risk of
damage.
Figure 45
6. Pull out double u-joint shaft from knuckle housing.
WARNING
damage.
Figure 46
DX210WA Front Axle

6-2-21
7. Pull out seal ring and afterwards the bushing behind from
the knuckle housing.
Figure 47
8. Pull out seal ring and afterwards the bushing behind from
the axle housing.
Figure 48
9. Pull out both bearing outer rings from the swivel bearing
holes.
Figure 49
Front Axle DX210WA

6-2-22
Differential - Input
If work is required on the differential and/or pinion, you may
disassemble the output(s) as one unit. as shown on the adjacent
photo.
Please take the required work steps (such as dismantling the tie
rod - bearing pins ecc. ...) from chapters.
• “Steering” on page 6-2-11 and
• “Knuckle Housing” on page 6-2-20 1/10.
Figure 50
WARNING
Pay attention to the seal ring in the axle housing - risk
of damage.
1. Fix axle housing part/II by means of a lifting strap, loosen

threaded joint of axle housing half on crown wheel side
(differential) and separate axle housing half part/II from
axle drive housing.
WARNING
Pay attention to the releasing differential.
Figure 51
2. Remove bearing outer ring (arrow1) and the shim behind

as well as O-ring (arrow 2) from axle housing part/II.
CAUTION
AVOID INJURY
Mark shim (regarding position/bearing allocation) -
assembly aid.
Figure 52
3. Lift off the differential from the axle drive housing.
Figure 53
DX210WA Front Axle

6-2-23
4. Pull out bearing outer ring and the shim behind from the
bearing hole of axle housing part/I.
CAUTION
AVOID INJURY
Mark shim (regarding position/bearing allocation) -
assembly aid.
Figure 54
Differential
1. Pull both taper roller bearings from differential carrier.
Figure 55
2. Loosen threaded joint (position "X").
CAUTION
AVOID INJURY
Screws are installed with locking compound (Loctite) -
disassembly is more difficult - if required, warm up
area of threaded joint (disassembly aid).
Figure 56
FG002350
Figure 57
Front Axle DX210WA

6-2-24
3. Separate differential carrier halves and remove releasing
single components.
Figure 58
4. Press off crown wheel from differential carrier half.
Figure 59
DX210WA Front Axle

6-2-25
Input 10
1
1. Legend to Figure 60.
Reference
Description
Number
1 Input Pinion 9
2 Hex. Nut 7
3 Washer 8
4 Input Flange 6 5
5 Screen Sheet 3 4
6 Seal Ring
2
7 Taper Roller Bearing
FG002353
8 Spacer Ring (Bearing Rolling Moment) Figure 60
9 Shim (Contact Pattern)
10 Input Housing
2. Loosen hex. nut and remove washer behind.
WARNING
Pay attention to support of axle housing (arrow).
Figure 61
3. Remove flange.
If required. remove screen sheet from output flange.
Figure 62
Front Axle DX210WA

6-2-26
4. Lift-off seal ring with lever.
Figure 63
5. Drive out input pinion.
CAUTION
AVOID INJURY
If taper roller bearings should not be replaced, pay
attention that the outside bearing inner ring - with all
its rolls - is in contact with bearing outer ring when
driving out the input pinion.
Figure 64
6. Remove spacer ring.
Figure 65
7. Press off bearing inner ring from input pinion.
Figure 66
DX210WA Front Axle

6-2-27
8. Extract outside bearing outer ring.
Figure 67
9. Drive out bearing outer ring from the inner bearing hole -
pay attention to the shim behind.
CAUTION
AVOID INJURY
Mark shim (reg. position/bearing allocation) - assembly
aid.
Figure 68
Pivot Bearing
If required:
Provide bushings with a separating slot - see arrow - (bushings
are destroyed by this).
Then remove bushings from holes.
Figure 69
Front Axle DX210WA

6-2-28
REASSEMBLY
Differential - Input
Reference
Description
Number
1 Drive Pinion
2 Differential (with Crown Wheel)
3 Shim for Contact Pattern (Bevel Gear Set)
Spacer Ring
4
(Bearing Rolling Moment/Pinion Bearing)
5 Shim For Backlash
Shim
6
(Bearing Rolling Moment/Differential Bearing)
7 Input Flange
Figure 70
8 Seal Ring
9 Axle Drive Housing
10 Axle Housing/Part I (10a = O-ring)
11 Axle Housing/Part II (Crown Wheel Side)
Just for "New part" assembly or if disassembled:

Install O-ring (10a) on axle housing/part I (10) and mount axle
drive housing (9) - observe installation position.
• Torque: 390 N.m (39.8 kg.m, 287.6 ft lb) (M 18/10.9)
Determine Thickness of the Shim to Obtain a Correct

Contact Pattern
1. Read dimension I from the axle drive housing.
• Dimension I e.g. = 154.05 mm
154.05
WE1400298
Figure 71
2. Read dimension II (pinion dimension).

• Dimension II e.g. = 116.00 mm
In case of a + or - deviation of the pinion dimension 116
for production reasons the relevant value is marked by
hand on the pinion.
Pinion dimension (without + or - deviation) = 116.0 mm
Pinion dimension with an indicated + 0.1 deviation = 116.1 mm
Pinion dimension with an indicated - 0.1 deviation = 115.9 mm
WE1400299
Figure 72
DX210WA Front Axle

6-2-29
3. Determine dimension III (bearing width).
CAUTION
AVOID INJURY
Make sure that the rollers are located without any play
(rotate bearing g inner ring several times in both
directions roller setting)!
WE1400300
Since the installed roller bearing is subject to a pre-load in Figure 73
installation position, consider an experience deduction of -
0.1 mm !
• Dimension III, e.g. 36.60 mm - 0.1 mm = 36.50 mm
Calculation Example A:
Dimension II 116.00 mm
Dimension III + 36.50 mm
Result dim. X = 152.50 mm
Calculation Example B:
Dimension I 154.05 mm
Dimension X - 152.50 mm
Difference = shim s = 1.55 mm
4. Insert the determined shim (e.g. s = 1.55 mm) into the
inner bearing hole.
WE1400301
Figure 74
Front Axle DX210WA

6-2-30
5. Super-cool bearing outer ring (see arrow) and bring it into
contact position in the inner bearing hole/pinion bearing by
means of the fixture.
Figure 75
6. Instal outside bearing outer ring/pinion bearing.
Figure 76
7. Mount heated bearing inner ring until contact is obtained

and readjust after cooling-down.
Figure 77
Adjust Rolling Moment of Drive Pinion Bearing

1. Mount spacer ring (s = optional).
CAUTION
AVOID INJURY
We would reconunend to re-install the spacer ring
found during disassembly. If, however, the required
rolling moment of 1.0 ~ 2.0 N.m (0.1 ~ 0.2 kg.m,
0.7 ~ 1.4 ft lb) (without seal ring) is not achieved - see Figure 78
bearing rolling moment test - correct the bearing
rolling moment by means of a corresponding spacer
ring.
DX210WA Front Axle

6-2-31
2. Insert the preassembled drive pinion, mount the heated
bearing inner ring until contact is obtained.
Figure 79
3. Mount flange, fix with washer and hex. nut.

Figure 80
4. Check rolling torque of pinion bearing.

Bearing rolling moment (without seal ring) 1.0 ~ 3.0 N.m
(0.1 ~ 0.3 kg.m, 0.7 ~ 2.2 ft lb).
Try to achieve upper value.
CAUTION
AVOID INJURY
If the rolling moment differs from the required value, Figure 81
correct it with a suitable spacer ring (See Figure 14 on
page -13).
CAUTION
AVOID INJURY
Reassemble seal ring - as shown in page -41 ~ 74 (after
completed differential assembly and positive contact
pattern check).
Front Axle DX210WA

6-2-32
Differential
1. Mount slotted pins (arrows) into differential carrier half,
considering the assembly specification, see Figure 82.
Figure 82
2. Assembly Specification:
Bring slotted pin(s) in a position where slot shows into the
direction of force (arrow).
In case of double slotted pins - bring the slots in a 180
degrees offset position to each other.
To sketch:
Reference
Description
Number
1 Differential Carrier Figure 83
2 Slotted Pin
Slotted Pin
3
(Just for Double Slotted Pin Version)
X Direction of Force
3. Press differential carrier until contact is obtained.

Assembly aid - insert two adjusting screws into crown
wheel.
• Torque: 145 N.m (14.8 kg.m, 106.9 ft lb)
Figure 84
4. Insert thrust washer and axle bevel gear.
CAUTION
AVOID INJURY
Put driving lugs of thrust washer into driving holes/
differential carrier - do not locate in oil supply
recesses.
Figure 85
DX210WA Front Axle

6-2-33
5. Install differential bevel gears and thrust washers on
differential spider and insert in differential carrier half I.
CAUTION
AVOID INJURY
Ensure radial installation position of thrust washers.
Lug is looking vertically upward (see arrow).
Figure 86
6. Insert second axle bevel gear.
Figure 87
7. Stick thrust washer with grease (assembly aid) into

differential carrier half II.
Locate differential carrier half II on differential carrier half I.
CAUTION
AVOID INJURY
differential carrier - do not locate in oil supply
recesses. Figure 88
8. Fasten differential carrier halves with cylinderical screws.

CAUTION
AVOID INJURY
Ensure radial installation position - designation at the
same time corresponds to radial position marking.
Figure 89
Front Axle DX210WA

6-2-34
CAUTION
AVOID INJURY
Insert hex screws with locking agent Loctite-no.262.
Figure 90
Press on both bearing inner rings until contact is obtained.
Figure 91
9. Wet some tooth flanks of the crown wheel with marking ink
(for contact pattern check - See Figure 102 on page -39).
Figure 92
DX210WA Front Axle

6-2-35
Adjust Backlash of Bevel Gear Set and Bearing Rolling
Moment of Differential Bearing
Backlash (crown wheel drive pinion) = 0.15 ~ 0.27 mm
Differential bearing preload = 0.10 ~ 0.15 mm

(corresponds to a bearing rolling moment of 1 ~ 4 N.m (0.1 ~ 0.4 kg.m,
0.7 ~ 2.9 ft lb)
CAUTION
AVOID INJURY
Bring axle drive housing/axle housing into upright position.
1. Insert shim (backlash) into hole of axle housing/part I and

install bearing outer ring until contact is obtained.
We would recommend to install the shim (experience value
= approximately 1.25 mm) found during disassembly - also
refer to disassembly instructions, See Figure 108 on page -
41.
CAUTION
AVOID INJURY Figure 93
However, the required backlash is decisive for the
shim(s) be used.
2. Insert preassembled differential.
Figure 94
Front Axle DX210WA

6-2-36
3. Place bearing outer ring.
CAUTION
AVOID INJURY
Locate the bearing outer ring on the bearing inner ring,
until all rollers are located without any play.
For this purpose rotate differential and bearing outer
ring both directions several times - roller setting.
Figure 95
CAUTION
AVOID INJURY
A correct positioning of bearing outer ring and differential
imperative for the following measuring operation.
4. Determine dimension "I", from mounting face of axle drive

housing to bearing contact.
• Dimension "I" e.g = 18.10 mm
CAUTION
AVOID INJURY
Make measurement on several points and calculate
mean value.
Figure 96
5. Determine dimension "II", from mounting face of axle

housing part II to contact face/bearing outer ring.
• Dimension "II" e.g. = 17.20 mm
Calculation Example:
• Dimension "I" e.g. =18.10 mm
• Dimension "II" e.g. =- 17.20 mm
• Difference = 0.90 mm
• Requ. bearing preload (0.10 ~ 0.15 mm): + 0.13 mm
• Result = 1.03 mm
• Reouired shim "S" →= 1.05 mm
Figure 97
DX210WA Front Axle

6-2-37
6. Insert determined shim(s) e.g. "S" = 1.05 mm into bearing
hole of axle housing/part II and instal bearing outer ring so
that contact is obtained.
CAUTION
AVOID INJURY
Instal (stick) bearing outer ring into hole with grease -
assembly aid.
Figure 98
7. Locate preassembled axle housing/part II (without O-ring)

(observe radial installation position) and temporarily fix
with hex. screws.
Figure 99
Backlash and Contact Pattern Check

1. Place dial indicator at right angles to a tooth flank of the
crown wheel (within the outer diameter area) through oil
drain hole and check backlash.
Backlash = 0.15 ~ 0.27 mm
CAUTION
AVOID INJURY
Figure 100
In case of a deviation from the specified backlash,
correct it with a suitable shim (Figure 100).
CAUTION
AVOID INJURY
A correction of shim/backlash also requires a
correction of shim/bearing rolling moment to the
opposite direction (Figure 98).
Front Axle DX210WA

6-2-38
2. Rotate drive pinion in both directions several times over
crown wheel/differential (contact pattern impression - in this
connection see Figure 102).
Figure 101
3. Remove differential.
Compare contact pattern (see arrow) with contact pattern
examples on page -7 ~ 9).
CAUTION
AVOID INJURY
If the contact pattern differs considerably, an error
was made when measuring the shim (See Figure 93 on
page -36), which needs to be corrected by all means. Figure 102
4. Oil O-ring and mount on collar (arrow) of axle housing half/

part II.
Figure 103
5. Reinstall differential.
Figure 104
DX210WA Front Axle

6-2-39
6. Instal preassembled axle housing half (observe radial
installation position), fix with hex. screws and washers.
• Torque (M18/10.9): 390 N.m (39.7 kg.m, 287.6 ft lb)
Figure 105
WARNING
Bring axle into horizontal position and secure with a
support (arrow).
Figure 106
7. Disassemble flange.
Figure 107
Front Axle DX210WA

6-2-40
Input Flange
Reference
Description
Number
1 Drive Pinion
2 Hex. Nut
3 Washer
4 Input Flange
5 Screen
6 Seal Ring
7 Bevel Roller Bearing
8 Spacer Ring
9 Input Housing
X Installation Dimension →13.5+0.2 mm
Figure 108
1. Place seal ring (6), considering the required installation

position (dimension "X") - see Figure 108.
Contact face (outer diameter) of seal ring:
- Wet it with spirit (assembly aid) if rubber-coated
- Apply sealing agent (Loctite no. 574) if made of metal
Apply grease on seal and dust lip of the seal ring.
CAUTION
Figure 109
AVOID INJURY
Ensure plane installation position of seal ring - use
suitable driver.
2. Press screen/thrust plate (5) on the input flange until

contact is obtained - also see Figure 108.
CAUTION
AVOID INJURY
Screen/thrust plate must not be deformed when
mounted - use suitable driver.
Figure 110
DX210WA Front Axle

6-2-41
3. Install preassembled input flange (4 + 5) and washer (3),
fix with hex. nut (2).
WARNING
Secure hex. nut with locking agent (Loctite-no. 262).

Figure 111
Output
1. Comment on Figure 112
Reference
Description
Number
1 Axle Housing
2 Knuckle Housing
3 Hub
4 Multi-disc Brake
5 Planetary Carrier Figure 112
2. Mount just for cpl. output - Figure 113

Locate the cpl. output on the axle - by installing the u-joint
shaft in the differential toothing.
WARNING
damage.
Figure 113
Other required work steps (bearing pin and tie rod
assembly) can be taken in extracts from the complete
assembly (“Knuckle Housing” on page 6-2-44 ~ 53 and
“Steering” on page 6-2-62).
Front Axle DX210WA

6-2-42
Preassemble Axle Housing
1. Legend on Figure 114 ~ Figure 118.
Reference
Description
Number
1 Axle Housing
2 Bushing (Observe Installation Position)
3 Seal Ring (Observe Installation Position)
4 Bearing Outer Rings (Pivot Bearing)
X Oil Chamber Side
Figure 114
Bushing - lubrication groove outlet installed in 6 o’clock
position (referred to the axle mounted in the vehicle).
2. Flush-mount bushing in the axle housing hole, considering
the installation position (see detailed sketch).
Figure 115
Detailed sketch - 90° offset:
Reference
Description
Number
1 Axle Housing
2 Bushing
Oil Chamber Side Observe Installation
X
Position of Bushing
Lubrication groove outlet in 6 o’clock position (referred to

axle mounted in vehicle).
Figure 116
3. Flush-mount seal ring (3, Figure 114) into axle housing

hole, with seal lip showing to oil chamber.
CAUTION
AVOID INJURY
- Apply sealing agent (Loctite no. 574) if made of Figure 117
metal
DX210WA Front Axle

6-2-43
CAUTION
AVOID INJURY
suitable driver.
4. Mount both bearing outer rings (4, Figure 114) into pivot
bearing holes of the axle housing.
Figure 118
WARNING
Carefully install u-joint shaft (Risk of damage - seal
ring).
Figure 119
Knuckle Housing
1. Just for assembly of a new knuckle housing (Figure 120):
Shut machining openings (3x - see arrows) of oil supply
holes with plugs.
Figure 120
Front Axle DX210WA

6-2-44
2. Legend to Figure 121 ... Figure 124.
Reference
Description
Number
1 Knuckle Housing
2 Bushing (Observe Installation Position)
3 Seal Ring (Observe Installation Position)
Installation Dimension (Seal Ring)
E
→4.00+ 0.3 mm
Installation position of bushing
Lubrication groove outlet in 6 o’clock Figure 121
X
position (referred to knuckle housing/axle
mounted in vehicle).
3. Flush-mount bushing into knuckle housing hole,

considering the installation position (Figure 121 and
detailed sketch).
Figure 122
Detailed sketch:
Reference
Description
Number
1 Knuckle housing
2 Bushing
Oil chamber side observe installation
position of bushing lubrication groove
X
outlet in 6 o’clock position (referred to
knuckle housing/axle mounted in vehicle).
Figure 123
4. Mount seal ring (3, Figure 121) into knuckle housing hole -
considering installation dimension "E" (Figure 121) and
installation position (seal lip showing to oil chamber).
Figure 124
DX210WA Front Axle

6-2-45
CAUTION
AVOID INJURY
- Apply sealing agent (Loctite no. 574) if made of
metal
CAUTION
AVOID INJURY
suitable driver.
CAUTION
AVOID INJURY
Locate preassembled knuckle housing on axle
housing, carefully mount u-joint shaft Seal ring - risk
of damage).
Figure 125
5. Legend to Figure 126 .... Figure 129.
Reference
Description
Number
1 Bearing Pin
2 Sealing Cap
3 O-ring
4 Bevel Roller Bearing
5 Shim (Just on Lower Bearing Pin)
6 Lubrication Nipple
Figure 126
7 Knuckle Housing
8 Axle Housing
X Area/Anti-corrosive Agent
Front Axle DX210WA

6-2-46
6. Mount sealing cap
Observe installation position (Figure 126).
Figure 127
7. Instal O-ring (arrow-1) and apply anti-corrosive agent on

bearing pin collar (arrow-2).
Mount bearing inner ring.
Figure 128
8. Just on lower bearing pin:

Instal shim for pivot bearing roller moment setting.
e.g. S = 0.80 mm (experience value) on lower bearing pin.
Figure 129
9. Install preassembled lower bearing pin and fix with hex.

screws.
CAUTION
AVOID INJURY
Observe installation position - mount bearing pin with
lubrication nipple showing to axle centre.
Figure 130
DX210WA Front Axle

6-2-47
10. Install O-ring.
Figure 131
11. Install preassembled upper bearing pin (Figure 127 and

Figure 128).
CAUTION
AVOID INJURY
Observe installation position - oil supply holes for
multi-disc brake.
Figure 132
12. Fix both bearing pins definitively.

Figure 133
13. Mount lubrication nipple (arrow-1) in both bearing pins and

provide pivot bearing with grease.
• Torque (M6 x 1): 6 N.m (0.6 kg.m, 4.4 ft lb)
Just on upper bearing pin:
Mount screw neck (arrow-2) with O-ring.
Mount breather valve (arrow-3) and apply dust cap.
• Torque (M14 x 1.5): 20 N.m (2 kg.m, 14.7 ft lb)
Figure 134
Front Axle DX210WA

6-2-48
14. Check rolling moment of pivot bearing.
For this purpose locate torque wrench on a hex. screw,
align at bearing pin center and determine bearing rolling
moment considering the following formula.
Bearing rolling moment
→50 ~ 60 N.m (5 ~ 6 kg.m, 36.8 ~ 44.2 ft lb)
CAUTION
Try to achieve the upper value of bearing roller moment.
In case of a deviation from the specified bearing
rolling moment, correct it with a suitable shim. (Figure
135)
Reference
Description
Number
Effective torque on the central swivel
TE
point (bearing pin center)
Distance - from torque wrench point of
L attach (hex. screw center) to grip center
(torque wrench) e.g. L = 300 mm (0.3 m) Figure 136
Distance - from torque wrench socket
(hex. screw center) to bearing pin center
A
(central swivel point) e.g. A = 60 mm
(0.06 m)
Value of the torque to be read from the
TS
scale
TS x (L + A)
TE =
L
TE x L
TS =
L+A
As a result the scale of the torque wrench must indicate a

value of 46 ~ 50 N.m (4.7 ~ 5 kg.m, 33.9 ~ 36.8 ft lb), which
corresponds to an effective bearing rolling moment of 50 ~
60 N.m (5 ~ 6 kg.m, 36.8 ~ 44.2 ft lb) in the swivel bearing.
DX210WA Front Axle

6-2-49
Hub
1. Install heated bearing inner ring until contact is obtained.
Figure 137
2. Mount wheel bolts (1).

Install both bearing outer rings (2) of hub bearing until
contact is obtained.
Oil O-ring (3) and locate in annular groove of hub.
Figure 138
3. Mount shaft seal, considering installation position (marking

out - side looking upward/outward) and installation
dimension "X" - see detailed sketch.
Legend to Figure 140 and detailed sketches.
Reference
Description
Number
1 Hub
2 Shaft Seal
X Installation Dimension
Figure 139
X = 6.0+0.2 mm
CAUTION
AVOID INJURY
Apply sealing agent (Loctite-Nr. 574) to contact face
shaft seal/hub.
CAUTION
Figure 140
AVOID INJURY
Wet contact face of shaft seal/hub carrier with spirit at
the very beginning of the assembly - assembly aid.
Front Axle DX210WA

6-2-50
4. Install preassembled hub until contact is obtained and fix
with heated outer bearing inner ring.
Figure 141
5. Oil a-rings and locate in annular groove (arrow) of knuckle

housing.
Then install disc carrier.
Figure 142
6. Bring hub bearing into contact position (Figure 143 ~

Figure 145):
Install ring gear (without sealing elements).
Figure 143
DX210WA Front Axle

6-2-51
7. Bring hub bearing into contact position - for this purpose
tighten slotted nut with a tightening torque of max.
1,400 N.m (142.7 kg.m, 1,032.6 ft lb)
CAUTION
AVOID INJURY
Apply lubricant (e.g. MOLYCOTE PASTE 1000) to
thread - knuckle housing/slotted nut.
Figure 144
CAUTION
AVOID INJURY
While tightening the slotted nut rotate hub in both
directions several times - roller setting.
8. Loosen slotted nut again and remove ring gear.
Figure 145
Multi-Disc Brake
1. Install disc pack alternately starting with an outer disc.
CAUTION
AVOID INJURY
Pay attention to installation position of inner discs -
Figure 147.
Figure 146
CAUTION
AVOID INJURY
Take the actually required disc fitting from the
corresponding spare parts list.
Front Axle DX210WA

6-2-52
2. Installation position of inner discs:
WARNING
Bring inner clutch discs in a position where one of the
tooth recesses (arrow) is in 6 o’clock position - with
axle being installed in the vehicle.
Figure 147
CAUTION
AVOID INJURY
Inner clutch discs s = 2.5 mm (Standard)
Install inner clutch discs with s = alternatively (2.0 -
2.5 - 3.0 mm) - required for disc clearance adjustment
- on the outside of the disc pack.
3. Oil O-ring and locate in annular groove of disc carrier.
CAUTION
AVOID INJURY
Stick O-ring by means of grease - assembly aid.
Figure 148
4. Oil sealing elements and locate in annular grooves

(arrows) of the ring gear - as shown in the detailed sketch.
CAUTION
AVOID INJURY
Pay attention to installation position and arrangement
of sealing elements.
Figure 149
DX210WA Front Axle

6-2-53
Legend to Figure 150 and detailed sketch.
Reference
Description
Number
1 Ring Gear
2 Support Ring
3 U-ring
4 U-ring
5 Support Ring
Figure 150
5. Just for "assembly of new parts" or if disassembled:

Mount cylindrical pins into piston, considering installation
dimension "X"
• X = 16.00 mm
Figure 151
6. Install piston on preassembled ring gear.
Figure 152
Legend to detail "A".

1
Reference
Description 2
Number
3
1 Hex. Screw
4
2 Spring Sleeve
3 Compression Springs (Outer)
4 Compression Springs (Inner)
Fix piston with spring sleeve (2), compression springs (3 WE1400307

and 4) and "new" hex screws (1). Figure 153
Front Axle DX210WA

6-2-54
CAUTION
AVOID INJURY
Use hex. screws just once for assembly.
• Torque (M 6/8.8): 11 N.m (1.1 kg.m, 8.1 ft lb)
Figure 154
7. Mount preassembled ring gear considering the installation

position (markings 0 in 12 o’clock position - see arrows,
detail "B").
CAUTION
AVOID INJURY
Ensure exact toothing position of oil supply holes -
knuckle housing/ring gear (pressure oil supply to
brake piston). Figure 155
Detail "B"
Figure 156
8. Oil O-ring and insert in recess (arrow).
CAUTION
AVOID INJURY
Apply lubricant (e.g. MOLYCOTE PASTE 1000) on
thread - knuckle housing/slotted nut.
Figure 157
DX210WA Front Axle

6-2-55
9. Fix ring gear with slotted nut.
CAUTION
AVOID INJURY
First tighten slotted nut with 1,400 N.m (142.7 kg.m,
1,032.5 ft lb) , then retighten slotted nut until a fixing
hole overlaps a threaded hole in the knuckle housing -
in this connection also refer to Figure 164.
Figure 158
CAUTION
AVOID INJURY
• Torque (M110 x 1.5):

1,400+200 N.m (142.7+20.3 kg.m, 1,032.5+147.5 ft lb)
Make Leakage Test of Multi-disc Brake

Mount breather valve (arrow) and connect HP pump (to
connection hole/bearing pin).
CAUTION
AVOID INJURY
Breathe brake completely before starting the test.
• Test media:
Figure 159
Motor oils SAE-lO W correspond to, MIL-L 2104 C, MIL-L
46152, API-CC, CD, SC, SD, SE, ATF-oils type A, Suffix A
Dexron of II D
• High-pressure test:
Build up test pressure p = 100 bar (101.9 kg/cm2, 1,469.5 psi)
and close locking valve of HP pump.
A pressure drop by max. 3 bar (3 kg/cm2, 43.5 psi) is
permissible during a 5-minute test duration.
• Low pressure test:
Reduce test pressure to p = 5 bar (5 kg/cm2, 72.5 psi) and
close locking valve.
No pressure drop is allowed during a 5-minute testing
duration.
Front Axle DX210WA

6-2-56
Adjust and Check Disc Clearance/Piston Stroke
Disc clearance/piston stroke "X" = 0.7 ~ 1.3 mm
Legend to Figure 161 and sketches Figure 162.
Reference
Description
Number
1 Ring Gear
2 Piston
3 Compress. Springs (Outer)
X Disc Clearance/Piston Stroke
Figure 160
CAUTION
AVOID INJURY
Build up braking pressure (100 bar (102 kg/cm2, 1,450.4 psi))

and find dimension "A", from face/ring gear (1) through
measuring hole (2) - See Figure 161 - to face/piston (3).
• Dimension "A" e.g. = 83.50 mm
Figure 161
Release pressure from brake - i.e. no pressure applied on brake,

piston is in contact with ring gear (reset piston through
compression springs) - and find dimension "B" from face/ring
gear (1) through measuring hole (2) - Figure 162 - to face/
piston(3).
• Dimension "B" e.g. = 82.10 mm
• Dimension "B" e.g. = - 82.10 mm
• Result →disc clearance = 1.40 mm Figure 162
CAUTION
AVOID INJURY
If the required disc clearance/piston stroke (X = 1.2 ~ 1.8 mm)
is not achieved, correct it with corresponding inner clutch
disc(s) - Figure 147.
DX210WA Front Axle

6-2-57
Dismantle HP pump.
Just for transport protection, install screw plug with O-ring in oil
supply hole.
• Torque (M14 x 1.5): 23 N.m (2.3 kg.m, 17 ft lb)
Figure 163
Secure slotted nut with cylinder screw - in this connection refer

to comment on Figure 158.
Figure 164
Install thrust washer.
CAUTION
AVOID INJURY
Observe installation position - ensure that both lugs of the
thrust washer are engaged each in a spare fixing hole of the
slotted nut.
Figure 165
Mount thrust washer (retaining ring fixing) - with shoulder

showing to retaining ring - then snap retaining ring.
Figure 166
Front Axle DX210WA

6-2-58
Planetary Carrier
Adjust axial play of sun gear shaft: 0.3 ~ 1.0 mm (Figure 167 ...
Figure 173)
1. Determine dimension I from mounting face of planetary
carrier to contact face of thrust washer.
• Dimension I, e.g. = 260.65 mm
Figure 167
2. Determine dimension II, from face (arrow) of sun gear to

mounting face of hub.
• Dimension II, e.g. = 255.70 mm
• Dimension II e.g. = - 255.70 mm
• Difference = 4.95 mm
• Required axial play (average) e.g. = - 0.65 mm
• Result: requir.thrust washer(s) e.g. s = 4.30 mm Figure 168
3. Insert thrust washer(s) (e.g. s = 4.30 mm) into planetary

carrier and press into contact position.
Figure 169
4. Preassemble planetary gear as shown in the figure beside.

Legend to Figure 170. 1
Reference 2
Description
Number 3
1 Planetary Gear
2 Roller Bearing
3 Retaining Ring
WE1400311
Figure 170
DX210WA Front Axle

6-2-59
5. Warm up bearing inner ring and install preassembled
planetary gear until contact is obtained.
CAUTION
AVOID INJURY
Mount planetary gear or bearing inner ring with large
radius looking to planetary carrier (downwards).
Figure 171
6. Fix planetary gear by means of retaining ring.
Figure 172
7. Install preassembled planetary carrier and fix with cylinder

screws.
Figure 173
8. Install screw plug with new O-ring.

• Torque (M36 x 1.5): 50 N.m (5 kg.m, 30.8 ft lb)
Figure 174
Front Axle DX210WA

6-2-60
Pivot Bearing
Heat pivot bearing hole by means of hot-air blower and insert
super-cooled bushing(s).
CAUTION
AVOID INJURY
Observe installation position for bushing version with slot,
insert bushings - with slot in 12 o’clock position. Figure 175
DX210WA Front Axle

6-2-61
Steering
Figure 176
Legend to Figure 176 .... Figure 190.
Reference Reference
Number Number
Steering Cylinder 7 Rod Wiper
1
(Cylinder Tube with Brake Head) 8 Dual Ring
2 Brake Head (Loose Part) 9 Circlip
3 Piston Rod 10 O-ring
4a O-ring 11 Retaining Ring
Piston Sealing
4b Form Seal Ring 12 Flange
5 Guide Ring 13 Circlip
6 U-ring 14 Wrench Socket (Piston Rod)
1. Mount U-ring (6) and wiper (7) in the steering cylinder (1).
CAUTION
AVOID INJURY
Observe installation position - in this connection see
detailed sketch.
Figure 177
Front Axle DX210WA

6-2-62
Detailed sketch:
Figure 178
2. Position inner installer (S1) on piston rod (3), install O-ring

(4b) and press with inner installer (S2) into annular groove
(arrow) of piston (3).
Figure 179
3. Install form seal ring (4a) and press with inner installer (S2)
into annular groove (arrow) of piston (3).
Figure 180
DX210WA Front Axle

6-2-63
4. Calibrate form seal ring (4a) by means of calibration bush
(S3).
Figure 181
5. Place both guide rings (5) into annular grooves of the

piston rod.
Figure 182
6. Insert preassembled piston rod in the preassembled

steering cylinder.
CAUTION
AVOID INJURY
Observe installation position - insert piston rod (3)
with wrench point of attach (14 - Figure 176) showing
in direction of arrow.
Figure 183
CAUTION
AVOID INJURY
Slightly oil all sealing elements before installing the
piston rod.
Front Axle DX210WA

6-2-64
7. Insert u-ring (6), rod wiper (7) and dual ring (8) in brake
head (2).
Observe installation position - in this connection refer to
detailed sketch.
Figure 184
Detailed Sketch:
Figure 185
8. Install preassembled brake head.
CAUTION
AVOID INJURY
Slightly oil all sealing elements before inserting the
brake head.
Figure 186
9. Push brake head into the steering cylinder (arrow) so that

the circlip (9) can be mounted.
Figure 187
DX210WA Front Axle

6-2-65
10. Bring the inserted brake head (8) into contact position
(arrow) on the snapped circlip (9).
Oil O-ring (10) and insert into recess.
Figure 188
11. Fix brake head (8) with retaining ring (11).
Figure 189
12. Install flange (12) and snap circlip (13).
CAUTION
AVOID INJURY
Observe installation position of flange - chamfer
(circlip contact arrow) to show towards circlip.
Figure 190
13. Provide both contact faces (steering cylinder/axle drive

housing) with sealing agent (Loctite-no. 574).
Figure 191
Front Axle DX210WA

6-2-66
14. Insert preassembled steering cylinder and fix with hex.
screws.
Fix hex screws with locking agent (Loctite-no. 243).
• Torque (M12/8.8): 79 N.m (8 kg.m, 58.2 ft lb)
Figure 192
15. If required - preassemble both tie rods.

Legend to Figure 193.
Reference
Description
Number
1 Axial Joint
2 Ball Joint with Tube
3 Clamp
16. Do not tighten the screw of the clamp before setting the
track. Figure 193
17. Provide connection - axial joint/piston rod (approximately 3
threads)- with locking agent (Loctite-no. 243).
CAUTION
AVOID INJURY
Observe installation position of tie rods - offset to
show towards knuckle housing/axle housing (see
arrow).
Figure 194
18. Fix both tie rods on steering.
19. Hang up tie rod and fix with "new" locking nut.
CAUTION
AVOID INJURY
Use locking nut just once for assembly.
• Torque (M27 x 1.5): 100 N.m (10.2 kg.m, 73.7 ft lb) + 200°
Figure 195
DX210WA Front Axle

6-2-67
Steering Setting and Checking
A2
5 5 Y
4 4
3 X
3
2 A1
1 1
WE1400465
Figure 196
Reference Reference
Number Number
1 Straightedge Stop Screw with Stop Washer
4
2 Measuring Device (Internal)
3 Nut 5 Stop Screw (Outer)
Front Axle DX210WA

6-2-68
Basic Track Setting
Bring piston rod to central position: Dimension "X" = 124 mm
Determine dimension: "X" (measured from face/steering cylinder
to face/axial joint).
Piston (rod) stop/l-h in cylinder "Dimension I" z.B. = 215 mm
Piston (rod) stop/r-h in cylinder "Dimension II" z.B. = 25 mm
Result = 190 mm ÷ 2
Dimension "X" z.B. = 95 mm
CAUTION
AVOID INJURY
During track setting, the axial position of the piston rod
must not be changed any more.
Mount straightedges (1) in horizontal and central axis position.

Fix measuring device (2) on input flange.
Loosen nut (3) and set length of tie rod (axial joint) until the
measuring device (2) indicates 0° (corresponds to a track setting
of "zero" mm).
CAUTION
AVOID INJURY
Make setting on both sides.
Check track setting (0°):

Determine dimension "A1".
Rotate both outputs by 180° - dimension "A2" must be equal to
"dimension A1".
Dimension "Y" = distance - wheel center to rim flange.
CAUTION
AVOID INJURY
For a toe-in and toe-out setting, which might be required,
stick to the vehicle manufacturer’s specification.
Afterwards fix both tie rods/axial joint again by means of a clamp (3).
• Torque (M 12 x 1.5): 75 N.m (7.6 kg.m, 55.3 ft lb)
DX210WA Front Axle

6-2-69
Steering Angle Setting
CAUTION
AVOID INJURY
Set steering angle - not before track setting is completed.
Set steering angle always on the curve inner output side.
5 5
4 4
3
3
2
1
WE1400466
Figure 197
Slew output until the required steering angle is achieved on the

measuring device (2, Figure 197)
(Measuring device must have parallel contact with the
straightedge (1, Figure 197)).
CAUTION
AVOID INJURY
Take the value of the steering angle "L" to be set (Figure
196) from the vehicle manufacturer’s specification.
Set inner stop through setting screw (4) with stop washer (s =
optional).
Fix outer stop through setting screw (5) with counter nut.
• Torque (MI8/10.9): 170 N.m (17.3 kg.m, 125.4 ft lb)
Make setting on both output sides.
Front Axle DX210WA

6-2-70
Check leakage of steering:
• Test pressure: 250 bar (254.9 kg/cm2, 3,625.9 psi)
Test medium: engine oil SAE 10W
Connect HP pump, Build up test pressure
• P = max. 250 bar (254.9 kg/cm2, 3,625.9 psi)
(bleed pressure chamber).
Close locking valve of HP pump.
A 5 bar pressure drop is permissible during a test duration of 20 sec.
Figure 198
An outer leakage is not permissible.
Make leakage test of steering in both steering directions.
Oil Drain Oil Filling

1. Mount oil drain plug with solenoid insert (1) - fitted with
"new" O-ring.
2. Mount oil filler and oil control plug (2) - fitted with "new" O-
ring.
• Torque (M 36 x 1.5): 50 N.m (5 kg.m, 36.9 ft lb)
Figure 199
3. Mount oil drain, oil filler and oil control plug with solenoid
insert (3) - fitted with "new" O-ring - in both outputs.
• Torque (M 36 x 1.5): 50 N.m (5 kg.m, 36.9 ft lb)
CAUTION
AVOID INJURY
Prior to putting the axle into operation fill it with oil in
accordance with the corresponding lubrication and
maintenance instructions. Figure 200
DX210WA Front Axle

6-2-71
Front Axle DX210WA
6-2-72
Rear Axle
Edition 1
DX210WA Rear Axle

6-3-1
MEMO
Rear Axle DX210WA

6-3-2
Table of Contents
Rear Axle
Safety Instructions.............................................6-3-5
General .............................................................6-3-5
Specification................................................................. 6-3-5
Parts List ...................................................................... 6-3-6
Lubrication and Maintenance............................6-3-7
Oil Change.............................................................. 6-3-7
Oil Change Interval................................................. 6-3-8
Oil Level Check....................................................... 6-3-8
Brake....................................................................... 6-3-8
Brake Wear Measurement................................6-3-9
Lining Wear Measurement of Multi - Disc Brake.. 6-3-10
Disassembly....................................................6-3-11
Output ........................................................................ 6-3-11
Brake.......................................................................... 6-3-13
Input - Transmission .................................................. 6-3-16
Differential .................................................................. 6-3-18
Reassembly ....................................................6-3-20
Hub Carrier/Hub......................................................... 6-3-20
Multi Disc Brake ......................................................... 6-3-23
Make Leakage Test of Multi-Disc Brake .............. 6-3-27
Adjust and Check Disc Clearance/Piston Stroke . 6-3-27
Planetary Carrier........................................................ 6-3-29
Differential/Input......................................................... 6-3-31
Determine Shim for Backlash (Crown Wheel/Drive
Pinion)................................................................... 6-3-34
Check Backlash and Contact Pattern .................. 6-3-38
Output ........................................................................ 6-3-40
DX210WA Rear Axle

6-3-3
Rear Axle DX210WA
6-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Type Fully Floating Planetary Drive
Overall Reduction Ratio 16 : 1
Oil Volume 14.5 L (3.8 U.S. gal.)
Differential Hub
Oil Volume Per Each 2.4 L (0.6 U.S. gal.)
Circle Diameter 335 mm
Wheel Bolt
No. of Bolt/Thread 10 ea/M22 X 1.5
Type Wet Disc
Brake
Operating Pressure 80 bar (77 kg/cm2, 1,138 psi)
Travelling 16,200 kg (35,715 lb)
Axle Loading
Working 39,250 kg (86,531 lb)
Weight 724 kg (1,596 lb)
DX210WA Rear Axle

6-3-5
Parts List
280
270
135
90 120
80 30
40 275
10
130 510
390-3
540 501
320
630 205
502
239 390-2 390-1
258 390-5
238
256 160 390
214
210
230
232
200 WE1400381
Figure 1
Reference Reference
Number Number
10 Ring; Cassette 280 Disc; I.clutch A = 2.0
30 Bearing; Roller 280 Disc; I.clutch A = 2.5
40 Bearing; Roller 320 Washer; Thrust S = 1.5
80 Hub 320 Washer; Thrust S = 1.7
120 Carrier; Disk 320 Washer; Thrust S = 2.2
160 Ring; Gear 320 Washer; Thrust S = 2.7
200 Piston 320 Washer; Thrust S = 3.0
205 Pin; Cylindrical 390 Carrier Assembly; Planet
210 U-ring 390 Carrier Assembly; Planetary Gear
214 Ring; Support 390-1 Carrier; Planet
230 U-ring 390-2 Gear; Planet
232 Ring; Support 390-3 Bearing; Roller
238 Spring; Compression 390-5 Ring; Retaining
239 Spring; Compression 501 Plug; Screw
256 Screw 502 O-ring
258 Sleeve; Spring 510 Screw; Hex
270 Disc; O.clutch 540 Bolt, Wheel; M22 x 1.5 x 48
275 Disc; I.clutch A = 2.5 630 Screw; Cap
280 Disc; I.clutch A = 3.0
Rear Axle DX210WA

6-3-6
LUBRICATION AND MAINTENANCE
Oil Change
A horizontal installation position of the axle in every direction is
precondition for an oil change according to specifications.
Place vehicle in a horizontal position.
Carefully clean all drain -, filler- and control plugs prior to opening.
Drain oil only right after a longer travel period.
2 WE1400382
Figure 2
Reference Reference
Number Number
Oil Drain Hole Oil Filler/Oil Check Hole
1 3
(M36 x 1.5 Axle Drive Housing) (M36 x 1.5 Axle Drive Housing)
Oil Drain/Oil Filler Hole 4 Brake Connection Pipe
2
(M36 x 1.5 Output Units) 5 Brake Breather Valve
1. Oil Drain from Axle

Loosen oil drain plugs (1) and drain oil from axle.
2. Oil Drain from Outputs
WARNING
plug (2), due to a possible pressure build-up in the oil
system of the planetary carrier, bring drain hole to
drain and oil filler plug (2).
Then bring drain hole to lowermost position (6 o’clock)
and drain oil from outputs.
DX210WA Rear Axle

6-3-7
3. Oil filling of axle
Provide drain plug (1, with magnetic) with a new O-ring and
mount it.
Fill up oil to the overflow of the filler hole (3).
Filling quantity approximately 14.50 L (3.8 U.S. gal)
4. Check
Check oil level after some minutes and fill-up to the
specified level, until level remains constant.
Provide filling and checking plugs (3) with new O-ring and
mount it.
5. Oil Filling of outputs
Position both oil drain and oil filler hole (2) (reference line
horizontally to road level) and fill up oil to overflow.
Filling quantity approximately 2.4 L (0.6 U.S. gal) per
output.
Provide drain and filling plug (2) with new O-ring and
mount it.
Oil Change Interval

First oil change after 500 operating hours, any further one after
2000 (i.e. after 2500/4500/6500 ....) operating hours, however,
at least once per year.
Oil Level Check

Check oil level every month, in particular, however, after putting
a vehicle into operation with new or repaired axles or axle parts.
Brake
The following oils are admissible for the pneum. hydraulic
operated or accumulator operated brake actuation:
1. Motor oils SAE 10 W acc. to specification MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF. oils type A, Suffix A, Dexron of II D
Rear Axle DX210WA

6-3-8
BRAKE WEAR MEASUREMENT
WARNING
The measurement of wear on the multi-disc brake only
gives limited information on the total state of the plate pack
- without disassembly of output.
Make measurement of lining wear at least once per year, in

particular, however, in case of modified braking behaviour, like:
• Brake noises
• Reduced braking power
• Modified deceleration
• Modified brake oil level
• Modified braking pressure
CAUTION
AVOID INJURY
To avoid injury when opening the oil drain/oil filler plug (1),
due to a possible pressure build-up in the planetary carrier
bring drain hole to topmost position (12 o’clock) and
carefully unscrew oil drain and oil filler plug (1).
Then turn output until oil filler/oil drain hole (1) is on 9 o’clock
position - Figure 3.
Oil Stand
FG006855
Figure 3
DX210WA Rear Axle

6-3-9
Sketches in Figure 4, Figure 5 are shown turned by 90° Legend
to Figure 3, Figure 4 and Figure 5. 3
Reference
Description
Number
1 Oil Filler - Oil Drain Hole
2 Gauge Hole (ø = 10 mm) in Ring Gear - 9
o’clock Position 4 5 6 7
3 Dial Indicator With Solenoid Support
4 Planetary Carrier
FG002281
5 Ring Gear Figure 4
6 Piston
7 Plate Pack
X Piston Stroke
Lining Wear Measurement of Multi - Disc Brake

With unapplied brake, piston is in contact with ring gear by
compression spring return - Figure 4
• Get dial indicator (3) into touch with piston (6) through oil
filler/oil drain hole (1) and gauge hole (2).
• Apply pressure on brake and determine piston stroke (X,
Figure 5) by means of dial indicator.
X
• Take limit value of piston stroke (at max. wear) from the
chart below. FG002282
Figure 5
Lined Piston Stroke with New Limit Value of Piston
Discs Discs Stroke (X) at Max. Wear
7Stk. 0.7 ... 1.3 mm 6.5 mm
Make lining wear measurement on both outputs!

Then provide oil drain/filler plug with new O-ring and install it.
Rear Axle DX210WA

6-3-10
DISASSEMBLY
Output
1. Mount the axle to the assembly truck.
Figure 6
2. Loosen oil drain plug and drain oil from the axle - use
suitable collecting basin.
Figure 7
WARNING
plug, due to a possible pressure build-up in the oil
system of the planetary carrier - bring drain hole to
drain and oil filler plug.
Then bring drain hole to lowermost position (6 o’clock) Figure 8
and drain oil from outputs - use suitable collecting
basin! Then bring drain hole to 6 o’clock position and
drain the oil.
DX210WA Rear Axle

6-3-11
CAUTION
AVOID INJURY
When working on the differential/input, you can
disassemble the output as a cpl. unit (Figure 9) and no
complete disassembly is required as illustrated in
Figure 10 ~ Figure 13.
For this purpose secure output assembly by means of

lifting bracket, loosen threaded connections and separate
output assembly from axle housing.
Figure 9
3. Secure planetary carrier by means of lifting strap, loosen

both cylinder screws (arrows) and separate planetary
carrier from hub.
Figure 10
4. Unsnap retaining ring.
Figure 11
5. Pull off planetary gear by means of two-armed puller.
Figure 12
Rear Axle DX210WA

6-3-12
6. Unsnap the retaining rings and pull out of the planetary
gear.
1
2
3
WE1400311
Figure 13
Brake
1. Remove slotted nut mount (cylinder screw).
Figure 14
2. Loosen slotted nut.
Figure 15
3. Remove sun gear shaft and stub shaft.
Figure 16
DX210WA Rear Axle

6-3-13
4. Press off ring gear with piston.
CAUTION
AVOID INJURY
Pay attention to the releasing O-ring (arrow).
Figure 17
5. Loosen hex screws, remove spring sleeves and

compression springs.
Figure 18
6. Press piston from ring gear.
Figure 19
7. Remove sealing elements (arrows) from ring gear.
Figure 20
Rear Axle DX210WA

6-3-14
8. Remove plate pack.
Figure 21
9. Remove O-ring (arrow) and lift-off disc carrier with lever,

then remove releasing O-ring.
Figure 22
10. Secure hub by means of lifting bracket, pull hub from hub
carrier by means of pressure piece and two-armed puller.
CAUTION
AVOID INJURY
Pay attention to the releasing bearing inner ring.
Figure 23
11. Lift-off shaft seal (arrow) with lever and remove both
bearing outer rings from hub.
Figure 24
DX210WA Rear Axle

6-3-15
12. Pull bearing inner ring from hub.
Figure 25
13. Fix hub carrier by means of a strap, loosen threaded

connection and separate hub carrier from axle housing.
Then remove single components such as screw neck,
breather valve and O-ring from hub carrier.
Figure 26
Input - Transmission
1. Fix transmission by means of a lifting strap and loosen
threaded connection. (Transmission/axle drive housing).
Figure 27
2. Separate transmission from axle.
CAUTION
AVOID INJURY
For assembly and disassembly of the transmission
stick to section.
Figure 28
Rear Axle DX210WA

6-3-16
3. Loosen threaded connection of axle housing half on crown
wheel side.
Figure 29
CAUTION
AVOID INJURY
Secure axle by means of a support (arrow).
4. Carefully separate axle housing half.
CAUTION
Figure 30
AVOID INJURY
Pay attention to releasing differential.
5. Lift off differential assembly from axle drive housing.
Figure 31
6. Pull bearing outer ring out of hole by means of a striker and

remove shim behind (backlash).
CAUTION
AVOID INJURY
Mark shim (installation position/bearing allocation) -
assembly aid.
Figure 32
DX210WA Rear Axle

6-3-17
7. Remove bearing outer ring and shim behind (rolling torque
differential bearing) from second axle housing half.
CAUTION
AVOID INJURY
Mark shim (installation position/bearing allocation) -
assembly aid!
Figure 33
Differential
1. Pull both taper roller bearings from differential carrier.
Figure 34
2. Loosen threaded connection (see position "X").
Figure 35
CAUTION
AVOID INJURY
Screw connection are insert with Loctite - difficult
disassembly - heating-up if necessary.
Figure 36
Rear Axle DX210WA

6-3-18
3. Separate differential carrier halves and remove releasing
single components.
Figure 37
4. Push crown wheel off from differential carrier half.
Figure 38
DX210WA Rear Axle

6-3-19
REASSEMBLY
Reference
Description
Number
1 Axle Housing
2 Hub Carrier
3 Hub
4 Multi-disc Brake
5 Planetary Carrier
Figure 39
Hub Carrier/Hub
1. Oil O-ring (1) and install on hub carrier.
Only applicable for assembly of a new hub carrier.
Close machining apertures (2) of the oil supply holes with
blanking plug.
Figure 40
2. Install preassembled hub carrier to axle housing,

considering the installation position - stamped circle in 12
o’clock position (see arrow) - fix with hex screws and
washers.
Figure 41
3. Mount wheel bolts (1).

Insert both bearing outer rings (2) of the hub bearing until
contact.
Oil O-ring (3) and locate in annular groove of hub.
Figure 42
Rear Axle DX210WA

6-3-20
4. Mount shaft seal, considering installation position (marking
out-side looking upward/outward) and rim offset "X" - see
detailed sketch.
Figure 43
5. Legend to Figure 43 and detail sketch.
Reference
Description
Number
1 Hub
2 Shaft Seal
X Rim Offset
• X = 6.0+ 0.2 mm
Figure 44
CAUTION
AVOID INJURY
Apply sealing agent (Loctite-no. 574) to contact face of
shaft seal/hub.
CAUTION
AVOID INJURY
Wet contact face of shaft seal/hub carrier with spirit at
the very beginning of the assembly - assembly aid.
Figure 45
6. Install preassembled hub until contact and fix with heated
outer bearing inner ring.
DX210WA Rear Axle

6-3-21
7. Oil O-ring and locate in annular groove (arrow) of disc
carrier.
Then install disc carrier.
Figure 46
8. Bring hub bearing into contact position (Figure 47 ~ Figure

50): Install ring gear (without sealing elements).
Figure 47
9. Insert stub shaft and sun gear shaft

(support for slotted nut wrench - Figure 48).
Figure 48
10. Bring hub bearing into contact position. for this purpose
tighten slotted nut with a tightening torque of max.
1,400 N.m (142.7 kg.m, 1,032.5 ft lb).
CAUTION
AVOID INJURY
Apply thread - hub carrier/slotted nut - with lubricant.
Figure 49
Rear Axle DX210WA

6-3-22
CAUTION
AVOID INJURY
11. Loosen slotted nut again and remove ring gear.
Figure 50
Multi Disc Brake

1. Install disc pack alternately starting with an outer disc.
CAUTION
AVOID INJURY
Pay attention to installation position of inner discs -
Figure 52.
Figure 51
CAUTION
AVOID INJURY
Take the actual necessary plate arrangement from the
corresponding spare parts list.
2. Installation position of inner discs.
CAUTION
AVOID INJURY
Position inner discs in such a way that one of the tooth
recesses (arrow) is in 6 o’clock position - when axle is
installed in vehicle.
Figure 52
DX210WA Rear Axle

6-3-23
CAUTION
AVOID INJURY
Inner clutch discs s = 2.5 mm (standard)
Install inner discs with s = alternatively (2.0 - 2.5 - 3.0
mm) - required to set the disc clearance - on outside
position in disc pack.
3. Oil O-ring and locate in annular groove of disc carrier.
CAUTION
AVOID INJURY
Stick O-ring by means of grease - assembly aid.
Figure 53
4. Oil sealing elements and locate in annular grooves

(arrows) of ring gear as shown in the detailed sketch.
CAUTION
AVOID INJURY
Pay attention to installation position and arrangement
of sealing elements.
Figure 54
Legend to Figure 54 and detail.
Reference
Description
Number
1 Ring Gear
2 Support Ring
3 U-ring
4 U-ring
5 Support Ring
Figure 55
Rear Axle DX210WA

6-3-24
5. Just for. assembly of new parts. or if disassembled.
Mount all cylindrical pins into piston considering installation
dimension "X".
• X = 16.00 mm
Figure 56
6. Install piston on preassembled ring gear.
Figure 57
Detail "A"
1
Reference
Description 2
Number
3
1 Hex. Screw
4
2 Spring Sleeve
3 Compression Springs (Outer)
4 Compression Springs (Inner)
WE1400307
Figure 58
7. Fix piston with spring sleeve (2), compression springs (3

and 4) and new hex. screws (1).
CAUTION
AVOID INJURY
Use hex. screws just once for assembly.

Figure 59
DX210WA Rear Axle

6-3-25
8. Mount preassembled ring gear, considering installation
position (markings O in 12 o’clock position - see arrows,
Detail "B")
Figure 60
Detail "B"
Figure 61
9. Oil the O-ring and insert it in recess (arrow).
CAUTION
AVOID INJURY
Apply thread - hub carrier/slotted nut - with lubricant.
Figure 62
10. Fix ring gear with slotted nut.
CAUTION
AVOID INJURY
First tighten slotted nut with 1,400 N.m (142.7 kg.m,
1,032.6 ft lb), then retighten slotted nut until a fixing
hole overlaps a threaded hole in the hub carrier - in
this connection also refer to Figure 69.
Figure 63
Rear Axle DX210WA

6-3-26
CAUTION
AVOID INJURY
• Torque (M110 x 1.5):

1,400+ 200 N.m (142.7+20.4 kg.m, 1,032.6+147.5 ft lb)
Make Leakage Test of Multi-Disc Brake

1. Mount breather valve (arrow) and connect HP-pump (to
connection hole on input side/hub carrier).
Test Media
Motor oils SAE-10W correspond, MIL-L 2104 C, MIL-L
46152, API-CC, CD, SC, SD, SE, ATF-oils type A, Suffix A,
Dexron of II D
A. High-pressure test
Figure 64
Build up testing pressure p = 100 bar (101.9 kg/cm2,
1,450 psi) and close locking valve of HP-pump.
The pressure is allowed to fall by max. 3 bar (3 kg/cm2 ,
43.5 psi) during a 5-minute test duration.
B. Low-pressure test
Reduce testing pressure to p = 5 bar (5 kg/cm2,
72.5 psi) and close locking valve.
The pressure is not allowed to fall during a 5 minute
testing duration!
Adjust and Check Disc Clearance/Piston Stroke

1. Disc clearance/piston travel "X" = 1.2 ~ 1.8 mm
Legend to Figure 66 and Figure 67.
Reference
Description
Number
1 Ring Gear
2 Measuring Hole
3 Piston
X Disc Clearance/Piston Stroke Figure 65
DX210WA Rear Axle

6-3-27
Build up braking pressure (100 bar (101.9 kg/cm2, 1,450
psi)) and find dimension "A", from front face/ring gear (1)
through measuring hole (2) - Figure 66 - to front face/piston
(3).
• Dimension A. e.g. = 83.50 mm
Release pressure from brake - i.e. no pressure applied on
brake, piston is in contact with ring gear (reset piston
through compression springs) - and find dimension "B"
from front face/ring gear (1) through measuring hole (2) -
Figure 66
Figure 67 - to front face/piston (3).
• Dimension "B" z.B. = 82.10 mm
• Dimension "A" z.B. = 83.50 mm
• Dimension "B" z.B. = - 82.10 mm
• Result →disc clearance = 1.40 mm
CAUTION
AVOID INJURY
Figure 67
If the required disc clearance/piston stroke (X = 1.2 ....
1.8 mm) is not achieved, correct it with corresponding
inner clutch disc(s) - Figure 52!
2. Dismantle HP-pump abbauen and mount screw neck with

O-ring. (Just for transport protection - mount protection cap
with O-ring on screw neck).
• Torque (M 14 x 1.5): 23 N.m (2.3 kg.m, 16.9 ft lb)
Figure 68
3. Secure slotted nut with cylinder screw - in this connection

refer to note on Figure 63!
Figure 69
Rear Axle DX210WA

6-3-28
Planetary Carrier
Adjust axial play of sun gear shaft: 0.3 ~ 1.0 mm (Figure 70~
Figure 75)
1. Determine dimension I, from mounting face of planetary
carrier to contact face of thrust washer.
• Dimension I, e.g. = 260.65 mm
Figure 70
2. Determine dimension II, from front face (arrow) of sun gear

to mounting face of hub.
• Dimension II, e.g. = 255.70 mm
• Dimension II e.g. = - 255.70 mm
• Difference: 4.95 mm
• Required axial play (average) e.g. = - 0.75 mm
Figure 71
• Result = requ. thrust washer(s) e.g. : s = 4.20 mm
3. Insert thrust washer(s) (e.g. s = 4.20 mm) into planetary

carrier and press into contact position.
Figure 72
4. Preassemble planetary gear, as shown in the figure

beside.
1
2
Reference 3
Description
Number
1 Planetary Gear
2 Roller Bearing
3 Retaining Ring
WE1400311
Figure 73
DX210WA Rear Axle

6-3-29
5. Warm up bearing inner ring and install preassembled
planetary gear until contact.
CAUTION
AVOID INJURY
Mount planetary gear or bearing inner ring with large
radius looking to planetary carrier (downwards).
Figure 74
6. Fix planetary gear by means of retaining ring.
Figure 75
7. Install planetary carrier and fix with cylindrical screws.

Figure 76
Rear Axle DX210WA

6-3-30
Differential / Input
1. Mount slotted pins (arrows) - considering the assembly
specification, Figure 78 - into differential carrier half.
Figure 77
2. Assembly specifications
Position slotted pin(s) so that slot is looking into the
direction of force (arrow). In case of double slotted pins -
bring the slots in a 180° offset position to each other.
To Sketch:
Reference
Description
Number
1 Differential Carrier
2 Slotted Pin
Figure 78
Slotted Pin
3
(Just for Double Slotted Pin Version)
4 Force Direction
3. Insert two adjusting screws into crown wheel and press

differential carrier until contact.
Figure 79
DX210WA Rear Axle

6-3-31
4. Insert thrust washer and axle bevel gear.
CAUTION
AVOID INJURY
differential carrier - do not position in oil supply
recesses.
Figure 80
5. Instal differential bevel gears and thrust washers on

differential spider and insert in differential carrier half I.
CAUTION
AVOID INJURY
Ensure radial installation position of thrust washers.
Lug is looking vertically upward (see arrows).
Figure 81
6. Insert second axle bevel gear.
Figure 82
7. Stick thrust washer with grease (assembly aid) into

differential carrier half II.
WARNING
Put driving lug of thrust washer into driving bores/
differential carrier - do not position in oil supply
recesses.
Figure 83
Rear Axle DX210WA

6-3-32
8. Fasten differential carrier halves with cylinderical screws.
WARNING
Ensure radial installation position - designation
corresponds to radial position marking.
• Torque: M12 x 1.5 = 122 N.m (12.4 kg.m, 90 ft lb)

M16 x 1.5 = 300 N.m (30.6 kg.m, 221 ft lb) Figure 84
9. Install both bearing inner rings (arrows).

Press on both bearing inner rings until contact is obtained.
Figure 85
10. Wet some tooth flanks of the crown wheel with marking ink
(for contact pattern check - See Figure 99 on page -38).
Figure 86
DX210WA Rear Axle

6-3-33
Determine Shim for Backlash (Crown Wheel/Drive Pinion)
C
Legend to Figure 87 ~ Figure 96. X
D
Reference
Description
Number
1 Axle Drive Housing
2 Shim Ring (ø = 160 mm)
3 Differential (Crown Wheel)
4 Shim (Backlash)
5 Axle Housing Half
6 O-ring
7 Hexagon Screws (with Washer)
Mounting Face/Axle Drive Housing Until Shim
A WE1400365
Ring (Outer Diameter)
Figure 87
B ½ ø of Shim Ring
Mounting Face/Axle Drive Housing until Plane
C
Face/Crown Wheel
Distance - Plane Face/Crown Wheel Until
D
Centre/Differential (Imprinted on Crown Wheel)
Mounting Face/Axle Drive Housing Until
X
Centre/Axle Drive Housing (Drive Pinion Bore)
Only for "new part" assembly or if disassembled:

Install O-ring (6) and mount axle drive housing (1) - Pay
attention to installation position axle drive housing (1) versus
axle housing half (5).
1. Insert shim (backlash) into hole of axle housing half and
install bearing outer ring until contact.
We would recommend to install the shim (e.g. s =
1.20 mm), found during disassembly - also refer to
disassembly instructions Figure 32 on page -17.
WARNING
However, the required backlash is decisive for the
shim(s) to be used. Figure 88
Rear Axle DX210WA

6-3-34
2. Instal shim ring (arrow, ø = 160 mm) and determine
dimension "A" - Figure 87, then remove shim ring.
• Dimension "A" z.B. = 39.92 mm
• Dimension "B" = 80.00 mm
• Result: Dimension "X"= 119.92 mm
Figure 89
3. Install preassembled differential.
CAUTION
AVOID INJURY
Ensure that inserted differential is perfectly positioned
(for this purpose rotate in both directions several
times - roller setting).
Figure 90
4. Determine dimension "C" - take measurements at several

points and find out mean value.
CAUTION
AVOID INJURY
Upon determination of dimension "C" take a corrective
value of + 0.07 mm (½ value of bearing preload of
differential bearing) into consideration.
Figure 91
• Dimension "C" e.g. = 48.98 mm
• Corrective value = - 0.07 mm
5. Read dimension "D" (distance) from crown wheel, or measure
it in case of a + or - deviation of the distance due to production
(the concerned value is marked by hand on the crown wheel).
• Distance "D" (without a + or - deviation) = 71.0 mm
• Distance "D" with an indicated+ 0.1 deviation = 71.1 mm
• Distance "D" with an indicated- 0.1 deviation = 70.9 mm
DX210WA Rear Axle

6-3-35
• Dimension "X" z.B. = 119.92 mm
• Dimension "C"(48.91)+ "D"(71.00) = 119.91 mm
CAUTION
AVOID INJURY
If the value of dimension "X" is not achieved, use a
corresponding shim for correction (4, Figure 87).
CAUTION
AVOID INJURY
Position the bearing outer ring on the bearing inner
ring, until all rollers are located without any play.
For the following determination of dimension pay
attention to an exact contact of the bearing outer ring
and to a correct positioning of the differential.
Figure 92
6. Determine dimension "Y" - from mounting face/axle drive
housing to front face/bearing outer ring (take
measurements at several points and determine mean
value).
• Dimension "Y" e.g. = 18.11 mm
7. Determine dimension "Z" - from mounting face/axle
housing to bearing hole/bearing outer ring contact.
• Dimension "Z" e.g. = 17.25 mm
Calculation example:
• Dimension "Y" e.g. = 18.11 mm
• Dimension "Z" e.g. = - 17.25 mm
• Difference: 0.86 mm
• Bearing preload
(0.15 ^ 3.0 = 4.0 N.m (0.4 kg.m, 2.9 ft lb) + 0.15 mm)
• Required shim (s) = 1.00 mm
Figure 93
Rear Axle DX210WA

6-3-36
CAUTION
AVOID INJURY
A bearing preload of 0.15 mm corresponds to a
bearing rolling moment of approximately 3.0 ~ 4.0 N.m
(0.3 kg.m, 2.2 ft lb), when using new taper roller
bearings.
8. Insert the determined shim (e.g. s = 1.00 mm) into bearing

hole and instal bearing outer ring until contact.
Figure 94
9. Install preassembled axle housing half (pay attention to

radial installation position), fix with hex. screws and
washers.
Figure 95
WARNING
Bring axle into horizontal position and secure with
support.
10. Position transmission on the axle and fix it.

Figure 96
DX210WA Rear Axle

6-3-37
Check Backlash and Contact Pattern
1. Place dial indicator through oil drain hole at right angles to
a tooth flank of the crown wheel (in the outer diameter
area) and check backlash.
CAUTION
AVOID INJURY
Figure 97
If, in case of a deviation, the required backlash is not
achieved, correct it with a suitable shim (Figure 94).
A correction of the shim/backlash also requires a
correction to the opposite direction of shim/bearing
rolling moment (Figure 94).
2. Disassemble transmission again.
Figure 98
3. Remove differential.
Compare contact pattern (see arrow) with contact pattern
examples on page -7 ~ 9.
CAUTION
AVOID INJURY
If contact pattern differs considerably, check pinion
distance of transmission section.
Figure 99
Rear Axle DX210WA

6-3-38
4. Reinstall differential.
Figure 100
5. Oil O-ring and install on axle housing half (arrow).
Figure 101
6. Bring axle housing half into correct position (pay attention

to correct installation position), fix with hex screws and
washers.
Figure 102
DX210WA Rear Axle

6-3-39
Output
1. Install plug shaft into toothing of axle bevel gear.
Figure 103
2. Bring output assembly on axle housing into correct

position, by mounting the plug shaft into the sun gear shaft.
CAUTION
AVOID INJURY
Observe O-ring (arrow).
Figure 104
3. Fix output unit with hex screws and washers.

4. Mount the second drive in the same way.
WARNING
Prior to putting the axle into operation fill it with oil -
for this purpose stick to the lubrication and Figure 105
maintenance instructions, page -8 ~ 12.
In addition observe the vehicle manufacturer's
regulations and instructions.
Rear Axle DX210WA

6-3-40
1Center Joint
Edition 1
DX210WA Center Joint

6-4-1
MEMO
Center Joint DX210WA

6-4-2
Table of Contents
Center Joint
General ...........................................................6-4-5
Overview ................................................................... 6-4-6
Parts List ................................................................... 6-4-7
Removal .........................................................6-4-8
Installation ....................................................6-4-15
Completing Work ..........................................6-4-15
Disassembly .................................................6-4-16
Reassembly ..................................................6-4-19

6-4-3
MEMO

6-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
The center joint (swivel) is designed to allow hydraulic oil from
the upper structure to flow to components in the lower structure.
It is capable of allowing continuous 360° rotation of the upper
structure in relationship to the lower structure.

6-4-5
Overview
9 8 14
13
15 6 11
10
5 4 12
1 2
7 3
2
4
3
5
6
7
12
10
8
11
9
15
1
WE1400395
Figure 1
Port Name Size Port Name Size

1 Travel Motor Drain PF 1/2" 10, 11 Dozer PF 1/2"
2 Inching Travel PF 1/4" 12 Travel Motor Make-up PF 3/4"
3 Chocking PF 1/4" SAE 1"
13, 14 Travel
4, 5 Transmission PF 3/8" (6,000 psi)
6, 7 Brake PF 3/8" 15 Dozer/Outrigger Select PF 1/4"
8, 9 Steering PF 1/2"

6-4-6
Parts List
19 18 15 18
17
16
16
18
20 21
18 15
2 1
21
20
6 5
7 4
9
3
11
12
10
14
Figure 2 13
WE1400396
Reference Reference
Number Number
1 Spindle Assembly 11 Shim
2 Body 12 O-ring
3 Seal; Rotary 110 x 120 x 4.8 13 Bolt
4 O-ring 14 Washer; Spring
5 O-ring 15 Plug; PT
6 Shim 16 Plug; PT
7 Plate; Thrust 17 Plug; Hex. Socket
8 Ring; Retaining 18 Plug
9 O-ring 19 Plug
10 Cover * Seal Kit; Center Joint
*: 3, 4, 5, 9, 12

6-4-7
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

2. Lower front attachment (bucket) to ground. (Figure 3)
3. Stop engine.
WE1400399
Figure 3

6-4-8
(Figure 4)
WARNING LOCK
WARNING
If engine must be running while performing or maintenance

190-00695A
maintenance, always use extreme caution. Always ON OFF

have one person in the cabin at all times. Never leave Figure 4 EX1401660

O O
10. Turn key to "O" (OFF) position and remove from starter switch.
11. Attach a maintenance warning tag on controls.
In Non-Rops Cabin In Rops Cabin
WE1401161
Figure 5
12. Turn battery disconnect switch to "OFF" position. (Figure 6)

OFF
ON
Figure 6 EX1401760

3
5 8
1 2
7 6
4
Figure 7 EX1401809

6-4-9
WARNING
doing any work.
Pulling the air breather cap upward, the check valve EX1402442
(0.45 bar) opens, and the air is discharged to the Figure 8
atmosphere from the top of the hydraulic oil tank.
14. Remove bolts (1, Figure 9) (16 ea) from propeller shaft.
• Tool: 14 mm ( ) 2

15. Remove bolts and washers (2) (4 ea) with center 3
propeller shaft includes bracket (3).
• Tool: 19 mm ( )
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) 1 1
• Center shaft weight with bracket: about 42 kg (92.6 lb)

WE1400400
Figure 9 Bottom of Chassis Frame
16. Losen the center joint mounting nuts (Figure 10) (4 ea)
from chassis frame.
NOTE: Do not remove nuts completely to hold the
position of center joint.
• Tool: 19 mm ( )
WE1400401

6-4-10
17. Remove hoses and adapters (Figure 11) from center joint.
Disconnect the hoses from the bottom to top of center joint.
FRONT 2 REAR
5
4
6
3 7
12
10
8 14
9 11
15
1
13
WE1400402
Figure 11 Hub of Center Joint
• Hoses and plugs parts

Port Name
1 from Travel Motor "T2" (Drain) PF 1/2" 27 93.1 9.5 68.7
2 to Travel Motor "X1" PF 1/4" 19 39.2 4 28.9
3 to Chocking Valve "Pi" PF 1/4" 19 39.2 4 28.9
4 to Transmision (High) "B" PF 3/8" 22 49.0 5 36.2
to Transmision (Low) "K" PF 3/8" 22 49.0 5 36.2
5
to Travel Motor "X2" PF 1/4" 19 39.2 4 28.9
6 to Front Axle Hub PF 3/8" 22 49.0 5 36.2
7 to Rear Axle Hub PF 3/8" 22 49.0 5 36.2
8 to Steer Cylinder "Right" 11/16"-16UN-2B 22 38.2 3.9 28.2
9 to Steer Cylinder "Left" 11/16"-16UN-2B 22 38.2 3.9 28.2
10 to Solenoid Valve (RH/LH) "A" 13/16"-16UN-2B 24 55.9 5.7 41.2
to Dozer Cylinder "Rod" 13/16"-16UN-2B 24 55.9 5.7 41.2
11
to Outrigger Cylinder "Rod" 13/16"-16UN-2B 24 55.9 5.7 41.2
to Chocking Valve "Y" (Make-up) PF 1/4" 19 39.2 4 28.9
12
to Travel Motor "S" (Make-up) 1 7/16"-12UN-2B 41 169.5 17.3 125.1
13 to Travel Motor "B" SAE 1", D25 10 107.8 11 79.5
14 to Travel Motor "A" SAE 1", D25 10 107.8 11 79.5
15 from Solenoid Valve (RH/LH) PF 1/4" 19 39.2 4 28.9

6-4-11
• Fitting
Size Torque
Port Name
1 Elbow PF 1/2" PF 1/2" 27 93.1 9.5 68.7
2 Elbow PF 1/4" PF 1/4" 19 39.2 4 28.9
3 Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
4 Elbow PF 3/8" PF 3/8" 22 49.0 5 36.2
5 Tee PF 3/8" PF 3/8", PF 1/4" 22 49.0 5 36.2
6, 7 Adapter PF 3/8" PF 3/8" 22 49.0 5 36.2
8, 9 Adapter PF 1/2" UNF 11/16-16 27 93.1 9.5 68.7
10 Adapter PF 1/2" UNF 13/16-16 27 93.1 9.5 68.7
Adapter PF 1/2" UNF 13/16-16 27 93.1 9.5 68.7
11
Tee UNF 13/16-16 UNF 13/16-16 24 55.9 5.7 41.2
Tee PF 3/4" PF 1/4", UNF 1 7/16-12 32 176.4 18 130.1
12
Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
15 Elbow PF 1/4" PF 1/4" 19 39.2 4 28.9
1 O-ring 1B, P18 (S8000181)
2, 3 O-ring 1B, P11 (S8000111)
4, 5, 6, 7 O-ring 1B, P14 (S8000141)
8, 9 O-ring 1B, P18 (S8000181) 1B, F-06 (S8030061)
10, 11 O-ring 1B, P18 (S8000181) 1B, F-08 (S8030081)
12 O-ring 1B, P23 (S8000231) 1B, P11 / 1B, F-16
13, 14 O-ring ID: 32.92, W: 3.53, B1 (2180-1026D19)
15 O-ring 1B, P11 (S8000111)
18. Disconnect the harness connector (1, Figure 12).

19. Remove bolts (2, Figure 12) (2 ea) with plate (3).
• Tool: 24 mm ( ) 1
3
2
WE1400403
Figure 12

6-4-12
20. Remove hoses and adapters (Figure 13) from center joint.
Disconnect the hoses from the bottom to top of center joint.
FR RE
ON AR
T
12
1 6 11 9
8 10
15
3
2
13 14 7
4 5
WE1400404
Figure 13 Spindle of Center Joint
• Hoses and plugs parts

Port Name
1 Drain PF 1/2" 27 93.1 9.5 68.7
from Solenoid Valve "IC"
2 PF 1/4" 19 39.2 4 28.9
(for Lower)
from Solenoid Valve "CH"
3 PF 1/4" 19 39.2 4 28.9
(for Lower)
from Solenoid Valve "B"
4 PF 3/8" 22 49.0 5 36.2
(for TM)
5 from Solenoid Valve (for TM) "K" PF 3/8" 22 49.0 5 36.2
from Shuttle Valve "B1"
6 PF 3/8" 22 49.0 5 36.2
(Brake Pedal)
from Shuttle Valve "B2"
7 PF 3/8" 22 49.0 5 36.2
(Brake Pedal)
8 from Steering Valve "R" 13/16"-16UN-2B 24 55.9 5.7 41.2
9 from Steering Valve "L" 13/16"-16UN-2B 24 55.9 5.7 41.2
10 from Control Valve "Ad" 1 3/16"-12UN-2B 36 124.5 12.7 91.8
11 from Control Valve "Bd" 1 3/16"-12UN-2B 36 124.5 12.7 91.8
12 from Oil Cooler Pipe 1 3/16"-12UN-2B 41 169.5 17.3 125.1
13 from Control Valve "At" SAE 1", D25 10 107.8 11 79.5
14 from Control Valve "Bt" SAE 1", D25 10 107.8 11 79.5
15 to Oil Tank PF 1/4" 19 39.2 4 28.9
• Fitting

6-4-13
Size Torque
Port Name
1 Adapter PF 1/2" PF 1/2" 27 93.1 9.5 68.7
2 Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
3 Adapter PF 1/4" PF 1/4" 19 39.2 4 28.9
4 Elbow PF 3/8" PF 3/8" 22 49.0 5 36.2
5 Elbow PF 3/8" PF 3/8" 22 49.0 5 36.2
6, 7 Adapter PF 3/8" PF 3/8" 22 49.0 5 36.2
8, 9 Adapter PF 1/2" UNF 13/16-16 27 93.1 9.5 68.7
10, 11 Adapter PF 1/2" UNF 1 3/16-12 36 93.1 9.5 68.7
12 Adapter PF 3/4" UNF 1 7/16-12 41 176.4 18 130.1
15 Elbow PF 1/4" PF 1/4" 17 39.2 4 28.9
1 O-ring 1B, P18 (S8000181)
2, 3 O-ring 1B, P11 (S8000111)
4, 5, 6, 7 O-ring 1B, P14 (S8000141)
8, 9 O-ring 1B, P18 (S8000181) 1B, F-08 (S8030081)
10, 11 O-ring 1B, P18 (S8000181) 1B, F-12 (S8030121)
12 O-ring 1B, P23 (S8000231) 1B, F-16 (S8030161)
13, 14 O-ring ID: 32.92, W: 3.53, B1 (2180-1026D19)
15 O-ring 1B, P11 (S8000111)
21. Remove nuts (4 ea) from chassis frame (Figure 14).
WE1400405
Figure 14
22. Install the bolts (M12 x 1.75 DP 17, 2 ea) to center joint
(13, 14 port), and tie the rope to the bolts to lift it.
23. Remove center joint mounting bolts (1, Figure 15) (4 ea)
from chassis frame.
1
WE1400406
Figure 15

6-4-14
24. Remove center joint from the frame slowly and carefully.
• Center joint weight: about 86 kg (190 lb)
WE1400407
Figure 16
INSTALLATION
WARNING
SERIOUS INJURY

2. When installing the hoses, install the drain hose as first
action.
3. To prevent the water from penetrating, apply silicon on the
mounting part of center joint.
COMPLETING WORK
1. Start the engine and run at low idling for about 5 minutes.

6-4-15
DISASSEMBLY
Refer to the parts list of the swivel joint for component
references (Figure 2).
IMPORTANT
Do not unbolt the center joint from the lower car body until
an adequate number of piping block-off plates are available,
for disconnected piping lines. Be sure that system pressure
has been vented - including the hydraulic accumulator and
tank reserve pressure - before disassembly is started.
1. Remove the center Joint from the machine.

Move the swivel joint removed from the vehicle to the work
table using a crane.
Figure 17 WE1400397
2. Remove cover.
• Remove the bolts and washers using a spanner
(wrench) or air impact.
• Remove the cover.
– Tool: 17 mm ( )
– Torque: 63.7 N.m (6.5 kg.m, 47 ft lb)
FG003767
Figure 18

6-4-16
3. Disassembling the retainer ring.
Insert an appropriate jig into the retainer ring holes, widen
the ring and remove it.
FG003769
Figure 19
4. Remove shim-A, shim-B, and thrust plate.

1
Reference
Description 2 3
Number
1 Shim-A
2 Thrust Plate
3 Shim-B
FG003770
Figure 20
5. Disassembling the spindle and body.

1
Lay the center joint horizontally. Drive the spindle a little
way out using a plastic hammer.
Reference
Description
Number
1 Plastic Hammer
FG003771
Figure 21
6. Disassembling the spindle and body.

Place the jig on the spindle, disassemble the spindle using
a plastic hammer.
Reference
Description
Number
1 Plastic Hammer
2 Jig
Figure 22

6-4-17
7. Disassembling the O-ring and seals.
Remove the seal in the groove of the swivel joint body. Be
careful not to damage the O-ring and seal.
CAUTION
AVOID INJURY
O-rings and seals should be replaced whenever the
assembly is being overhauled or re-assemble.
Figure 23
8. Body, spindle, cover

Be sure to check for any defects such as scratches or
dents on the spindle, body, and seals.
CAUTION
AVOID INJURY
Be sure to check for any dent-like scratches in the
direction of operation.
WE1400398
Figure 24

6-4-18
REASSEMBLY
1. Prelubricate O-rings with hydraulic oil, white grease or
petroleum jelly.
CAUTION
AVOID INJURY
Apply a very light film of white grease or petroleum
jelly to the lower rim of the stem and inner surface of
the center swivel body. Apply slow, even-handed
pressure, using both hands, to slowly push the stem
into the body. Seals may be damaged if the stem is
pushed in too quickly.
2. Thoroughly clean all other component surfaces of dirt or

grease before reassembly.
3. Reverse disassembly steps for reassembly.
4. Clean threads of fasteners before preapplying Loctite #243
to the threads, and before torquing the thrust plate and
cover bolts.
5. Prefill the center swivel with clean hydraulic fluid before
reassembly of high-pressure and drain line piping. Clean
and prefill piping line ends to reduce the amount of air in
the system. Bleed air from the hydraulic system and verify
hydraulic tank fluid level before returning the excavator to
service.

6-4-19
6-4-20
1Travel Motor
Edition 1
DX210WA Travel Motor

6-5-1
MEMO
Travel Motor DX210WA

6-5-2
Table of Contents
Travel Motor
General ...........................................................6-5-5
Specification .............................................................. 6-5-6
Overview ................................................................... 6-5-7
Schematic.................................................................. 6-5-9
Control.................................................................. 6-5-9
Counter Balance Group...................................... 6-5-10
Parts List ................................................................. 6-5-11
Travel Motor ....................................................... 6-5-11
Counter Balance Valve....................................... 6-5-12
Torque Control ................................................... 6-5-14
Retarding Function ............................................. 6-5-19
Circuit Operation ..................................................... 6-5-20
During Forward (Reverse) High-speed (3rd Gear)
Driving (Vg min. (39.6 cc) - Vg max. (160 cc)) ... 6-5-20
Accelerator Pedal Released During Forward Driving at
High Speed (Vg Retarding: 85 cc)...................... 6-5-21
Accelerator Pedal Released During Reverse Driving at
High Speed (3rd Gear) (Vg min.: 39.6 cc).......... 6-5-23
During Forward (Reverse) Driving at Low Speed (2nd
Gear) (Vg min. (64 cc) - Vg max. (160 cc)) ........ 6-5-24
Accelerator Pedal Released During Forward (Reverse)
Driving at Low Speed (2nd Gear) (Vg ret1: 39.6 cc) . 6-
5-25
During Driving at Inching Speed (1st Gear) (Vg max.:
160 cc Maintained) ............................................. 6-5-26
Motor Pressure over 240 bar (245 kg/cm2, 3,481 psi)
(Vg max.: 160 cc Maintained)............................. 6-5-27
Driving Performance Curve of Travel Motor ............ 6-5-31
Beginning of Regualtion ..................................... 6-5-31
Switch Pressure ................................................. 6-5-31
Removal .......................................................6-5-32
Installation ....................................................6-5-36

6-5-3
Completing Work ..........................................6-5-36
Section View .................................................6-5-37
General Repair Guidelines ...........................6-5-38
Seal Kits and Sub-assemblies ......................6-5-39
Replace Seal Nut .................................................... 6-5-41
Disassembly .................................................6-5-42
Sealing the Drive Shaft............................................ 6-5-42
Seal of the Control Parts ......................................... 6-5-43
Seal of the Relief Valve/Counter-balance Valve ..... 6-5-46
Counterbalance Valve ........................................ 6-5-48
Brake Release Valve (Pos.4) ............................. 6-5-49
Shuttle Valve (Pos.3).......................................... 6-5-49
Diassembly of the Port Plate ................................... 6-5-50
Remove of the Positioning Piston ........................... 6-5-51
Remove Rotary Group ............................................ 6-5-53
Exchanging of the Rotary Group ............................. 6-5-54
Inspection Notes...................................................... 6-5-55
Assembly ......................................................6-5-58
Rotary Group Assembly .......................................... 6-5-58
Rotary Group Adjustment........................................ 6-5-60
Assembly of the Port Plate ...................................... 6-5-62

6-5-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This travel motor is bent-axis piston motor, with the function to
control the traveling torque automatically which is corresponding
to the traveling resistance.
Also, it is equipped with the motion control valve as the
prevention against the over-speed.

6-5-5
Specification
Type Axial Piston Unite Bent Axis Design, Variable Displacement
Displacement (Vg max.) 160.0 cm3
Displacement (Vg min.) 39.6 cm3
Travel Displacement (min.) 64.0 cm3
Retarding Displacement (1st) 39.6 cm3
Retarding Displacement (2nd) 85.0 cm3 (Switching Pressure: 210 +30
- 0 bar)
Rated Pressure 400 bar (408 kg/cm2, 5,801.5 psi)

Travel Motor Peak Pressure 450 bar (459 kg/cm2, 6,526.7 psi)
Working Pressure 370 bar (377 kg/cm2, 5,366.0 psi)
3,100 rpm (Case drain pressure may not exceed absolute
Max. Speed at Vg max.
3 bar (3 kg/cm2, 43.5 psi).)
4,900 rpm (Case drain pressure may not exceed absolute
Max. Speed at Vg < 101 cm3
3 bar (3 kg/cm2, 43.5 psi).)
Operating Speed (Rated) Max. 3,750 rpm (at Vg = 64 cm3)
Direction of Rotation Alternating (the View from Shaft End)
Moment of Inertia 2.53 kg.cm2
Switch Pressure (P Switch) 210 bar (214 kg/cm2, 3,046 psi)
Beginning of Regulator (P)
Hydraulic (Differential Pressure Between 240 bar (245 kg/cm2, 3,481 psi)
Vg min. and Vg max.: P<10 bar)
Cross Over Relief Valve (P) 360 bar (367 kg/cm2, 5,221 psi)
308 rpm (3.7 km/h)
1st Speed (Inching)
(X1: 30 bar over, Vg max.: Swivel Angle Max.)
2nd Speed (Low-speed) 766 rpm (9.2 km/h) (X1: 0 bar)
Speed
3rd Speed (High-speed) 3,116 rpm (37 km/h) (X1: 0 bar)
• Inching, 1 Speed Traveling - 1 Speed (Low) Solenoid Valve Operaton
• 2 Speed Traveling - 2 Speed (High) Solenoid Valve Operaton

6-5-6
Overview
Rotary Group Relief Valve, Counter Balance Valve

Torque Control (Motion Control Valve)
X1 (IC)
U T1 MB G ext
B (FWD)
T2
A (REV)
MA
M3
M2
X2
WE1400251
Figure 1

6-5-7
MA (MB)
M3 X2 M2
U
S
A T T
X2
X1
B
M3 M2 G
WE1400252
Figure 2
Port Name Size

A, B Main Ports SAE 1 1/4"
G Ports for Synchronous Control M14 x 1.5
X1 Inching Travel Pilot Pressure Port M14 x 1.5
T Drain Port M26 x 1.5
U Flushing Port M22 x 1.5
S Make Up Port M27 x 2.0
MA, MB Gauge Ports M18 x 1.5
M2 Gauge Port for Stroke Limitation M10 x 1.0
M3 Gauge Port for Control Pressure M10 x 1.0
X2 Port for Stroke Limiter M14 x 1.5

6-5-8
Schematic
Control
X1 (IC)
Torque Control
Counter Balance Valve

G
U T1 MB G ext
B (FWD)
Servo Piston
T2
A (REV)
MA
M3
M2
X2 Stroke Limiter Block
Stroke Limiter Block
Q min. Stopper
Servo Piston
Check Valve
Shuttle Valve
Q max. Stopper
Counter Balance Block
Torque Control Block
WE1400253
Figure 3

6-5-9
Counter Balance Group
Normally, counter balance valve is neutral position, if high-
pressure comes up for traveling, spool is switched (Return line
will be open). If machine goes to down hill road, the counter
balance valve will be neutral position.
X1 (IC)
U T1 MB G ext
T2
A
MA
M3
M2
X2
A B
Check Valve
Counter Balance Spool
Relief Valve
WE1400254
Figure 4

6-5-10
Parts List
Travel Motor
17 18 1 12
8 13
5 51
10
11
9
WE1400255
Figure 5
Reference Reference
Number Number
1 Rotary Group 11 Shim
2 Control Group 12 O-ring
5 Housing; Pump 13 Plug
8 Plug 17 Bolt; Stud
9 Ring; Retaining 18 Nut; Lock
10 Seal; Oil 51 Counter Balance Valve

6-5-11
1-11
20 1
24
1-11
27
25
22
24 30
11
23
28
2
27
21
6
26
23
10
29
WE1400256
Figure 6

6-5-12
Reference Reference
Number Number
1 Valve 22 Plug
11-1 O-ring 23 O-ring
2 Valve; Shuttle 24 O-ring
3 Valve; Brake 25 O-ring
6 Housing 26 Plug
10 Cover 27 Plug
11 Cover 28 Screw
20 Plug 29 Bolt; Socket
21 Bolt; Socket 30 Bolt; Socket

6-5-13
Theory of Operation
Torque Control
Torque Control Concept
WE1400257
Figure 7
Now machine is traveling on road

• Machine should be high speed.
• Traveling pressure (load) should be low.
• Travel motor torque should be low.
Machine is traveling on upward slope
• Machine should be low speed.
• Traveling pressure (load) should be high.
• Travel motor torque should be high.
When machine is traveling on upward slop, travel motor torque
should be changed to high torque (Max. displacement position)
automatically by traveling system pressure.

6-5-14
Adjustment Screw
Torque Control Spool
Small Chamber
Servo Piston
Maximum Displacement
(Low Speed, High Torque) Large Chamber
Minimum Displacement
(High Speed, Low Torque)
WE1400258
Figure 8
A B
PB
Max. Min.
(X)
G
Vg min. Vg max.
HA Curve
T (T1)
- Automatic Control
Regulating Valve Adjusting Cylinder - High-pressure Related
(Adjusting Piston)
- PB: Operating Pressure
with Setting Spring - Vg: Displacement (Motor Speed)
WE1400259
Figure 9
1. Provided that the pump flow and high-pressure remain constant, then
• Reducing displacement gives higher speed and lower torque
• Increasing displacement does higher torque and lower speed
2. The displacement is set "Automatically" dependent on operating pressure.

6-5-15
Torque Control (Given Pressure, HA Control)
Hydraulic pressure at each high-pressure side (A or B) is led into the small chamber of the servo piston through
the check valve, and this leads to switching of the motor swivel angle to the minimum displacement position.
Also, hydraulic pressure at each high-pressure side (A or B) is delivered to the primary chamber of the pilot piston
while oil in the secondary chamber is led to the large chamber of the servo piston.
Small Chamber
Large Chamber
U B X M1
A
Servo Piston
Q Min.
Q Max.
Spring
Tank Load Secondary Port
A G T
Primary Port
Adjustment Screw Pilot Piston

WE1400260
Figure 10

6-5-16
1. When the machine is driven on an uphill road, its driving resistance (motor pressure) rises. This increased
high-pressure oil compresses the spring to switch the pilot piston. As a result, the oil passages to the
primary and secondary ports become available and oil in the primary side is led into the large chamber of the
servo piston to change the motor's swivel angle to the maximum displacement position (Q max).
(As the motor's displacement increases, the torque is increased and the revolution speed is decreased.)
X1
G
PB
U T1 MB G ext
S
Max.
240 bar
T2
B
Vg min. Vg max.
MA
M3
M2 Increased Displacement
- High Torque, Low Speed
X2
WE1400261
Figure 11
X1 (IC)
U T1 MB G ext
Q Max.
S
Q Min.
A
T2
B
MA
M3
M2
X2
WE1400262
Figure 12

6-5-17
2. When the machine is driven on even ground, its driving resistance (motor pressure) is decreased.
Under this condition, as the force of the spring of the pilot piston is higher than the pressure on the primary
side, the pilot piston is not switched.
Therefore, oil in the large chamber of the servo piston is led to the tank line through the pilot piston to
change the motor's swivel angle to the minimum displacement position (Q min.). As a result, the motor's
displacement is decreased, resulting in decrease of the torque and increase of the revolution speed.
X1
G Set Pressure
PB
U T1 MB G ext
S
Min.
240 bar
T2
B
MA Vg min. Vg max.
M3
M2
Decreased Displacement
- High Speed, Low Torque
X2
WE1400263
Figure 13

6-5-18
Retarding Function
WE1400264
Figure 14
Machine is traveling on down hill road and the operator want to

stop machine. To stop the machine, operator releases
accelerator pedal and press brake pedal. As operator releases
accelerator pedal, machine speed is retarded by hydraulic
energy.
P P
Start Retarding
A B
A Traveling
Stop
B
Time
WE1400265
Figure 15
When the travel motor operates as a pump at putting on a brake

or down a hill, it causes braking pressure (counter pressure).
By using this braking pressure, the displacement will be a little
bit larger, which results in a better braking performance. We call
that retarding function.
Because there are some concerns that the cavitation occurs
when the variation of the displacement is large, it is necessary to
select the proper displacement with considering the conditions
and the feeling over the real machine.

6-5-19
Circuit Operation
During Forward (Reverse) High-speed (3rd Gear) Driving (Vg min. (39.6 cc) - Vg max. (160 cc))
• In running at port (B) pressurized (Figure 16), the pressure at port (MA) becomes a high-pressure at the brake.
• The stroke limiter piston is operated once by the forward driving pressure.
(Vg retarding (39.6 cc) →Vg min. (64 cc))
• The motor's swivel angle is changed by the pressure of the driving motor.
Transmission Torque Control
(High) (Low) X1 (IC)
P1 P2
G
U T1 240 bar MB G ext
B (FWD)
T2 A (REV)
J M
MA
M3
M2
210 bar
X2
- Min. Travel Displacement
Stroke Limiter Control
WE1400266
Figure 16

6-5-20
Accelerator Pedal Released During Forward Driving at High Speed (Vg Retarding: 85 cc)
When that pressure exceeds the setting pressure (210 bar (214 kg/cm2, 3,046 psi)) of the switching valve 1, the
switching valve 1 shifts and the high-pressure line connects with port (M2). This causes the control piston to move
toward the larger swivel angle and thus the displacement becomes a middle displacement. (Q min.)
In this case the pressure at port (X2) is unloaded.
Stopping pressure (reverse MA) over (210 bar (214 kg/cm2, 3,046 psi)) during abrupt stopping ((Vg min. (39.6 cc)
→Vg retarding (85 cc)) - Retarding function available
NOTE: Stopping pressure (reverse MA) under (210 bar (214 kg/cm2, 3,046 psi)) during stopping (Vg min.
(39.6 cc) constant)) - Retarding function unavailable
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
Switching Valve 1 M3
M2
X2 210 bar
- Min. Hold Displacement
Switching Valve 2
Figure 17 WE1400267

6-5-21
• Stroke limiter control
A. Accelerator pedal released abruptly during forward driving at high speed (3rd gear) (Vg min. (39.6 cc) -
Vg max. (160 cc)) The driving spool of the control valve and the counter balance spool of the driving
motor are rapidly returned to their neutral positions. As a result, oil delivery from the motor is blocked.
However, as the motor keeps rotating under the influence of inertia, it functions as a pump.
This action increases the pressure in the reverse driving side line (port MA).
When this pressure is over (210 bar (214 kg/cm2, 3,046 psi)), the stroke limiter piston is switched to
increase the motor's swivel angle, resulting in deceleration. (Vg min. (39.6 cc) →Vg ret2 (85 cc))
B. Accelerator pedal released abruptly during driving at low speed (2nd gear) (Vg min. (39.6 cc) - Vg max.
(160 cc)). As the stroke limiter piston cannot function due to the stopper, the motor's swivel angle is
decreased.
As a result, abrupt stopping of the motor by inertia is prevented. (Vg min. (64 cc) →Vg ret1 (39.6 cc))
X2
X2
M2
M3
from Shuttle Valve
Servo Piston Large Chamber
M3
M2
210 bar
X2
WE1400268
Figure 18

6-5-22
Accelerator Pedal Released During Reverse Driving at High Speed (3rd Gear) (Vg min.: 39.6 cc)
In case of abrupt stopping during reverse driving at a high speed (3rd gear) (Vg min. (39.6 cc) - Vg max. (160 cc)),
the stroke limiter piston is operated only once by the stopping pressure (MB).
• Retarding function not available (Vg min.: 39.6 cc maintained)
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
X2 210 bar
WE1400269
Figure 19

6-5-23
During Forward (Reverse) Driving at Low Speed (2nd Gear) (Vg min. (64 cc) - Vg max. (160 cc))
• The stroke limiter piston is operated only once by forwarding driving pressure.
(Vg ret1 (39.6 cc) →Vg min. (64 cc))
• The motor's swivel angle is changed according to the pressure of the driving motor.
(Below 210 bar (214 kg/cm2, 3,046 psi) - Vg min. (64 cc), over 210 bar (214 kg/cm2, 3,046 psi) (Vg max. (160 cc))
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
210 bar
X2
WE1400270
Figure 20

6-5-24
Accelerator Pedal Released During Forward (Reverse) Driving at Low Speed (2nd Gear) (Vg ret1: 39.6 cc)
By pressurizing port (X2), the switching valve 1 is kept off-state and the motor's displacement doesn't change.
switching valve 2 has the function to select the displacement in proportionth the transmission gear ratio (first gear
or second gear), by pressurizing (X2), the switching valve 2 becomes on-state and the minimum displacement at
first gear selected.
• The stroke limiter is not operated due to the low-speed transmission shift pressure (X2).
(Swivel angle decreased from Vg min. (64 cc) to Vg ret1 (39.6 cc))
– Retarding function available
As the swivel angle is decreased and maintained to the minimum level, abrupt stopping of the motor by
inertia is prevented during stopping. (The machine is stopped smoothly.)
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
Switching Valve 1 M3
M2
210 bar
X2
- Very Smallest Displacement
Switching Valve 2
Figure 21 WE1400275

6-5-25
During Driving at Inching Speed (1st Gear) (Vg max.: 160 cc Maintained)
• When the inching speed (1st gear) is selected, the inching solenoid valve is operated to supply oil in the pilot
pump to the port (X1) of the driving motor. As a result, the torque control piston is switched to change the
servo piston to the maximum swivel angle position, resulting in increase of hill-climbing performance
(maximum swivel angle maintained).
– Inching traveling: below 5km/h
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
210 bar
X2
PB
Port (X1 (IC)) Pressure: over 30 bar

(Current Supply at Inching Solenoid Valve)
Pilot Pressure: 40 bar
Vg min. Vg max.
WE1400276
Figure 22

6-5-26
Motor Pressure over 240 bar (245 kg/cm2, 3,481 psi) (Vg max.: 160 cc Maintained)
• When the pressure of the driving motor is over 240 bar (245 kg/cm2, 3,481 psi) (beginning of regulation)
during driving at a low or high speed (2nd or 3rd gear), the torque control piston is switched to change the
servo piston to the maximum swivel angle position in order to enhance the hill-climbing performance
(maximum swivel angle maintained).
Torque Control
Transmission
P1 P2
G
B (FWD)
T2 A (REV)
J M
MA
M3
M2
210 bar
X2
PB PB
Vg min. Vg max. Vg min. Vg max.
Motor Pressure: over 240 bar Motor Pressure: below 240 bar
WE1400277
Figure 23

6-5-27
Torque Control
1. Motor pressure: over 240 bar (245 kg/cm2, 3,481 psi)
Q min. Stopper
Servo Piston
Q max. Stopper

WE1400278
Figure 24

6-5-28
2. Motor pressure: below 240 bar (245 kg/cm2, 3,481 psi)
Q min. Stopper
Servo Piston
Q max. Stopper

WE1400279
Figure 25

6-5-29
Torque Control Adjustment Method
- Adjustment
- Setting Pressure: 240 bar
Adjustment Screw
WE1400280
Figure 26
Adjustment
1. Increase of torque
PB
Vg min. Vg max.
WE1400281
Figure 27

6-5-30
2. Decrease of torque
PB
240 bar
Vg min. Vg max.
WE1400282
Figure 28
Driving Performance Curve of Travel Motor

Beginning of Regualtion
P (bar)
• Setting pressure: 240 bar (245 kg/cm2, 3,481 psi)
NOTE: X1 indicates the pilot pressure (40 bar (41 kg/cm2,
580 psi)) for driving at inching speed (1st gear).
260
250
240
230
64 160 q (cc)
WE1400283
Figure 29
Switch Pressure
PMA (bar)
• Setting Pressure: 210 -+30
0 bar (214 kg/cm , 3,046 psi)
2
210
64 85 q (cc)
WE1400284
Figure 30

6-5-31
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

2. Lower front attachment (bucket) to ground. (Figure 31)
3. Stop engine.
WE1400214
Figure 31

6-5-32
(Figure 32)
WARNING
LOCK
WARNING

190-00695A

have one person in the cabin at all times. Never leave Figure 32 EX1401660

O O
WE1401161
Figure 33

OFF
(Figure 34)
ON
Figure 34 EX1401760

3
5 8
1 2
7 6
4
Figure 35 EX1401809

6-5-33
WARNING
doing any work.
Pulling the air breather cap upward, the check valve EX1402442
(0.45 bar) opens, and the air is discharged to the Figure 36
atmosphere from the top of the hydraulic oil tank.
14. Remove nuts (1, Figure 37) (16 ea) with rear propeller
shaft (2). 1 1
• Tool: 14 mm ( )
• Rear propeller shaft weight: about 17 kg (37.5 lb)
WE1400215
15. Remove hoses and adapters (Figure 38) from travel motor.
X2
for reassembling. X1
After disconnecting hoses, plug them to prevent
dirt or dust from entering.
A
travel motor.
T2
B S WE1400216
Figure 38
• Thread of hoses and plugs

Port Name
A from Center Joint "14" SAE 1 1/4", D30 12 176.4 18 130.1
B from Center Joint "13" SAE 1 1/4", D30 12 176.4 18 130.1
from Center Joint "12"
S 1 7/16"-12UN-2B 41 169.5 17.3 125.1
(make-up)
X1 from Center Joint "2" PF 1/4" 19 39.2 4 28.9
X2 from Center Joint "5" PF 1/4" 19 39.2 4 28.9
to Center Joint "1"
T2 PF 1/2" 27 93.1 9.5 68.7
(Drain)

6-5-34
• Fitting
Size Torque
Port Name
S Adapter M27 x 2.0 UNF 1 7/16-12 41 90.0 9 65.1
X1 Adapter M14 x 1.5 PF 1/4" 19 30.0 3 21.7
X2 Adapter PF 1/4 PF 1/4" 22 39.2 4 28.9
T2 Adapter M26 x 1.5 PF 1/2" 32 70.0 7 50.6
A, B O-ring ID: 37.69, W:3.53, 1B (2180-1026D23)
S O-ring 1B, F-16 (S8030161)
16. Support travel motor using like or similar picture.

• Travel motor weight: about 86 kg (37.5 lb)
NOTE: When support it, be careful do not to damage
the relief valve on travel motor.
WE1400217
Figure 39
17. Remove bolts (1, Figure 40) (4 ea), and separate travel
motor (2) from transmission (3).
• Tool: 14 mm ( )
3
1
2
WE1400218
Figure 40

6-5-35
18. Remove travel motor slowly and carefully.
• Travel motor weight: about 86 kg (37.5 lb)
WE1400219
Figure 41
INSTALLATION
WARNING
SERIOUS INJURY
NOTE: When mounting travel motor to transmission, intall O-

ring (Part No.: 1.180-00147) to travel motor first
(Figure 42).
Never reuse O-ring, replace it with a new one when
reassembling.
2. When installing the hoses, install the drain hose as first
action.
Figure 42 WE1400220
COMPLETING WORK
1. Start the engine and run at low idling for about 5 minutes.

6-5-36
SECTION VIEW
X2
U MB X1 M2 M3
G ext
MA G T
U
M2
M3
MB MA
G
X1
WE1400306
Figure 43

6-5-37
GENERAL REPAIR GUIDELINES
CAUTION
AVOID INJURY
Observe the following notices when carrying out repair
work at hydraulic aggregates.
HB7M3002
Figure 44
1. Close all ports of the hydraulic aggregates.
HB7M3003
Figure 45
2. Replace all seals.

Use only original Hydromatik spare parts.
HB7M3004
Figure 46
3. Check all seal and sliding surfaces for wear.
CAUTION
AVOID INJURY
Rework of sealing area f. ex. with abrasive paper can
damage surface.
HB7M3005
Figure 47

6-5-38
4. Fill up hydraulic aggregates with hydraulic oil before start-
up.
HB7M3006
Figure 48
SEAL KITS AND SUB-ASSEMBLIES

1. Seal Kit for Drive Shaft.
HB7M3007
Figure 49
2. External Seal Kit
HB7M3008
Figure 50

6-5-39
3. Housing
HB7M3009
Figure 51
4. Complete Rotary Group
HB7M3010
Figure 52
5. Port Plate with Control Piston
HB7M3011
Figure 53
6. Counter-balance Valve
HB7M3012
Figure 54

6-5-40
7. Relief Valve / Make up Check Valve
Figure 55
Replace Seal Nut

1. Replace seal nut.
First measure and record setting height.
HB7M3014
Figure 56
2. When tightening, counterhold setting screw, then check

setting height.
HB7M3015
Figure 57

6-5-41
DISASSEMBLY
Sealing the Drive Shaft
HB7M3016
Figure 58
1. Protecting the drive shaft.

Remove retaining ring and shim.
HB7M3017
Figure 59
2. Screw in sheet metal screw into the holes fitted with

rubber.
Pull out seal with pliers.
HB7M3018
Figure 60

6-5-42
3. Press in shaft seal and shim with bush to stop.
CAUTION
AVOID INJURY
Pay attention to pressing depth
CAUTION Figure 61
AVOID INJURY
Mark for pressing depth.
Assemble retaining ring.
Seal of the Control Parts
Figure 62 HB7M3020
4. Disassembly position:
Pos. 1
Remove cover pos. 1
Figure 63 FG007441

6-5-43
Reference 1
Description
Number 2
1 O-ring
2 Input Flow of Oil Control
3 Throttle Pin
CAUTION
3 HB7M3022
Installation position differs according to the control
components
Reference
Description 1
Number
5
1 Input Flow of Oil Control
2 High-pressure/Low-pressure 2 3
3 High-pressure/Low-pressure
4 Leakage Oil
5 Control Piston 4
HB7M3023
Figure 65
HB7M3024
Figure 66

6-5-44
5. Disassembly position: Remove cover pos. 2.
CAUTION
AVOID INJURY
X
Attention! Spring load.
Dimension x : Note dimension (begin of regulation).

Pos. 2
FG007442
Figure 67
Reference
Description
Number 1
1 Check of O-ring
HB7M3026
Figure 68
Reference
Description
Number 1
O-ring/High Pressure - Small Control 2
1
Piston Side
2 O-ring/Control Pressure 4
3 O-ring/High Pressure - Check Valve

3
4 O-ring/High Pressure - Check Valve
HB7M3027
Figure 69

6-5-45
Seal of the Relief Valve/Counter-balance Valve
1. Remove relief valve.
HB7M3028
Figure 70
2. Inspect!
O-ring
Figure 71
3. Remove counter-balance valve Inspect!

O-ring
HB7M3030
Figure 72

6-5-46
6-5-47
Counterbalance Valve
1-11
20 1
24
1-11
27
25
22
24 30
11
23
28
2
27
21
6
26
23
10
29
WE1400256
Figure 73

6-5-48
Reference Reference
Number Number
1 Valve 22 Plug
11-1 O-ring 23 O-ring
2 Valve; Shuttle 24 O-ring
3 Valve; Brake 25 O-ring
6 Housing 26 Plug
10 Cover 27 Plug
11 Cover 28 Screw
20 Plug 29 Bolt; Socket
21 Bolt; Socket 30 Bolt; Socket
Brake Release Valve (Pos.4)

1. These parts are not available separately.
Reference
Description
Number
1 Brake Piston
2 Valve Bushing
3 Throttle Pin
4 Valve Screw
5 Bolt
Figure 74
6 Spring Collar
11 Pressure Spring
Shuttle Valve (Pos.3)

25
1. These parts are not available separately. 11
Reference 12
Description
Number
10 Valve Screw
10
11 Valve Bush
12 Ball
HB7M3033
Figure 75

6-5-49
Diassembly of the Port Plate
1. Note dimension x.
Remove Q min.-screw.
Swivel rotary group to zero position.
CAUTION
AVOID INJURY
For disassembly of the port plate, swivel always rotary
group to zero position.
Piston rings to hang out of the cylinder boring.
Figure 76

6-5-50
2. Port plate
Mark position. Loosen screws.
Removal
HB7M3035
Figure 77
3. Check O-ring.
CAUTION
AVOID INJURY
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring. HB7M3036
Figure 78
Remove of the Positioning Piston
HB7M3037
Figure 79

6-5-51
1. Loosen fixing screw.
Use only socket wrench.
HB7M3038
Figure 80
2. Remove piston with piston ring
HB7M3039
Figure 81
3. Warm up fixation screw * for positioning plug

via boring (screw glued - to turn out).
CAUTION
AVOID INJURY
Use new screw.
Precote coating.
Note tightening torque!
Figure 82
CAUTION
AVOID INJURY
Stick control lens in sliding surface with grease.
Assembly in reversal order.
Mount port plate.
HB7M3041
CAUTION Figure 83
AVOID INJURY
Rotary group vertical.

6-5-52
Remove Rotary Group
HB7M3042
Figure 84
1. Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Size 28 : M4 x 58 mm
55 : M5 x 71 mm
80 : M6 x 82 mm
107 : M6 x 92 mm
140 : M8 x 105 mm
160 : M8 x 105 mm
200 : M8 x 109 mm
HB7M3043
Figure 85
2. Press out rotary group!
CAUTION
AVOID INJURY
If the bearings are used again do not hit on the drive
shaft.
HB7M3044
Figure 86
3. Complete rotary group

6-5-53
Exchanging of the Rotary Group
CAUTION
AVOID INJURY
Setting of hydraulic part necessary.
HB7M3010
Figure 87
1. Rotary group
A. Mechanical part: Adjust drive shaft with bearing.
B. Hydraulic part:
CAUTION
AVOID INJURY
Adjustment necessary.
FG003029
Figure 88

6-5-54
2. Remove fixing screw (cylinder).
Remove cylinder.
HB7M3047
Figure 89
3. Disassemble retaining plate.
CAUTION
AVOID INJURY
Screws are glued.
Use Torx-tools.
HB7M3048
Figure 90
Inspection Notes
1. Free of corrosion, erosion or fretting; no damage to splines
or keyways.
HB7M3049
Figure 91

6-5-55
2. Pistons
No scoring and no pittings.
HB7M3050
Figure 92
3. Center pin
No scoring and no pittings. 1 2
HB7M3051
Figure 93
4. Retaining plate
No scoring and no evidence of wear
HB7M3052
Figure 94
5. Cylinder block / control lens

A. Bores free of scoring, no evidence of wear.
1
B. Faces smooth and even, free of cracks and scoring.
2
1 2
HB7M3053
Figure 95

6-5-56
6. Control housing Sliding surface and side guides free of
scoring and no wear.
HB7M3054
Figure 96
7. Visual check:
Bearing areas free of scoring and no evidence of wear.
HB7M3055
Figure 97

6-5-57
ASSEMBLY
Rotary Group Assembly

1. Rotary group completely assembled ready for assembly.
Figure 98
2. Place assembly sleeve.
Figure 99

6-5-58
3. Warm up housing to 80° C.
HB7M3058
Figure 100
4. Insert rotary group into housing to seat position.
Figure 101

6-5-59
5. Fix zero position of cylinder with Q max.-screw.
A. Disassemble cylinder fixing screw.
B. Insert O-ring.
Figure 102
Rotary Group Adjustment

1. Determine cylinder swivel range to max. angle with screw.
Figure 103
2. * Disc
Figure 104

6-5-60
3. Place centering disc.
HB7M3063
Figure 105
4. Mount measuring device.
Figure 106
5. Check dimension X.
Figure 107

6-5-61
Assembly of the Port Plate
1. Assemble port plate.
CAUTION
AVOID INJURY
Take care of assembly design.
Tighten fixing screws with torque.
2. Set Qmin. - screw to dimension*.

3. Assemble plug.
4. Remove assembly sleeve.
Figure 108
5. Assemble control components.

Assemble cover.
HB7M3067
Figure 109
6. Assemble cover. Pos. 1
FG007441
Figure 110

6-5-62
7. Assemble shaft seal, disc and safety ring.
Press-in with assembly sleeve.
CAUTION
AVOID INJURY
Take care of press-in depth.
Figure 111
8. Assemble counter-balance valve with bolt (1).

WE1400221
Figure 112

6-5-63
6-5-64
Driveshaft
Edition 1
DX210WA Driveshaft
6-6-1
MEMO
Driveshaft DX210WA
6-6-2
Table of Contents
Driveshaft
General ...........................................................6-6-5
Specification .............................................................. 6-6-5
Overview ................................................................... 6-6-6
Front/Rear Driveshaft ........................................... 6-6-6
Center Driveshaft ................................................. 6-6-6
Removal (Front Driveshaft).............................6-6-7
Installation (Front Driveshaft) .........................6-6-9
Removal (Center Driveshaft) ..........................6-6-9
Installation (Center Driveshaft) .....................6-6-11
Removal (Rear Driveshaft) ...........................6-6-12
Installation (Rear Driveshaft) ........................6-6-14
DX210WA Driveshaft
6-6-3
Driveshaft DX210WA
6-6-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Weight Installation Length Closed Length
No. Description
(kg (lb)) (mm) (mm)
1 Front Driveshaft 17 (37.5) - 878 ±3
2 Center Driveshaft 16 (37.3) 342.4 -
3 Rear Driveshaft 17 (37.5) - 878 ±3
DX210WA Driveshaft
6-6-5
Overview
Chassis Frame
1 2 3
Front Axle Rear Axle
Figure 1 Transmission WE1400234
Reference Reference
Number Number
1 Front Driveshaft 3 Rear Driveshaft
2 Center Driveshaft
Front/Rear Driveshaft
3 1 2 3
Figure 2 WE1400235
Reference Reference
Number Number
1 Grease Nipple 3 Universal Joint
2 Grease Nipple
Center Driveshaft
2
Figure 3 1 WE1400236
Reference Reference
Number Number
1 Grease Nipple 2 Bearing Unit
Driveshaft DX210WA
6-6-6
REMOVAL (FRONT DRIVESHAFT)
2. Lower all attachments (bucket, outrigger, dozer) to ground.
(Figure 4)
3. Stop engine.
WE1400214
Figure 4

(Figure 5)
WARNING LOCK
WARNING
190-00695A

EX1401660

O O
WE1401161
Figure 6
12. Turn battery disconnect switch to "OFF" position. (Figure 7)

OFF
ON
Figure 7 EX1401760
DX210WA Driveshaft
6-6-7
3
5 8
1 2
7 6
4
Figure 8 EX1401809
13. Remove bolts and nuts (Figure 9) (8 ea) from front axle.
• Tool: 14 mm ( )
Front Axle
WE1400237
14. Remove bolts and nuts (Figure 10) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
WE1400238
15. Remove front propeller shaft slowly and carefully.

• Propeller shaft weight: about 17 kg (37.5 lb)
WE1400239
Driveshaft DX210WA
6-6-8
INSTALLATION
(FRONT DRIVESHAFT)
1. Perform installation in the reverse order to removal
normally.
NOTE: Apply the loctite #262 to threaded area.
After assembling, pour grease to grease nipple of universal joint
(Figure 12).
WE1400240
REMOVAL (CENTER DRIVESHAFT)

(Figure 13)
3. Stop engine.
WE1400214
Figure 13

(Figure 14)
WARNING LOCK
WARNING
190-00695A

EX1401660

DX210WA Driveshaft
6-6-9
O O
WE1401161
Figure 15

OFF
(Figure 16)
ON
Figure 16 EX1401760

3
5 8
1 2
7 6
4
Figure 17 EX1401809
13. Remove bolts and washers (1, Figure 18) (4 ea) with cover
(2) from bracket. 1
• Tool: 19 mm ( )
• Cover weight: 8 kg (17.6 lb)
3
2
WE1400241
Driveshaft DX210WA
6-6-10
14. Remove bolts and nuts (Figure 19) (16 ea) from propeller
shaft. FRONT
• Tool: 14 mm ( )
WE1400242
15. Remove bolts and washers (1, Figure 20) (4 ea) from
bracket. 1
• Tool: 24 mm ( ) 2

16. Remove center propeller shaft (2, Figure 20) slowly and
carefully.
WE1400243
INSTALLATION
(CENTER DRIVESHAFT)
normally.
When assembling, make the same direction of grease nipples
as shown in Figure 21.
After assembling, pour grease to grease nipple of bearing WE1400244
(Figure 21). Figure 21 Bottom of Chassis Frame
DX210WA Driveshaft
6-6-11
REMOVAL (REAR DRIVESHAFT)
(Figure 22)
3. Stop engine.
WE1400214
Figure 22

(Figure 23)
WARNING LOCK
WARNING
190-00695A

EX1401660

O O
WE1401161
Figure 24

OFF
(Figure 25)
ON
Figure 25 EX1401760
Driveshaft DX210WA
6-6-12
3
5 8
1 2
7 6
4
Figure 26 EX1401809
13. Remove nuts (Figure 27) (8 ea) from transmission.
• Tool: 14 mm ( )
Transmission
Figure 27 WE1400245
14. Remove bolts and nuts (Figure 28) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
WE1400246
15. Remove rear propeller shaft slowly and carefully.

WE1400247
DX210WA Driveshaft
6-6-13
INSTALLATION
(REAR DRIVESHAFT)
normally.
After assembling, pour grease to grease nipple of universal joint
(Figure 30).
WE1400248
Driveshaft DX210WA
6-6-14
1Transmission
Edition 1
DX210WA Transmission
6-7-1
MEMO
Transmission DX210WA
6-7-2
Table of Contents
Transmission
General ...........................................................6-7-5
Specification .............................................................. 6-7-6
Overview ................................................................... 6-7-6
Theory of Operation .................................................. 6-7-8
Transmission Solenoid Valve (Gear Shift) ........... 6-7-8
Parking Brake....................................................... 6-7-9
Towing.................................................................. 6-7-9
Gear Shift Mechanism........................................ 6-7-11
Section View .................................................6-7-13
Separate the Transmission from the Axle.....6-7-14
Disassembly - Brake/Clutch/Planet Carrier .....6-7-15
Downshift Interlock .................................................. 6-7-15
Speed Transmitter................................................... 6-7-18
Emergency Release (Parking Brake) ...................... 6-7-19
Input Housing and Modulation Valve....................... 6-7-20
Brake/Clutch............................................................ 6-7-22
Planet Carrier .......................................................... 6-7-27
Disassembly - Output ...................................6-7-30
Reassembly - Output ....................................6-7-34
Axle Attachment ...................................................... 6-7-34
Determine Adjusting Shim for Pinion Gap.......... 6-7-37
Determine the Adjusting Ring for Rolling Moment/
Pinion Bearing .................................................... 6-7-41
Check the Rolling Moment of the Pinion Bearing .. 6-7-43
Shaft Seal/Output Flange ................................... 6-7-43
Check the Pinion Gap ........................................ 6-7-45
Reassembly - Brake/Clutch/Planet Carrier ...6-7-46
Planet Carrier .......................................................... 6-7-46
Brake/Clutch............................................................ 6-7-52
6-7-3
Disc Components Brake and Clutch .................. 6-7-54
Adjust and Check the Disc Clearance/
Piston Stroke of Brake and Clutch ..................... 6-7-56
Modulation Valve and Input Housing....................... 6-7-64
Emergency Release (Parking Brake) ...................... 6-7-66
Check the Emergency Release for
Leak Tightness .................................................. 6-7-67
Check the Multi-Disc Brake and Multi-Disc Clutch
for Leak Tightness as well as Closing Pressure.... 6-7-68
Speed Transmitter................................................... 6-7-69
Reassembly - Downshift Interlock ................6-7-70
Downshift Interlock .................................................. 6-7-70
Attach the Transmission to the Axle .............6-7-78
6-7-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This transmission is a 2-speed powershift transmission.
The transmission consists of the rotating multi-disc clutch and
multi-disc brake, which is fixed to the transmission body.
The disc brake is held by force of the spring (for parking brake
function), but it is released by hydraulic pressure during
activation.
The downshift interlock (transmission governor) function is to
maintain the high speed (3rd gear) driving condition until the
driving speed reaches the low speed (2nd gear) when
attempting to shift to the low (2nd) gear from the high (3rd) gear
(driving at 10 km/h or higher).
When the driving speed reaches the low speed (2nd gear),
which is called "Downshift Point", the transmission is shifted
from the high speed (3rd gear) to the low speed (2nd gear).
(The downshift operation is performed when the driving speed is
reduced to approximately 70% of the full speed from the high
(3rd) gear.)
The gear shift operation is performed between 2-speeds while
there are 3 driving speeds for an actual machine.
• 1st speed driving
(inching solenoid valve and low speed solenoid valve)
• 2nd speed driving (low-speed solenoid valve)
• 3rd speed driving (high-speed solenoid valve)
6-7-5
Specification
Gear Ratio 1st: 4.87, 2nd: 1.2
Pilot Pressure 30 ~ 35 bar (30.6 ~ 35.7 kg/cm2, 435.1 ~ 507.6 psi)
Volume of Oil 2.5 L (0.6 U.S. gal)
Mounting Type Direct Mounting to Axle
Overview
5
EN
EN 8 7 UN PN
UN
12
WE1400249
Figure 1
Reference Reference
Number Number
1 Lubrication Pressure 8 Road Speed (Brake)
2 Shift Interlock 12 Oil Drain Plug (M24 x 1.5)
3 Brake Pressure Relief Valve (Emergency
UN
4 Clutch Actuation Parking Brake)
Speed Transmitter Bleed Valve (Emergency
5 EN
(Output Speed) Actuation Parking Brake)
7 Off-Load Speed (Clutch) PN Grease Nipple
6-7-6
Hydraulic Circuit
Valve Block
P
Pressure Valve
M Gear Shift Valve

T
Shift Modulation Valve B K M2 M1
K B
Rotary Upper Chassis
/Undercarriage
S
K B
M
J Gear Shift Piston
Check
EB Valve
EK
Nab Change-over
LB Check Valve
Leakage Check
Valve
Pressure Limiting Valve

LK
Pump for Lube Oil and
Control Pressure Shift
Inter Lock
Travel Motor
Shift Inter Lock
UN Output Output
PN S
EN Transmission
WE1400250
Figure 2
6-7-7
Theory of Operation
Transmission Solenoid Valve (Gear Shift)

The valve block is equipped with the pressure valve to prevent
damage of the transmission by shift pressure drop.
When the shift pressure is below 26 bar (26 kg/cm2, 377 psi), oil
supplied to the shift solenoid valve is cut off.
(Parking brake function)
Shift between the low speed (off-road speed) and high-speed
(road speed) is performed by operation of the shift solenoid
valve which is installed to the valve block.
If the control pressure exceeds 32 bar (32 kg/cm2, 464 psi) it will
be reduced to 32 bar (32 kg/cm2, 464 psi) by the integrated
pressure reducing function.
The control pressure existing at the gearshift valve can be
measured on measuring connection. (M10 x 1)
M2 M1 P M2 M1 B K T
M T DV P M
WE1400272
Figure 3
Reference Reference
Number Number
M1 Solenoid Valve (Off-road Speed) B Brake (Road Speed)
M2 Solenoid Valve (Road Speed) P Pilot Pressure Input
DV Pressure Valve T Tank
K Clutch (Off-road Speed) M Measuring Point System Pressure
6-7-8
Parking Brake
The parking brake is put into function by actuation of the parking
brake switch.
The parking brake position of the gearshift valve in the Solenoid
Valve block is shifted by not applying any current to both of the
solenoids (M1) and (M2).
This means in case of a power failure, the parking brake is
engaged automatically.
Towing
The emergency power cut-off system cuts off power flow
between the input and output of the transmission. It applies
grease (10) with the grease gun to disengage the disc brake and
clutch simultaneously until the pressure reaches the relief valve
setting pressure.
This device is designed to draft an implement effectively.
In this case, as the transmission cannot be lubricated EN
separately, the specified draft speed and distance should be
maintained. PN
• Towing speed: Max. 10 km/h UN
• Towing distance: Max. 5 km

1. Activate the emergency actuation WE1400273
Figure 4
A. Engine stop.
B. Grease with grease gun on the grease nipple (PN)
until it comes visibly out at the pressure relief valve
(EN) of the emergency actuation.
2. Deactivate the emergency actuation
To deactivate the emergency power cut-off system, open
the emergency activation bleeder (EN) and set the shift
lever to the road speed (2nd gear) position.
Then, grease is drained through the bleeder (EN).
After draining grease as mentioned above, close the
bleeder (EN).
6-7-9
Emergency Actuation Deactivated Emergency Actuation Activated
1 2 3
4 5 6 7 8 9 10 11
WE1400274
Figure 5
Reference Reference
Number Number
Set of Springs (Plate Spring) for Pressure Ring for the Emergency
1 7
Multi-plate Clutch Actuation
2 Clutch Piston 8 Ring for the Emergency Actuation
3 Multi-plate clutch 9 Multi-plate Brake
Set of Springs (Plate Spring) for 10 Grease
4
Multi-plate Brake 11 Grease Nipple
5 Brake Piston
6 Pin
IMPORTANT
No gear must be selected if the emergency control is
activated - apply parking brake.
If the emergency actuation device is deactivated
incorrectly, the transmission will be damaged during
operation.
6-7-10
Gear Shift Mechanism
1. 1st speed operation
When placing the gear shift lever in the 1st gear position, an electric signal is sent to the solenoid on the
valve block (M1) side.
This electric signal switches the solenoid valve of the valve block to open the port (K).
Then, the pilot pressure in the port K is led into the chamber (CK) in the transmission.
When this pressure overcomes the force of the cup spring (KS), the piston (KP) is pushed to the left.
As a result, the piston (KP) is separated from the disc (A), resulting in rotation of the drive shaft at the 1st
gear speed.
Travel Motor
P
Control Pressure Valve (32 bar)
M Gear Shift and Parking Brake Valve
Orifice “K”
T B (Hi) K (Low) Transmission Control Valve
Modulation Accumulator “B”

Orifice “B”
BS CK CB BP Separation Disc (B)
K B
Disc (A)
KS
KP
Shaft
Figure 6 WE1400285
6-7-11
2. 2nd speed operation
When placing the gear shift lever in the 2nd gear position, an electric signal is sent to the solenoid on the
valve block (M2) side.
This electric signal switches the solenoid valve of the valve block to open the port (B).
Then, the pilot pressure in the port (B) is led into the chamber "CB" in the transmission.
When this pressure overcomes the force of the cup spring "BS", the piston "BP" is pushed to the left.
As a result, the piston "BP" is separated from the disc (B), resulting in rotation of the drive shaft at the 2nd
gear speed.
Travel Motor
P
Control Pressure Valve (32 bar)
M Gear Shift and Parking Brake Valve
Orifice “K”
T B (Hi) K (Low) Transmission Control Valve
Modulation Accumulator “B”

Orifice “B”
BS CK CB BP Separation Disc (B)
K B
Disc (A)
KS
KP
Shaft
Figure 7 WE1400286
6-7-12
SECTION VIEW
1 2 3 4 5 6
Input
10
Output Output
9 8
WE1400271
Figure 8
Reference Reference
Number Number
Cup Springs for Multi-disk Brake 6 Lube Oil Pump
1
and Multi-disk Clutch 7 Spur Gear Drive
2 Input Shaft Output Pinion -
8
3 Multi-disk Brake Rear Axle Direct Attachment
4 Multi-disk Clutch 9 Output Flange - Front Axle
5 Planetary Drive 10 Travel Motor Mounting
6-7-13
SEPARATE THE TRANSMISSION FROM THE AXLE
1. Drain oil from the axle casing.
use a suitable collector.
Figure 9
2. Pick-up the transmission by means of the lifting tackle,

loosen the bolt connection and the complete transmission
from the axle casing.
Figure 10
6-7-14
DISASSEMBLY - BRAKE/CLUTCH/PLANET CARRIER
1. Mount the transmission to the assembly truck.
Figure 11
2. Loosen the screw plug and drain the oil - use a suitable
collector.
Figure 12
Downshift Interlock
1. Disassemble both oil tubes.
Figure 13
2. Loosen the bolt connection of the shift interlock (3 x cap

screws) and remove complete. shift interlock.
Figure 14
6-7-15
3. Loosen the cover bolt connection, remove cover and flat
gasket (also see Figure 16).
Figure 15
4. Take the filter out of the housing.
Figure 16
5. Loosen pump cover bolt connection.
Figure 17
CAUTION
AVOID INJURY
Keep pump to contact and rotate it by 180° -
disassembly aid.
6. Then pull the pump in vertical position out of the housing -

pay attention to possibly released balls/compression
springs (Figure 19).
Figure 18
6-7-16
7. Remove outer (1) and internal rotor (2) and take the
released ball [(3) driver] out of the control housing (4).
Outer, internal rotor and control housing = rotor set
Figure 19
8. Remove control housing and the released balls and

compression springs (3 pcs. each).
Figure 20
9. Unsnap the retaining ring.
Figure 21
10. Pull the cpl. pump shaft out of the pump cover.
Figure 22
6-7-17
11. Unsnap the retaining ring and press the ball bearing from
the shaft.
Figure 23
12. Pull the needle sleeve out of the housing bore.
Figure 24
Reference
Description
Number
1 Housing
2 O-rings
3 Check Valve (010)
4 G.shift Piston
5 Check Valve (009)
6 Check Valve (008)
7 Pressure Limiting Valve
Figure 25
13. Remove O-rings and all single parts/valves.
Speed Transmitter
Loosen the screw and pull off the speed transmitter.
Figure 26
6-7-18
Emergency Release (Parking Brake)
CAUTION
AVOID INJURY
Position of the single connection or bleeder valves/
lubrication nipples etc.
Figure 27
1. Remove bleeder.
2. Remove compression spring and the ball.
Figure 28
3. Remove threaded element (see Detail "X") with O-ring

from the bore.
Figure 29
4. Remove lubrication nipple, both screw plugs and the

bleeder valve - see arrow.
Figure 30
6-7-19
Input Housing and Modulation Valve
CAUTION
AVOID INJURY
Loosen the bolt connection of the input housing equally -
the input housing is subject to a cup spring and
compression spring preload.
Figure 31
1. Take off the input housing and remove O-ring (arrow).
Figure 32
2. Modulation valve:
Remove compression spring and the O-ring (arrow).
Figure 33
6-7-20
3. Pull the complete piston out of the bore.
Figure 34
6-7-21
Brake/Clutch
1. Remove cup springs from the brake.
Figure 35
2. Remove cup springs from the clutch.
Figure 36
3. Remove piston.
Figure 37
4. Pull off both cylinder pins (arrows).
Figure 38
6-7-22
WARNING
Attach 2 (two) eyebolts and pull the piston cautiously
out of the housing - risk of damage.
Figure 39
5. Remove both seals (arrows) from the piston.
Figure 40
6. Remove axial roller cage with both thrust washers.
Figure 41
7. Remove pressure piece and the compression spring.
Figure 42
6-7-23
WARNING
Remove pressure ring with ring - also Figure 44 -
cautiously by means of lever action - risk of damaging
the sealing surfaces.
CAUTION Figure 43
AVOID INJURY
Ring can also remain in the housing - disassemble the
ring separately.
WARNING
Remove pressure ring from the ring cautiously by
means of lever action - risk of damaging the sealing
surfaces.
Figure 44
8. Remove gasket and O-rings from the pressure ring/ring.
Figure 45
9. Take the disc set of the brake with end shim(s) out of the
housing.
Figure 46
6-7-24
Figure 47
11. Remove snap ring and the shim.
Figure 48
12. Take the disc set of the clutch (with end shim/s) out of the
internal gear.
Figure 49
13. Remove assembly input shaft with internal gear from the
housing.
Figure 50
6-7-25
Figure 51
15. Press the input shaft out of the ball bearing/internal gear.
Figure 52
Figure 53
17. Press the centering disc from the input shaft.
CAUTION
AVOID INJURY
In case of an extremely fixed seat - heat the centering
disc - disassembly aid.
Figure 54
6-7-26
18. Unsnap the retaining ring and remove ball bearing.
Figure 55
Planet Carrier
1. Remove axial needle cage with both thrust washers.
Figure 56
2. Loosen the bolt connection and remove washer - fasten

the output flange by means of the fixture.
Figure 57
3. Press the cpl. planet carrier out of the roller bearing.
CAUTION
AVOID INJURY
Pay attention to the released planet carrier and the
bearing innerring.
Figure 58
6-7-27
4. Pull the second bearing inner ring from the planet carrier.
Figure 59
5. If required - expel both bearing outer rings (arrow) from the

bearing bore.
CAUTION
AVOID INJURY
If the taper roller bearings are reused - pay attention to
the bearing location, i.e. respective bearing inner ring
to bearing outer ring.
Figure 60
Figure 61
7. Remove planetary gear by means of lever action - pay

attention to the released shim and the cylindrical rollers.
Figure 62
6-7-28
8. Pull off the bearing inner ring in case of an extremely fixed
seat heat the bearing inner ring.
Figure 63
9. Remove both seals (1).

Remove both bleeder valves (2) and all screw plugs (3)
with sealing and O-ring respectively.
Figure 64
10. Remove screen sheet (2) from the planet carrier (1).
Figure 65
6-7-29
DISASSEMBLY - OUTPUT
1. Loosen the bolt connection, remove cover and the O-ring.
Figure 66
2. Pull off the flange.
Figure 67
3. Remove shaft seal by lever action.
Figure 68
4. Fasten the pinion by means of the device and press it off.
CAUTION
AVOID INJURY
Pay attention to the released bearing inner ring and
the adjusting ring (rolling moment/pinion bearing)
behind it.
Figure 69
6-7-30
5. Remove O-ring (arrow) and the bush from the pinion.
Figure 70
6. Pull off and press off respectively the bearing inner ring.
Figure 71
7. Pull the bearing outer ring out of the bearing cover.
CAUTION
AVOID INJURY
Pay attention to the shim behind it (pinion gap setting).
Figure 72
6-7-31
8. Pull off the bearing cover.
Figure 73
9. Remove O-rings (arrows).
Figure 74
10. Remove shaft seal.
Figure 75
11. Lift the output gear with oil baffle plate out of the housing.
Remove oil baffle plate from the output gear.
Figure 76
6-7-32
12. Remove screen sheet.
Figure 77
13. Expel the bearing outer ring from the housing bore (arrow).
Figure 78
14. Remove stud bolts, if necessary.
Figure 79
6-7-33
REASSEMBLY - OUTPUT
Only when a new housing is installed (Figure 80):
Seal the finished holes (8x) of the oil supply bores with screw
plugs.
Figure 80
Axle Attachment
1. Install the stud bolts.
CAUTION
AVOID INJURY
Observe the installation position. Figure 81.
• Tightening torque MA = 20 N.m (2 kg.m, 14.8 ft lb) Figure 81
2. Insert the bearing outer ring until contact.
Figure 82
3. Insert the slotted pin (arrow).
Figure 83
6-7-34
4. Position the screen sheet - with slotted pin (Figure 83) into
the fixing bore (arrow).
CAUTION
AVOID INJURY
Observe the installation position - slotted pin = radial
fixing of the screen sheet.
Figure 84
5. Insert the output gear - Observe the installation position.
Figure 85
6. Contact face (external shell of the shaft seal) if:

• Rubberized ⇒to be wet with spirit
• Metal ⇒ to be provided with sealing compound
(Loctite No. 586).
CAUTION
AVOID INJURY
Installation position of the shaft seal - Sealing lip Figure 86
showing to the oil sump (Figure 87).
CAUTION
AVOID INJURY
Install the shaft seal (1) considering the required
installation position (Dim. "X" - Figure 87).
6-7-35
CAUTION
AVOID INJURY
Grease the shaft seal in the area around the sealing
and dust lip.
7. Exact installation position of the shaft seal is guaranteed

by use of the specified mounting tool.
Reference
Description
Number
1 Shaft seal
2 Bearing cover
X Installation Dimension →69.5 - 0.5 mm
Figure 87
6-7-36
Determine Adjusting Shim for Pinion Gap
Reference
Description
Number
1 Pinion
2 Roller Bearing
3 Bearing Cover
4 Ball (ø = 7 mm)
A Auxiliary Dimension
B Bearing Width
C Reference Dimension
Contact Surface/Bearing Cover to
D
Contact/Bearing Bore
E 73.0 mm (Constant Value)
Pinion Dimension
X
(Engraved on the Pinion)
189.0 mm (Contact Surface/Bearing
Z
Cover to Center/Axle Casing)
CAUTION Figure 88
AVOID INJURY
For a correct installation and positioning of the pinion, the
following steps are to be carried out as exactly as possible.
1. Determine the auxiliary dimension "A".

Position the ball (ø = 7 mm) into the centering bore of the
pinion and determine Dim. "A", from the contact surface/
pinion shoulder to the ball.
Auxiliary dimension "A" = e.g. 42.56 mm
CAUTION
AVOID INJURY
Auxiliary dimension "A" is obligatory to determine the
reference dimension "C" - on the installed pinion
(Figure 115).
Figure 89
6-7-37
2. Read pinion dim. "X" on the pinion (see arrow) or measure
it in case of manufacturing-specific + or - deviation from the
pinion dim. (relating value is marked by hand on the pinion
e.g. + 0.1).
Pinion dim. "X" (without + or - deviation) = 116.0 mm
Pinion dim. "X" with an indicated deviation + 0.1 = 116.1 mm

Pinion dim. "X" with an indicated deviation - 0.1 = 115.9 mm
Figure 90
3. Determine Dim. "D" bearing width, paying attention that the

rollers are seated without clearance (aligning of rollers -
rotate the bearing inner ring in both directions several
times).
CAUTION
AVOID INJURY
Since the installed roller bearing is subject to a
preload, deducting an empirical value of - 0.1 mm is to Figure 91
be considered.
Dim. "B" = e.g. 36.65 mm - 0.1 mm →36.55 mm

4. Determine Dim. "D" (contact surface/bearing cover to
contact/bearing bore).
Dim. "D" = e.g. 34.50 mm
Example:
Dim. "Z" .......................................................... 189.00 mm
Dim. "X" z.B. ................................................. - 116.00 mm
Result →Dim. "E" ........................................... = 73.00 mm
Dim. "E" ............................................................ 73.00 mm
Dim. "B+D" (e.g. 36.55 + 34.50) ..................... - 71.05 mm Figure 92
Result →required shim "S" .............................. = 1.95 mm

5. Insert the determined shim(s) "S" = e.g. 1.95 mm and
install the bearing outer ring subsequently until contact is
obtained.
Figure 93
6-7-38
6. Oil the O-rings (arrows) and insert them into the ring
grooves of the bearing cover.
Figure 94
7. Bend the edges of the fixing straps of the oil baffle plate
slightly - assembly aid (sheet is fixed to the bearing cover -
Figure 96).
Figure 95
8. Mount the oil baffle plate on the bearing cover.
CAUTION
AVOID INJURY
Observe the installation position - locate the fixing lug
of the oil baffle plate into the recess of the bearing
cover (see arrow).
Figure 96
9. Oil the contact face/oil baffle plate/housing (assembly aid).

Mount the preassembled bearing cover and by means of
hexagon nuts (use washers) locate it equally until contact.
Then remove hexagon nuts again.
Figure 97
6-7-39
10. Mount the heated bearing inner ring until contact and after
cooling-down install it subsequently until contact is
obtained.
Figure 98
11. Mount the bush, oil the O-ring (arrow) and put it into the
ring groove.
Figure 99
12. Mount the preassembled pinion.
Figure 100
6-7-40
13. Fasten the pinion by means of the clamping bar.
Figure 101
Determine the Adjusting Ring for Rolling Moment/

Pinion Bearing
1. Rotate the transmission by 180°.
Mount the adjusting ring (s = optional).
CAUTION
AVOID INJURY
It is recommended to reinstall the adjusting ring (e.g. s Figure 102
= 1.35 mm) from the disassembly, if however the
required rolling moment of 1.5 ~ 3.0 N.m (without shaft
seal) is not obtained - see bearing rolling moment
check Figure 107 - the bearing rolling moment is to be
corrected with an adequate adjusting ring.
2. Mount the heated bearing inner ring and install it

subsequently until contact.
Figure 103
6-7-41
3. Mount the flange.
Figure 104
4. Put on the washer and fasten the flange with hexagon

screws.
CAUTION
AVOID INJURY
Rotate the pinion - when tightening - in both directions
(aligning of rollers) several times.
• Tightening torque (M 10/8.8) Figure 105

MA = 46 N.m (4.7 kg.m, 34 ft lb)
5. Turn back the pinion fastening and remove clamping bar
respectively.
Figure 106
6-7-42
Check the Rolling Moment of the Pinion Bearing
1. Bearing rolling moment (without shaft seal) 1.5 ~ 3.0 N.m
(When using new roller bearings - upper value should be
achieved)
CAUTION
AVOID INJURY
If the required rolling moment deviates, it is to be
corrected with an adequate adjusting ring (Figure 102).
Figure 107
2. Remove flange again.
Figure 108
Shaft Seal/Output Flange

1. Contact face (external shell of the shaft seal) if
• Rubberized ⇒to be wet with spirit
• Metal ⇒ to be provided with sealing compound
(Loctite No. 586).
CAUTION
AVOID INJURY
Installation position of the shaft seal. Sealing lip
showing to the oil sump (Figure 110).
Install the shaft seal (1) considering the required

installation position (Dim. "M" - Figure 110).
Grease the shaft seal in the area around the sealing and
dust lip.
Figure 109
Exact installation position of the shaft seal is guaranteed
by use of the specified mounting tool.
6-7-43
Legend to the sketch:
Reference
Description
Number
1 Shaft Seal
2 Screen Sheet
3 Flange
4 Roller Bearing
5 Bearing Cover
M Installation Dimension →17.6 - 0.5 mm
Figure 110
N Installation Dimension →27.5 + 0.3 mm
2. Only for installation of a new flange or if stud bolts were

removed (Figure 111) Install the stud bolts
Installation position - Stud bolts with short thread length
into flange.
• Tightening torque (M10 x 1)
MA = 20 N.m (2 kg.m, 14.8 ft lb)
Figure 111
3. Only for installation of a new flange/screen sheet or if

removed (Figure 112) Install the screen sheet (2),
considering the required installation position (Dim. "N" -
Figure 110).
Exact installation position of the screen sheet is
guaranteed by use of the specified mounting tool.
Figure 112
4. Mount the preassembled flange and put the O-ring into the
recess.
Figure 113
6-7-44
5. Place the washer and fasten it by means of hexagon
screws.
• Tightening torque (M10/8.8)
MA = 46 N.m (4.7 kg.m, 34 ft lb)
Figure 114
Check the Pinion Gap

1. Position the ball [use ø = 7 mm → ball ø like for the
determination of auxiliary dimension "A"] into the centering
bore of the pinion and determine Dim. "C" (Figure 88), from
the contact surface/bearing cover to the ball.
Example:
Reference dimension "C" e.g. .......................... 115.58 mm
Auxiliary dimension "A" (Figure 89) e.g ............ - 42.56 mm
Result (Dim. "E") ............................................ = 73.02 mm
Figure 115
CAUTION
AVOID INJURY
If the constant value of Dim. "E" = 73.00 ±0.05 mm is
not achieved, it is to be corrected with an adequate
shim/pinion gap (Figure 93).
2. For a correction of the shim/pinion gap, a countercorrection

of the adjusting ring of the rolling moment/pinion gap -
Figure 102 is also to be considered.
6-7-45
REASSEMBLY - BRAKE/CLUTCH/PLANET CARRIER
Planet Carrier
1. Illustration shows the "Axle Attachment".
Install the bearing outer ring until contact.
CAUTION
AVOID INJURY
Observe the bearing location - bearing inner ring to
bearing outer ring - also see instructions for Figure 116
disassembly page -28, Figure 60.
2. Rotate transmission by 180°.

Install the second bearing outer ring until contact.
CAUTION
AVOID INJURY
Observe the bearing location - bearing inner ring to
bearing outer ring - also see instructions for
disassembly page -28, Figure 60.
Figure 117
3. Install the screen sheet (2) considering the installation

dimension "X" (see detail sketch) onto the planet carrier
2
(1).
3
1
Figure 118
Legend to detail sketch:
Reference
Description
Number 1
1 Planet Carrier 2 X
3
2 Screen Sheet
Contact Surface - Axial Needle Cage/
3
axial Washer
X Install. Dim. 1.5 - 0.5 mm
Figure 119
6-7-46
4. Insert the slotted pins (6x), considering the installation
dimension "X" = 28.0 - 1.0 mm and the installation position -
Figure 121 (slot is showing to the center).
CAUTION
AVOID INJURY
Prior to installation grease the slotted pin - assembly X
aid.
Figure 120
Legend to the sketch:

1
Reference
Description
Number 2
1 Planet Carrier
2 Slotted Pins (6x)
3 Center (Planet Carrier)
3
Figure 121
Legend to Figure 122 ~ Figure 128:
Reference
Description
Number
1 Bearing Inner Ring with Cylinder Rollers
1a Packing Sleeve + Assembly Aid
2 Planetary Gear
3 Cylinder Rollers
3a Packing Sleeve + Assembly Aid
4 Shim
Figure 122
6-7-47
5. Position the planetary gear (2) - with the marking showing
downwards.
Put the bearing inner ring (1) onto the planetary gear (2)
and press it until contact is obtained.
Then remove loose packing sleeve (1a).
CAUTION
AVOID INJURY
Figure 123
Keep the bearing inner ring to contact and rotate the
planetary gear by 180°.
6. Position the cylinder rollers (3) onto the planetary gear (2).
Figure 124
7. By means of the mounting tool press the cylinder rollers (2)

into the planetary gear (2).
Then remove two loose packing sleeves (3a).
Figure 125
6-7-48
CAUTION
AVOID INJURY
Keep the bearing inner ring with cylinder rollers to
contact - and mount the preassembled the planetary
gear to the planet carrier pin.
Figure 126
8. Press the planetary gear (bearing inner ring) until contact.
Figure 127
9. Mount the shim (4). marking showing upwards. and snap in

the retaining ring.
CAUTION
AVOID INJURY
Install the retaining ring subsequently until contact at
the groove base is obtained.
Install the remaining planetary gears analogously. Figure 128
10. Press the bearing inner ring onto the planet carrier until
contact ist obtained.
Figure 129
6-7-49
11. Insert the preassembled planet carrier.
Figure 130
12. Fasten the planet carrier by means of pressure plate and

clamping bar.
Figure 131

Check locating of the bearing outer ring (arrow) -
installation of the bearing outer ring - Figure 116.
Figure 132
6-7-50
14. Mount the heated bearing inner ring until contact.
Figure 133
15. Position the shim and attach the hexagon screws by hand
(fixing of the planet carrier).
Then remove clamping bar - Figure 131.
Figure 134
16. Fasten the fixture to the output flange.
CAUTION
AVOID INJURY
Tighten the hexagon screws equally - risk of
distortion.
• Tightening torque (M 10/8.8)

MA = 46 N.m (4.7 kg.m, 34 ft lb) Figure 135
WARNING
When tightening the hexagon bolts rotate the planet
carriers - into both directions. several times (aligning
of rollers).
6-7-51
Brake/Clutch
1. Mount the heated centering disc and press it until contact
is obtained.
Figure 136
2. Fasten the centering disc by means of the retaining ring.
Figure 137
3. Insert the ball bearing into the internal gear and fasten it by
means of the retaining ring.
Figure 138
6-7-52
4. Heat the bearing inner ring of the ball bearing.
Figure 139
5. Mount the preassembled internal gear to the input shaft

until contact is obtained.
Figure 140
6. Snap in the retaining ring.
Figure 141

Position the axial needle cage with both thrust washers (1x
each, underneath and onto the axle needle cage resp. -
see Figure).
CAUTION
AVOID INJURY
Fix the axial needle cage and the thrust washers by
means of grease centrically - assembly aid. Figure 142
6-7-53
8. Mount the preassembled input shaft (with internal gear).
Figure 143
Disc Components Brake and Clutch

Reassembly of both disc sets is shown below.
For information about number and arrangement of the discs -
also see the perspective illustration in the respective spare parts
list.
Reference
Description
Number
Lower Ring Groove
A
(Item Retaining Ring -1)
1 Retaining Ring
2 End Shim/Brake (1 Pc.)
3 Outer Disc/Brake (9 Pcs.)
4 Inner Disc/Brake (8 Pcs.)
5 Inner Disc/Clutch (12 Pcs.) Figure 144
6 Inner Disc/Clutch (11 Pcs.)
7 Transmission Housing
8 Disc Carrier/Internal Gear
1. Brake
Snap the retaining ring (1) into the ring groove (A).
CAUTION
AVOID INJURY
Observe the installation position of the retaining ring
(1) - ring groove (A).
Figure 145
6-7-54
2. Insert the end shim (2).
Figure 146
3. Insert the disc set (outer/inner discs) - beginning with an

outer disc - alternately.
CAUTION
AVOID INJURY
Position the outer disc (1 pc.) s = variable 2.8 ~ 3.7 mm,
in the disc set on the top (piston-side).
With outer disc s = variable, the disc clearance/piston
stroke will be adjusted - Figure 160. Figure 147
4. Clutch:
Insert the disc set (outer/inner discs) - beginning with an
outer disc - alternately.
CAUTION
AVOID INJURY
Position the outer disc (1 pc.) s = variable 1.2 ~ 1.6 mm,
in the disc set on the top (piston side).
Figure 148
With outer disc s = variable, the disc clearance/piston
stroke will be adjusted - Figure 159.
6-7-55
Adjust and Check the Disc Clearance/Piston Stroke of
Brake and Clutch
1. Mount the pressure piece (without compression spring).
Figure 149
2. Oil the axial roller cage and mount it with both thrust
washers (1x each, positioned underneath and onto the
axial needle cage respectively).
Figure 150
3. Insert the piston (brake) - without sealing elements

installed.
Figure 151
4. Insert the piston (clutch) - without sealing elements

installed.
Figure 152
6-7-56
5. Insert both cup springs/clutch.
Fix the cup springs by means of grease and position them
centrically. assembly aid.
CAUTION
AVOID INJURY
Observe the installation position - also see Figure 155.
Figure 153
6. Insert both cup springs/brake.

Fix the cup springs by means of grease and position them
centrically. assembly aid.
CAUTION
AVOID INJURY
Observe the installation position - also see Figure 155.
Figure 154
Legend to Figure 155 ~ Figure 160:
Reference l ll lll
Description
Number
1 Measuring Fixture 5
D C B A
2 Piston/Clutch 3 X
Y
3 Cup Springs/Clutch 4
2
4 Piston/Brake 6
5 Cup Springs/Brake
6 Transmission Housing FG002838
Figure 155
I Measuring Bore (Disc Clearance/Clutch)
II Measuring Bore (Disc Clearance/Brake)
A Mounting Face/Housing - Face/Piston
Mounting Face/Housing -
B
Piston Contact/Housing
C Mounting Face/Housing - Face/Piston
Mounting Face/Housing -
D
Piston Contact/Housing
Y Disc Clearance/Clutch →2.4 +0.3 mm

(Piston Stroke)
X Disc Clearance/Brake →1.8 + 0.3 mm

(Piston Stroke)
6-7-57
CAUTION
AVOID INJURY
Locate the measuring fixture with hexagon screws
equally (risk of breakage) until contact is obtained.

MA = 80 N.m (8.2 kg.m, 59 ft lb)
Figure 156
7. Determine Dim. "A" (Measuring bore "I") from mounting

face/housing to the face/piston (clutch).
Dim. "A" e.g. .................................................. = 22.45 mm
Figure 157
8. Determine Dim. "C" (Measuring bore "II") from mounting

face/housing to the face/piston (brake).
Dim. "C" e.g. .................................................. = 11.85 mm
Figure 158
9. Determine Dim. "B" from mounting face/housing to clutch

piston contact/housing.
Dim. "B" e.g. .................................................. = 19.95 mm
Example:
Dim. "A" e.g. ..................................................... 22.45 mm
Dim. "B" e.g. ................................................... - 19.95 mm
Result .............................................................. = 2.50 mm
Clutch disc clearance (piston stroke) = 2.4 + 0.3 mm

Figure 159
6-7-58
WARNING
If the required disc clearance (piston stroke) is not
obtained, this is to be corrected with a suitable outer
disc - Figure 148.
10. Determine Dim. "D" from mounting face/housing to brake

piston contact/housing.
Dim. "D" e.g. ..................................................... = 9.95mm
Example:
Dim. "C" e.g. ..................................................... 11.85 mm
Dim. "D" e.g. ..................................................... - 9.95 mm
Result .............................................................. = 1.90 mm
Disc clearance (piston stroke) Brake = 1.8 + 0.3 mm

Figure 160
WARNING
If the required disc clearance (piston stroke) is not
obtained, this is to be corrected with a suitable outer
disc n see Figure 147.
11. Remove measuring fixture again. loosen the screws

equally.
Remove all cup springs, both pistons, axial roller cage with
thrust washers and pressure piece.
Figure 161
12. Insert the oil baffle plate into the disc carrier and fix it with
the snap ring.
Figure 162
6-7-59
13. Oil the sealing faces and the O-ring.
Insert the O-ring (arrow) into the groove and insert the ring.
CAUTION
AVOID INJURY
Observe the installation position - Figure 163.
Figure 163
14. By means of the mounting tool locate the ring until contact
is obtained.
Figure 164
15. Oil the sealing faces and the sealing elements.
Figure 165
16. Insert the seal (1) with the sealing lip showing to the oil
sump. also see detail sketch.
Put both O-rings (2) into the ring grooves of the pressure
ring (3) and insert the preassembled pressure ring -
observe the installation position.
Figure 166
6-7-60
17. By means of the mounting tool locate the pressure ring
until contact.
Figure 167
18. Insert the compression spring.
Figure 168
19. Insert the pressure piece.
Figure 169
6-7-61
20. Oil the axial roller cage and mount it with both thrust
washers (1x each to be positioned underneath and onto
the axial needle cage respectively).
Figure 170

Insert the seal (2, with the sealing lip showing to the oil
sump) and the seal (3) - Figure 172 - into the housing (1).
Figure 171
22. Legend to Figure 172 as well as Figure 171 and Figure

173:
Reference
Description
Number
1 Housing
2 Seal (With Sealing Lip)
3 Seal
4 Piston/Brake
7 Piston/Clutch
Figure 172

Insert the seals (5 and 6, Figure 172), with the sealing lip
showing to the oil sump, into the piston/brake (4).
Figure 173
6-7-62
24. Insert the preassembled piston/brake until contact is
obtained.
CAUTION
AVOID INJURY
Piston is to be positioned that the oil supply bore
(arrow) - with the transmission installed into the
vehicle - is at 12 o’clock position.
Figure 174
25. By means of the mounting tool locate the piston until

contact.
Figure 175
26. Insert both cylinder pins (arrow).
Figure 176
27. Insert the piston/clutch.
Figure 177
6-7-63
28. Press the piston axially, contrary to the compression spring
preload, and seal the pressure oil supply bore by means of
screw plug/sealing ring (arrow) - thus the piston is kept in
axial position - assembly aid for input housing assembly
(Figure 184 and 213).
Figure 178
29. Insert both cup springs/clutch.
CAUTION
AVOID INJURY
Observe the installation position - Figure 179 and also
Figure 155 respectively.
Figure 179
30. Insert both cup springs/brake.
CAUTION
AVOID INJURY
Observe the installation position -Figure 180 and also
Figure 155.
Figure 180
Modulation Valve and Input Housing

1. Insert the modulation valve (cpl. - can only be replaced as
unit).
Figure 181
6-7-64
2. Place the O-ring (arrow) and insert the compression
spring.
Figure 182
3. Input housing:
Oil the O-ring and put it into the ring groove of the input
housing.
Figure 183
4. Position the cup springs centrically - assembly aid.

Insert two adjusting screws (M 12), mount the input
housing and fasten it with hexagon screws.
Figure 184
WARNING
Locate the input housing with hexagon screws equally
(risk of breakage) until contact is obtained.

MA = 80 N.m (8.2 kg.m, 59 ft lb)
Figure 185
6-7-65
Emergency Release (Parking Brake)
Legend to Figure 186:
Reference
Description
Number
1 Input Housing
2 Housing
3 O-ring
4 Threaded Element (Orifice)
5 Ball
6 Compression Spring
7 O-ring
8 Bleeder Figure 186
9 Lubrication Nipple
1. Install the threaded element (4) with O-ring (3).

• Tightening torque (M10 x 1)
MA = 24 N.m (2.4 kg.m, 17.7 ft lb)
Figure 187
2. Insert the ball (5).
Figure 188
3. Insert the compression spring (6).
Figure 189
6-7-66
Check the Emergency Release for Leak Tightness
1. Install the bleeder valve (1), screw plugs (2) with O-ring
screw plug (3) with O-ring and compressed air connection
piece (4).
• Tightening torque
– Bleeder valve (M10 x 1)
MA = 22 N.m (2.2 kg.m, 16.2 ft lb)
– Screw plug (M10 x 1 with O-ring)
MA = 25 N.m (2.5 kg.m, 18.4 ft lb)
– Screw plug (M18 x 1.5 with O-ring)
MA = 35 N.m (2.2 kg.m, 16.2 ft lb)
• Compr.air connect. piece (M10 x 1) w. seal. ring)
MA = 15 N.m (1.5 kg.m, 11.1 ft lb)
Figure 190
Figure 191
2. Pressurize the emergency release with compressed air p =

5 + 1bar and close the shut-off valve.
During a test duration of 3 minutes no pressure drop is
allowed.
Figure 192
6-7-67
3. Remove screw plug and the compressed air connection
piece (Figure 191).
Install the bleeder (3) with O-ring and lubrication nipple (4).
– Lubrication nipple (M10 x 1)
MA = 22 N.m (2.2 kg.m, 16.2 ft lb)
– Bleeder (M18 x 1.5)
MA = 22 N.m (2.2 kg.m, 16.2 ft lb)
Figure 193
Check the Multi-Disc Brake and Multi-Disc Clutch for Leak

Tightness as well as Closing Pressure
Reference
Description
Number
1 Transmission Housing
2 Input Housing
AB Pressure Oil Connection - Multi-disc Brake
AK Pressure Oil Connection - Multi-disc Clutch
EB Bleeder Valve - Multi-disc Brake
EK Bleeder Valve - Multi-disc Clutch
Figure 194
1. Multi-disc brake:
Connect the HP-Pump ("AB" - Figure 194 and Figure 193),
Build up a pressure of p = 30 ... max. 35 bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable
pressure drop is allowed!
Figure 195
6-7-68
2. Closing pressure test (Cup spring preloading force):
When measuring the closing pressure the valve block is
not allowed to be attached to the transmission due to the
by-pass function between brake and clutch.
Connection "AK" (See Figure 194 respectively) open (not
closed and tank connection respectively).
Reduce the pressure slowly, when pressure range 11 ~ 9
bar (closing pressure) is reached, the input shaft has to be
locked at a tightening torque of 50 ±5 N.m.
Figure 196
3. Multi-disc clutch:
Connect the HP-Pump ("AK" - See Figure 194), build up a
pressure of p = 30 ... max. 35 bar
- Bleed the pressure chamber (several times).
Close the shut-off valve.
During a test duration of 3 minutes no measurable
pressure drop is allowed.
Test medium:
According to the "Table of recommended lubricants" of Figure 197
operation manual.
Speed Transmitter
Install the speed transmitter with O-ring.
• Tightening torque (M 8/8.8)
MA = 23 N.m (2.3 kg.m, 17 ft lb)
Figure 198
6-7-69
REASSEMBLY - DOWNSHIFT INTERLOCK
Downshift Interlock
Reference
Description
Number
1 Housing
2 G.shift Piston
3 Pressure Limiting Valve
4 Check Valve (008)
5 Check Valve (009)
6 Check Valve (010) Figure 199
7 Filter
8 Lube Oil Pump
Install the gasket (consisting of plastic and O-ring (Fig. No. 23

and 24)
1. Put the O-ring (see arrow) into the ring groove of the
piston.
Lead the plastic ring by means of the mounting bush (S)
over the piston and position it at the O-ring.
Figure 200
2. Calibrate the plastic ring by means of the bush.
Figure 201
6-7-70
3. Insert the compression spring, oil and mount the
preassembled piston.
Figure 202
4. Fix the piston with screw plug (1- with O-ring).

Install the screw plug (2, with sealing ring).
• Tightening torque:
– Screw plug (M24 x 1.5)
MA = 50 N.m (5.1 kg.m, 36.9 ft lb)
– Screw plug (M10 x 1)
MA = 15 N.m (1.5 kg.m, 11.1 ft lb)
Figure 203
5. Install the single parts according to the illustration on the

left.
CAUTION
AVOID INJURY
Observe the installation position of the different check
valves.
Oil the single parts acc. to the "Table of
Recommended Lubricants" pages of operation
manual. Figure 204
Reference Torque
Description
Number N.m kg.m ft lb
1 Pressure Limiting Valve (Cpl.) 10 1 7.4
2 Check Valve (Cpl.) 10 1 7.4
6-7-71
6. Secure the check valves and the pressure limiting valve by
two blows each with the center punch.
Figure 205
7. Check passage of the orifice/oil bore in the housing

bottom.
CAUTION
AVOID INJURY
Insert the needle sleeve to installation dimension "X".
"X" = 0.2 ~ 0.7 mm below plane face/housing

Figure 206
CAUTION
AVOID INJURY
The exact installation position is ensured by use of the
specified mounting tool.
CAUTION
AVOID INJURY
Insert the needle sleeve with marked face showing
upwards.
8. Mount the ball bearing onto the shaft and fasten it with the
retaining ring.
Figure 207
6-7-72
9. Press the preassembled pump shaft into the pump cover
and fasten it with the retaining ring.
Figure 208
10. Insert the compression springs (1) and ball (2) into the
bores (see arrows - 3x).
WARNING
Prior to installation oil single parts of the pump/rotor
set (control housing, internal and outer rotor) - use oil
acc. to the "Table of Recommended Lubricants" pages
of operation manual. Figure 209
CAUTION
AVOID INJURY
Keep the pump shaft/cover in "Vertical" position - pay
attention to the position of the inserted balls/
compression springs - See Figure 250 ~ Figure 256).
11. Mount the control housing.

Control housing/internal and outer rotor
Figure 210
6-7-73
12. Position the ball - see arrow -(drive for internal rotor) with
grease (assembly aid) into the recess of the pump shaft.
Figure 211
13. Mount the internal rotor
CAUTION
AVOID INJURY
Place the groove of the internal rotor over the driving
ball (see arrows).
Figure 212
14. Assemble the outer rotor.
Figure 213
15. Keep the preassembled pump (see Instructions Figure

209) and put on the housing.
Figure 214
6-7-74
CAUTION
AVOID INJURY
Keep the assembled pump to contact and rotate the
housing by 180°.
Fasten the pump with hexagon screws.

MA = 9.5 N.m (1 kg.m, 7 ft lb) Figure 215
16. Insert the screen filter - Observe the installation position.
Figure 216
17. Place the gasket.
Figure 217
18. Position the cover, fasten it with hexagon screws and

washers.
CAUTION
AVOID INJURY
Pay attention to different screw length.

6-7-75
19. Oil both O-rings (arrows) and put them into the ring
grooves of the housing.
Figure 219
20. Mount the preassembled downshift interlock and fasten it

with cap screws and washers.
CAUTION
AVOID INJURY
Pay attention to different screw length.

21. Install both screw-in sleeves and the screw plug (see
arrows) - with O-rings.
– Screw-in sleeve (M16 x 1.5)
MA = 23 N.m (2.3 kg.m, 17 ft lb)
– Screw plug (M18 x 1.5)
MA = 35 N.m (3.6 kg.m, 25.8 ft lb)
Figure 221
Reference
Description
Number
1 Oil Tube
2 Union Screw (M16 x 1.5)
3 Sealing Ring
4 Union Screw (M14 x 1.5)
5 Sealing Ring
Figure 222
6-7-76
22. Install both oil tubes.
– Union screw (M14 x1.5)
MA = 25 N.m (2.5 kg.m, 18.4 ft lb)
– Union screw (M16 x1.5)
MA = 45 N.m (4.6 kg.m, 33.2 ft lb)
Figure 223
6-7-77
ATTACH THE TRANSMISSION TO THE AXLE
1. Position the assembly transmission to the axle.
Figure 224
2. Fasten the transmission to the axle by means of hexagon

screws and nuts.
MA = 79 N.m (8.1 kg.m, 58.3 ft lb)
WARNING
Prior to put the unit into operation the specifications
and regulations respectively as well as the Figure 225
instructions of the transmission operating and
maintenance instructions.
6-7-78
1Front
Boom and Arm
Edition 1
DX210WA Boom and Arm

7-1-1
MEMO
Boom and Arm DX210WA

7-1-2
Table of Contents
Boom and Arm

Specifications .................................................7-1-6
One - Piece Boom ..................................................... 7-1-6
Two - Piece Boom ..................................................... 7-1-8
Removal .......................................................7-1-10
Arm Removal........................................................... 7-1-10
Boom Removal........................................................ 7-1-12
Installation ....................................................7-1-13
Arm Installation........................................................ 7-1-13
Boom Installation..................................................... 7-1-13
Completing Work ..........................................7-1-13

7-1-3
7-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

7-1-5
SPECIFICATIONS
The table below has a complete listing of dimensional
specifications for all mounting pins used on the front attachment.
NOTE: Some mounting pins must be drilled and tapped for
lubrication fittings and piping, or may have other
required specifications. Consult DOOSAN After Sales
Service for information on wear tolerances and
replacement limits for mounting pins.
One - Piece Boom
A C E D F
B K I J H
WE1400515
Figure 1

7-1-6
Criteria
Mark Measuring Part Standard Tolerance Standard Clearance Remedy
Size Pin Hole Clearance Limit
90 mm -0.10 +0.18
A Boom Foot 0.13 ~ 0.33 1.5
(3.543") -0.15 +0.03
80 mm -0.06 +0.18
B Boom Cylinder Head 0.09 ~ 0.29 1.5
(3.150") -0.11 +0.03
80 mm -0.06 +0.18
C Boom Center 0.09 ~ 0.29 1.5
(3.150") -0.11 +0.03
90 mm -0.10 +0.18
D Boom End 0.13 ~ 0.33 1.5
(3.543") -0.15 +0.03
80 mm -0.06 +0.18
E Arm Cylinder Head 0.09 ~ 0.29 1.5
(3.150") -0.11 +0.03
80 mm -0.06 +0.18
F Arm Cylinder Rod 0.09 ~ 0.29 1.5 Replace
(3.150") -0.11 +0.03
80 mm -0.06 +0.18
G Bucket Cylinder Head 0.09 ~ 0.29 1.5
(3.150") -0.11 +0.03
71 mm -0.06 +0.18
H Arm Link 0.09 ~ 0.29 2.0
(2.795") -0.11 +0.03
80 mm -0.06 +0.18
I Arm End 0.09 ~ 0.29 2.0
(3.150") -0.11 +0.03
80 mm -0.06 +0.18
J Bucket Cylinder Rod 0.09 ~ 0.29 2.0
(3.150") -0.11 +0.03
80 mm -0.06 +0.18
K Push Link to Bucket 0.09 ~ 0.29 2.0
(3.150") -0.11 +0.03

7-1-7
Two - Piece Boom
A L C M E D F
B K I J H
WE1400516
Figure 2

7-1-8
Criteria
Mark Measuring Part Standard Tolerance Clearance Remedy
Size Pin Hole Limit
90 mm -0.10 +0.18
A Boom Foot 1.5
(3.543") -0.15 +0.23
80 mm -0.06 +0.18
B Boom Cylinder Head 1.5
(3.150") -0.11 +0.03
100 mm -0.06 +0.25
C Lower Boom End 1.5
(3.937") -0.11 +0.2
90 mm -0.10 +0.054
D Boom End 1.5
(3.543") -0.15 0
80 mm -0.06 +0.046
E Arm Cylinder Head 1.5
(3.150") -0.11 0
80 mm -0.06 +0.046
F Arm Cylinder Rod 1.5
(3.150") -0.11 0
80 mm -0.06 +0.046
G Bucket Cylinder Head 1.5 Replace
(3.150") -0.11 0
71 mm -0.06 +0.20
H Arm Link 2.0
(2.795") -0.11 +0.15
80 mm -0.06 +0.20
I Arm End 2.0
(3.150") -0.11 +0.15
80 mm -0.06 +0.20
J Bucket Cylinder Rod 2.0
(3.150") -0.11 +0.15
80 mm -0.06 +0.20
K Push Link to Bucket 2.0
(3.150") -0.11 +0.15
90 mm -0.10 +0.054
L Arti Boom Cylinder Head 1.5
(3.543") -0.15 0
90 mm -0.10 +0.054
M Arti Boom Cylinder Rod 1.5
(3.543") -0.15 0

7-1-9
REMOVAL
DANGER
AVOID DEATH
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment or any other part, may
affect the stability of the machine. This could cause
unexpected movement, resulting in death or serious injuries.
front attachment has been removed.
IMPORTANT
WE1400011
Figure 3
Always break down the front attachment by removing

outermost sections first - the bucket before the arm, the
arm before the boom. Reinstallation of the attachment must
begin with the boom and end with the bucket.
Refer to the appropriate Bucket section for its removal and

installation procedure before going onto the initial step of the
front attachment removal or installation procedure.
Arm Removal
WARNING
This procedure is intended for routine removal or
replacement of the attachment by ONLY authorized and
trained service persons. Call you local Doosan distributor
for assistance.
DO NOT allow other personnel to go under the boom, arm
or attachment sections, if not properly supported.
Keep away from pressurized hydraulic lines to prevent
death or serious injury from high-pressure oil.
Complete the bucket end removal procedure by pulling out the

two bucket linkage pins and the bucket cylinder mounting pin, on
the arm. Use an assist crane or hoist to lift the cylinder and
relieve weight on mounting pins.
Park the excavator away from obstructions and all traffic on
clear, flat, level ground. Extend the arm cylinder and crowd the

7-1-10
arm into the boom. Partially retract the boom cylinder so the
boom is stretched out in front of the excavator, as low to the
ground as possible, with the arm crowded under the boom.
The tip of the arm point must be lowered to secure blocking that
will safely support the weight of the arm. Place the blocking
directly in front of the excavator and make sure that it will not be
unbalanced with an initial weight load that is all to one end,
under the arm point.
Shut off the engine and release hydraulic system pressure -
move any of the control levers with the engine off to release
pressure built up in the accumulator. Manually vent residual
hydraulic pressure in the tank by moving the lever near the cap,
on top of the reservoir.
WARNING
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 1,320 kg (2,910 lb), not including
the weight of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins,

disconnect the arm cylinder hydraulic hose couplings and put a
clean plug in the end of each one. Use any reasonable
precautions necessary to avoid introducing dirt or other
contaminants into the hydraulic system. Wipe down coupling
points before disconnecting hydraulic lines and use evaporative
type solvent spray cleaner. Tag and mark hoses for reassembly,
if necessary.
Place a sling under the arm cylinder (the cylinder used to extend
and retract the attachment arm, pinned to the top of the boom).
Lift the sling so the weight load on the rod end of the arm
cylinder (pinned to the ears on the inner end of the arm) is
released. Prepare blocking under the arm that will securely
support the weight of the arm and arm cylinder.

7-1-11
IMPORTANT
To make sure that polished surfaces of cylinder rod ends
are not damaged during disassembly or removal
procedures, wrap exposed rod surfaces (especially those of
boom cylinders) with a protective covering material.
Immediately the following disassembly and removal,
cylinder rods should always be fully retracted. This eases
handling problems and avoids possible damage.
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.
Boom Removal
NOTE: Boom removal may be simplified if the shell of the
operator's cabin is taken off the turntable deck first.
Refer to the Operator's Cabin Removal procedure
before continuing, if both components are to be
removed from the excavator.
After the bucket, arm and arm cylinder have been removed,
lower the end of the boom to a stable, secure blocking support.
Attach the assist crane sling to the body of either boom cylinder,
break the mounting pin connection to the boom by tapping
through the pin from the same side of the boom and repeat for
the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as
previously outlined in the Arm Removal Procedure, observing
the same precautions.
Disconnect wiring for work light assemblies and any other
accessory lines or connections. Locate the sling of the assist crane
near the center of gravity, optimum lift point for the boom, and use
the crane to take pressure off the boom foot pin. Drive out the pin
after disassembling retainers and carefully lift away the boom.
WARNING
If either the front attachment or counterweight has been
removed, stability of the excavator will be affected. Never
travel with the excavator, swing the turntable or drive over
uneven or sloping terrain if one of these components have
been removed. Tipping or a rollover could result in death or
serious injury.
To maintain stability, the counterweight must be removed

whenever the front attachment is taken off the machine.

7-1-12
INSTALLATION
Arm Installation
Reattach the base of the arm cylinder to the mounting point on
top of the boom.
WARNING
Before assembling the front attachment, make sure that
individual boom, arm and bucket sections are all
compatible for work intended. Refer to the General Safety
Pages, Lift Ratings, Working Range Diagrams and Weights
of Materials sections in the Operation & Maintenance
Manual. Consult your dealer or DOOSAN After Sales
Service for more information if you have any questions.
Begin with the arm securely supported on blocking in front of the

excavator. Pregrease the mounting pin for the rod end of the
arm cylinder and push it through the ears on the end of the arm.
Attach a sling around that mounting pin and lift the arm with an
assist crane until it is in position for the boom-arm pin
connection to be made.
Relieve hydraulic pressure from all points of the system before
any hydraulic lines are opened, then carefully assemble
hydraulic connections to the arm cylinder.
Remove sling from around the rod end arm cylinder pin,
withdraw the pin and lift the body of the arm cylinder to repin the
mounting connection.
Boom Installation
Before reassembling the attachment, make sure to inspect all
bushings and pivot points of each section. To avoid damaging
the seats, bushings should never be hammered or chiseled out
of their seats.
Installation is otherwise a reversal of the removal procedures.
COMPLETING WORK
Once the boom has been serviced, it must be lubricated as
outlined in the initial start-up procedures of the operation
manual. Refer to the appropriate Operation & Maintenance
Manual for unit.

7-1-13
7-1-14
1Bucket
Edition 1
DX210WA Bucket
7-2-1
MEMO
Bucket DX210WA
7-2-2
Table of Contents
Bucket
Bucket Tooth Inspection and Replacement ....7-2-6
Bucket O-ring Replacement ...........................7-2-7
Installation ................................................................. 7-2-8
Bucket Detaching and Reversal .....................7-2-9
Detaching .................................................................. 7-2-9
Reversal .................................................................... 7-2-9
DX210WA Bucket
7-2-3
Bucket DX210WA
7-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX210WA Bucket
7-2-5
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket tooth. Some of the most common types are
shown in the following drawings.
Bucket tooth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no longer
make full contact through the length of the pinhole.
• Lock washers or pins show obvious damage or weakness.
• Wear points on the working surfaces of tooth points - pits,
cracks, chips or craters - are larger than 8 mm to 10 mm
(1/3" to 1/2") across.
FG004607
Figure 1
HDO5057I-1
Figure 2
1. On a routine basis, inspect the bucket tooth to make sure

that tooth wear or breakage has not developed. Do not
allow the replaceable bucket tooth to wear down to the
point that bucket adapter is exposed. See Figure 1.
2. To replace a tooth (1, Figure 3), use a hammer and punch
to drive the locking pin (2) and lock washer (3) out of the
tooth adapter (4).
3. Once the worn tooth has been removed, use a putty knife
to scrape the adapter as clean as possible. 4
3
4. Slide the new tooth into position and insert the lock
2 1
washer.
5. Insert the locking pin into the tooth and with a hammer,
drive the pin in until lock washer seats in the locking Figure 3 EX1403298
groove.
Bucket DX210WA
7-2-6
BUCKET O-RING REPLACEMENT
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
1. Roll the old O-ring (1, Figure 4) onto the boss.

1 Arm 1
1 1
EX1404393
Figure 4
2. Remove double nut (1, Figure 5) and bolt (2).
• Tool: 24 mm ( ) 2
WE1400634
Figure 5
3. Remove the bucket pin (1, Figure 6).

• Bucket pin weight: about 20 kg (44 lb)
WE1400635
Figure 6
DX210WA Bucket
7-2-7
4. Separate the arm from the bucket and remove the O-ring
(1, Figure 7).
WE1400636
Figure 7
Installation
NOTE: Assemble double nut like Figure 9.
WE1400637
Figure 8
1 ~ 2 mm
EX1404398
Figure 9
Bucket DX210WA
7-2-8
BUCKET DETACHING AND REVERSAL
Detaching
Park the excavator away from obstructions on clear, flat, level
ground. Lower the bucket carefully to preassembled blocking on
the ground. Brace the bucket so that there is no load weight on
the pin connecting the bucket and arm. Disassemble the
fasteners on the end of the bucket pin and pull out the pin.
If the pin sticks and resists normal withdrawal, there may be a
load on it. Raise and lower the arm slightly until an unstressed
pin position is located.
CAUTION
AVOID INJURY
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble the
link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be
carried away or another end attachment can be put on the
excavator.
Reversal
Follow instructions for "Detaching" and remove both the bucket
and link pins. Rotate the bucket 180° to change bucket
configuration. This procedure is greatly simplified if some type of
rotating or swiveling support can be used, on the ground
underneath the bucket. Follow instructions for "Bucket
Attachment" to replace pins.
WARNING
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
DX210WA Bucket
7-2-9
Bucket DX210WA
7-2-10
Cylinders
Edition 1
DX210WA Cylinders
7-3-1
MEMO
Cylinders DX210WA
7-3-2
Table of Contents
Cylinders
General ...........................................................7-3-5
Specification .............................................................. 7-3-5
Parts List ................................................................... 7-3-6
Boom Cylinder (LH).............................................. 7-3-6
Boom Cylinder (RH) ............................................. 7-3-8
Arm Cylinder....................................................... 7-3-10
Bucket Cylinder .................................................. 7-3-12
Arti Boom Cylinder ............................................. 7-3-14
Seal of Cylinder ....................................................... 7-3-17
Special Tools and Materials .........................7-3-19
Piston Nut................................................................ 7-3-19
Piston Jig................................................................. 7-3-20
Steel Bushing Jig..................................................... 7-3-21
Dust Wiper Jig ......................................................... 7-3-22
Slipper Seal Jig ....................................................... 7-3-23
Slipper Seal Straightening Jig ................................. 7-3-24
Rod Bushing (DD-bushing) Pushing-in Jig.............. 7-3-25
Disassembly .................................................7-3-26
Reassembly ..................................................7-3-31
DX210WA Cylinders
7-3-3
Cylinders DX210WA
7-3-4
SAFETY INSTRUCTIONS
WARNING
machine. Read and understand the Operation & Maintenance
Manual and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs, adjustments
or servicing. Check for correct function after adjustments
repairs or service. Untrained operators and failure to follow
instructions can cause death or serious injury.
GENERAL
General Description
Two essentially similar types of hydraulic cylinders are used on
the excavator. The cylinder that is used to operate the excavator
boom or bucket is equipped with a rod stopper, which acts as a
cushion only when the cylinder rod is fully retracted (and the
bucket is pulled close to the arm). This type of cylinder is shown
in the lower drawing. Arm cylinders have a cushion or stopper
for operation in both directions. This type of cylinder is shown in
the upper drawing.
Specification
Rod O.D
Tube I.D
Stroke
Closed Length
Figure 1 EX1400068
Boom Arm Bucket Boom Arm Bucket

Arti Boom
(Mono) (Mono) (Arm 2.75, 3.0 m) (Arti) (Arti) (Arm 2.4 m)
Quantity 2 1 1 2 1 1 1
Tube I.D ø120 ø135 ø120 ø120 ø170 ø135 ø120
Rod O.D ø85 ø95 ø80 ø85 ø105 ø95 ø80
Stroke (mm) 1,225 1,450 1,060 1,045 748 1,440 1,060
Closed Length (mm) 1,800 2,010 1,630 1,550 1,253 2,105 1,630
Head End Cushion X O X X X O X
Rod End Cushion O O O O O O O
DX210WA Cylinders
7-3-5
Parts List
The following parts list is for complete parts list information.
Boom Cylinder (LH)
33
32
30
31
2
28
29
26
40
39
1 27
38
24
37
23
36 34 17
22
21
35 19
18
19
20
16
14
13
15
25 7
6
5
8 3
9
10
11
4
12
WE1400543
Figure 2
Cylinders DX210WA
7-3-6
Reference Reference
Number Number
1 Tube Assembly, Cylinder 22 Ring; Backup
2 Bush 23 Nut; Piston
3 Rod Assembly, Cylinder 24 Screw; Set
4 Bush 25 Bolt; Socket
5 Cover; Rod 26 Pipe Band Assembly
6 DD-bush 27 Band; Pipe
7 Ring; Retaining 28 Washer; Spring
8 Seal; Buffer 29 Bolt
9 U-packing 30 Pipe Assembly - H (LH)
10 Ring; Backup 31 O-ring
11 Wiper; Dust 32 Washer; Spring
12 Ring; Retaining 33 Bolt; Socket
13 O-ring 34 Pipe Assembly - R (LH)
16 Ring; Cushion 37 Bolt; Socket
17 Piston 38 Clamp; Pipe
18 Seal; Slipper 39 Washer; Spring
19 Ring; Wear 40 Bolt
20 Ring; Dust * Seal Kit; Boom
21 O-ring
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210WA Cylinders
7-3-7
Boom Cylinder (RH)
33
32
30
40
31
39
29
38
28 2
26
27
24
23
37 34
17
36 22
21
19
18
35 19
20
16
14
13
15
25 7
6
5
8 3
9
10
11
4
12
WE1400544
Figure 3
Cylinders DX210WA
7-3-8
Reference Reference
Number Number
1 Tube Assembly, Cylinder 22 Ring; Backup
2 Bush 23 Nut; Piston
3 Rod Assembly, Cylinder 24 Screw; Set
5 Cover; Rod 26 Pipe Band Assembly
8 Seal; Buffer 29 Bolt
9 U-packing 30 Pipe Assembly - H (RH)
13 O-ring 34 Pipe Assembly - R (RH)
20 Ring; Dust * Seal Kit; Boom
21 O-ring
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210WA Cylinders
7-3-9
Arm Cylinder
47
45 46
38
2
36
41 28
40 29
37
30
34
39 31
35 24
23
24
17
1 20
19
18
19
20
21
16 22
27 14
13
7 15
6
8
5 3
9
10
11
12 4
WE1400545
Figure 4
Cylinders DX210WA
7-3-10
Reference Reference
Number Number
1 Tube Assembly 22 Ring; Backup
2 Bush 23 Nut, Piston
3 Rod Assembly, Cylinder 24 Screw, Set
5 Cover, Rod 28 Valve; Check
6 DD-bush 29 Spring
7 Ring; Retaining 30 Support; Spring
8 Seal; Buffer 31 Plug; Hex. Socket
9 U-packing 34 Washer; Spring
10 Ring, Backup 35 Bolt; Hex
11 Wiper; Dust 36 Pipe Band Assembly - B
12 Ring; Retaining 37 Band; Pipe
13 O-ring 38 Pipe Assembly - R
18 Seal; Slipper 46 Washer, Spring
20 Ring; Dust * Seal Kit; Arm Cylinder
21 O-ring
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210WA Cylinders
7-3-11
Bucket Cylinder
36
35
27
34
2
26
38 39
30
40
26
33
32 28
34
27 37 35
29
31 36
24
1 23
24
17
20
19
18
19
20
21
22
16
14
13
25 15
7
6
5
8
9
10
11
12
3
WE1400546
Figure 5
Cylinders DX210WA
7-3-12
Reference Reference
Number Number
1 Tube Assembly 22 Ring; Backup
2 Bush 23 Nut, Piston
3 Rod, Cylinder 24 Screw; Set
4 Bushing, Carburizing 25 Bolt; Socket
5 Cover, Rod 26 Pipe Band Assembly
8 Seal; Buffer 29 Bolt; Hex
9 U-packing 30 Pipe Assembly - R
13 O-ring 34 Clamp; Pipe
14 Ring; Backup 35 Washer, Spring
15 O-ring 36 Bolt
16 Ring; Cushion 37 Pipe Assembly - H
17 Piston 38 O-ring
20 Ring; Dust * Seal Kit; Bucket Cylinder
21 O-ring
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210WA Cylinders
7-3-13
Arti Boom Cylinder
39 32
39
38 31
37 38
29
37
30
40
33
36
2
35
25
34
26
27 23
28
22
16
18
17
18
5 19
21
24 20
21
14
13
15
7
6
8
9
10
11
12 3
40
WE1400547
Figure 6
Cylinders DX210WA
7-3-14
Reference Reference
Number Number
1 Tube Assembly 22 Nut; Piston
2 Bushing 23 Screw; Set
3 Rod Assembly 24 Bolt; Socket
4 Bushing 25 Pipe Band Assembly
5 Cover; Rod 26 Band; Pipe
6 DD-bush 27 Washer; Spring
7 Ring; Retaining 28 Bolt
8 Seal; Buffer 29 Pipe Assembly - H
9 Packing; U 30 O-ring
10 Ring; Backup 31 Washer; Spring
11 Wiper; Dust 32 Bolt; Socket M10 x 1.5 x 60
12 Ring; Retaining 33 Pipe Assembly - R
13 O-ring 34 O-ring
14 Ring; Backup 35 Washer; Spring
15 O-ring 36 Bolt; Socket
18 Ring; Wear 39 Bolt; Socket
19 Ring; SLYD 40 Nipple; Grease
20 O-ring * Seal Kit; Arti Boom
21 Ring; Backup
*: 8, 9, 10, 11, 13, 14, 15, 17, 18, 19, 20, 21
DX210WA Cylinders
7-3-15
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
Cylinder piston rods are extended or retracted by oil flow to the

back side of the cylinder (shown as ("oil path A") or to the front of 3
the cylinder ("oil path B"). 2
The cylinder rod is extended as oil flow is pumped through the
circuit to the back side of the piston. The force (F1) of the piston
stroke can be expressed by the formula below, where P = circuit FG001456
oil pressure and the inside diameter of the cylinder is expressed Figure 7
by D (Figure 7).
F1 = P x πD2
4
(P: Pressure, π = 3.14, D: Cylinder Inside Diameter)
1 Cylinder Inside Diameter - D

2 Oil Path A
4
3 Oil Path B
4 Rod Diameter - R
1
When the cylinder rod is retracted, oil flow through the circuit
from the pump to the front side of the cylinder generates a force 2
(F2) that can be expressed by the formula in which the diameter
3
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression. FG001458
F2 = P x π(D2-R2) Figure 8
4
Because the volume of oil needed to lengthen the cylinder rod

(Q1) is greater than the volume of oil required to retract the
cylinder rod, it takes more time to extend a cylinder than it does
to retract it. 1
Q1 = S x π(D2)
4
Q2 = S x π(D2-R2)
4
Q1 > Q2 FG001459
Figure 9
Cylinders DX210WA
7-3-16
Seal of Cylinder
1. Assembly location and shape of seals
A. Rod cover seal
U-packing
Backup Ring
Retaining Ring
O-ring
Dust Wiper
Retaining Ring (DKBI Type)
Buffer Seal
DD(DU)-Bush
EX1301741
Figure 10
B. Piston seal
Dust Ring Dust Ring
Wear Ring Wear Ring

Piston Seal
Backup Ring
O-ring
EX1301742
Figure 11
DX210WA Cylinders
7-3-17
2. Seal function
No Name Function Material

Seal the hydraulic oil between the piston and the Slipper Seal, Glyd Ring,
1 Piston Seal inner surface of the tube. Compact Seal
Prevents scratch on the inner surface of the tube
Wear Ring and the rod surface caused by foreign materials,
2 and eccentric center, and eccentric load, and Phenol, Aramid
(DU-bushing) plays role bearing keeping stable friction
materials.
Contamination Protects the piston seal against the intrusion of
3 foreign material to keep the functions of the seal Dust Ring, Slyd Ring
Seal intact.
Seals for preventing leak of hydraulic oil between
4 Rod Seal U-packing, V-packing
the friction material and the cover of the rod.
Prevents surge/shock applied directly to the rod
5 Buffer Seal seal to extent lifecycle of the seal on the system Step Seal
for high-pressure.
Dust Seal Prevents intrusion of foreign materials into the
6 cylinder from outside environment to protect the Single Lip, Double Lip
(Dust Wiper) rod seal.
Prevents intrusion of foreign materials (e.g., rain
and snow), and makes sealing between the inner
7 O-ring surface of the tube and the rod cover, and NBR
between the rod and the inner diameter of the
piston.
Prevents disengaging U-packing and O-ring
8 Backup Ring PTFE, Nylon
because of pressure and gap.
Cylinders DX210WA
7-3-18
SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
A
35
350
Figure 12 FG018703
Material SM45C (AISI 1045)

Rockwell Hardened from 22 - 27
Oil Quench
Cylinder A
81.0 mm
Boom
(3.19 in)
101.0 mm
Arm
(3.98 in)
81.0 mm
Bucket
(3.19 in)
111.0 mm
Arti
(4.37 in)
DX210WA Cylinders
7-3-19
Piston Jig
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
5
R
4-
30
ARS4740L
Figure 13
Material SM45C (AISI 1045)
Rockwell Hardened from 22 ~ 27
Oil Quench
Cylinder A (±0.1) øB øC øD
90.0 mm 14.0 mm 80.0 mm 120.0 mm
Boom
(3.54 in) (0.55 in) (3.15 in) (4.72 in)
110.0 mm 14.0 mm 90.0 mm 135.0 mm
Arm
(4.33 in) (0.55 in) (3.54 in) (5.31 in)
90.0 mm 14.0 mm 80.0 mm 120.0 mm
Bucket
(3.54 in) (0.55 in) (3.15 in) (4.72 in)
130.0 mm 14.0 mm 105.0 mm 160.0 mm
Arti
(5.12 in) (0.55 in) (4.13 in) (6.30 in)
Cylinders DX210WA
7-3-20
Steel Bushing Jig
(5)
"B" + 40
"A" - 20
∅ "B"
∅"A"
(∅20)
15 F E
G
ARS4750L
Figure 14
Material: SM45C which is done thermal refining <QT> HRC 22 ~ 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.05
-0.15
øB (±0.1) E F+0.05
0
79.5 mm 94.0 mm 30.0 mm 6.5 mm
Boom
(3.13 in) (3.70 in) (1.18 in) (0.26 in)
79.5 mm 94.0 mm 30.0 mm 6.5 mm
Arm
(3.13 in) (3.70 in) (1.18 in) (0.26 in)
79.5 mm 94.0 mm 30.0 mm 6.5 mm
Bucket
(3.13 in) (3.70 in) (1.18 in) (0.26 in)
89.5 mm 104.0 mm 30.0 mm 6.0 mm
Arti
(3.52 in) (4.10 in) (1.18 in) (0.24 in)
DX210WA Cylinders
7-3-21
Dust Wiper Jig
5
C 1.
3-
R0.2
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 15
Material: SM45C which is done thermal refining <QT> HRC 22 ~ 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinder øA-0.2
-0.3 øB -0.2
-0.3 C 0-0.1 D
83.0 mm 99.0 mm 5.5 mm 10.0 mm
Boom
(3.27 in) (3.90 in) (0.22 in) (0.39 in)
93.0 mm 109.0 mm 5.0 mm 10.0 mm
Arm
(3.66 in) (4.29 in) (0.20 in) (0.39 in)
78.0 mm 94.0 mm 5.5 mm 10.0 mm
Bucket
(3.07 in) (3.70 in) (0.22 in) (0.39 in)
103.0 mm 121.0 mm 5.0 mm 10.0 mm
Arti
(4.06 in) (4.76 in) (0.20 in) (0.39 in)
Cylinders DX210WA
7-3-22
Slipper Seal Jig
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 16
Cylinder øA+0.2
+0.1 B+0.2
+0.1
120.0 mm 28.5 mm
Boom
(4.72 in) (1.12 in)
135.0 mm 26.0 mm
Arm
(5.31 in) (1.02 in)
120.0 mm 28.5 mm
Bucket
(4.72 in) (1.12 in)
170.0 mm 23.0 mm
Arti
(6.70 in) (0.91 in)
DX210WA Cylinders
7-3-23
Slipper Seal Straightening Jig
C2
∅20
1
2 -C
4
R
2-5
15
20
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 17
Cylinder øA+0.2
+0.1
120.7 mm
Boom
(4.75 in)
135.7 mm
Arm
(5.34 in)
120.7 mm
Bucket
(4.75 in)
170.7 mm
Arti
(6.72 in)
Cylinders DX210WA
7-3-24
Rod Bushing (DD-bushing) Pushing-in Jig
C1
A1
B
C1
C D
EX1301743
Figure 18
Inner diameter (A1): "A"-20 (no machining required on the inner

diameter)
Cylinder øA+0.2
-0.1 øB (±0.1) C D E
83.0 mm 89.0 mm 30.0 mm 67.0 mm 97.0 mm
Boom
(3.27 in) (3.50 in) (1.18 in) (2.64 in) (3.82 in)
94.0 mm 99.0 mm 30.0 mm 75.0 mm 105.0 mm
Arm
(3.70 in) (3.90 in) (1.18 in) (2.95 in) (4.13 in)
79.0 mm 84.0 mm 30 .0mm 67.0 mm 97.0 mm
Bucket
(3.11 in) (3.31 in) (1.18 in) (2.64 in) (3.82 in)
104.0 mm 109.0 mm 40.0 mm 14.0 mm 54.0 mm
Arti
(4.09 in) (4.29 in) (1.57 in) (0.55 in) (2.13 in)
1. Assemble the rod bushing with the exclusive jig (if

disassembled).
Push in the rod bushing in true vertical direction to prevent
inclining of the bushing.
Apply small volume of operating oil on inner surface of the
rod cover for facilitating pushing in.
2. Remove all of pushing-in residues generated during the
pushing-in process.
3. Mount the retaining ring on the rod cover groove at the end
of the rod bushing after cleaning to prevent disengagement
of the rod bushing.
(Mount the retaining ring manually with pliers, and check if
the ring is securely mounted.)
DX210WA Cylinders
7-3-25
DISASSEMBLY
CAUTION
AVOID INJURY
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement hydraulic fluid
into the system if excessive fluid is lost.
1. Following removal of cylinder from excavator attachment,

support cylinder on some type of sturdy work platform and
drain all oil. Rotate cylinder so piping ports are on top, to
allow trapped air to vent.
Figure 19
2. Position piston rod so it is extended approximately one half

meter (20").
Figure 20
Cylinders DX210WA
7-3-26
3. Remove bolts (27) on the end of cylinder.
NOTE: Wrap a cloth or other protective material around
piston rod, to avoid possibility of accidentally
scratching or scoring rod surface while
fasteners are being loosened and removed.
Component parts (numbered in parentheses)
are keyed to Figure 4.
Figure 21
4. Tap two bolts into cover of cylinder head, 180° apart.

Tighten them in a staggered, even sequence, to back off
piston rod end cover from edge of cylinder wall. Look for
adequate clearance between cover and end of cylinder
wall before using a plastic or other soft faced hammer for
final disassembly.
Figure 22
5. Begin withdrawing piston rod assembly, away from

cylinder. Attach a lifting support when final 1/3 of rod is still
inside barrel of cylinder. Prepare support blocks for piston
rod before it has been completely withdrawn.
Figure 23
6. Lower piston rod to support blocks and detach wear ring

(outer surface) (19) from end of rod.
Figure 24
DX210WA Cylinders
7-3-27
7. Immobilize piston rod by inserting a wooden or other
nonscoring, nonmetallic support through end of rod.
Figure 25
8. Remove set screw using socket wrench.
HAOF340L
Figure 26
9. Fabricate or purchase a piston nut removal wrench.

(Dimensions are called off at beginning of this procedure.
This tool may also be ordered through your local DOOSAN
Parts distributor). Remove nut from end of piston.
Figure 27
10. Use second piston tool described at beginning of this

procedure to separate piston. Detach cushion ring (16),
taking care not to damage cushion ring.
Figure 28
Cylinders DX210WA
7-3-28
11. Use a plastic hammer to evenly pull off rod cover (5) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 29
12. Use a dull, rounded tip tool to pry off O-ring (13) and
backup ring (14).
HAOF37OL
Figure 30
13. Find a screwdriver with an appropriate width tip to facilitate

removal of slipper seal (18), wear ring (19) and slide ring
(20) from piston (17).
Figure 31
14. Remove O-ring (21) and backup ring (22) from cylinder
head.
HAOF38OS
Figure 32
DX210WA Cylinders
7-3-29
15. During disassembly of cylinder head, be careful not to
damage buffer seal (8) and U-packing (9).
HAOF39OL
Figure 33
16. Disassemble retaining ring (12) and dust wiper (11).

Separate retaining ring (7) and rod bushing (6).
Figure 34
17. Force out pin bushing (2), (4) from body of cylinder.
Figure 35
Cylinders DX210WA
7-3-30
REASSEMBLY
IMPORTANT
Before reassembly:
• Inspect and replace damaged or excessively worn
parts.
• Clean parts and lubricate with clean hydraulic oil.
• Make sure work area is clean.
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts must be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
NOTE: Reassemble the subassemblies of the cylinder in the

following order:
1. Body of the cylinder.
2. Piston rod.
3. Piston assembly.
4. Cylinder head assembly.
1. Reassemble pin bushing (2), (4) to piston rod and body of
cylinder.
Figure 36
DX210WA Cylinders
7-3-31
2. Following reassembly of rod cover components, install the
dust wiper (11) and rod bushing (6) to the rod cover (5).
Insert retaining rings (7 and 12).
Figure 37
3. Prelubricate O-rings and seals before reassembly (Figure

38).
Figure 38
4. Before starting to rebuild piston assembly, heat slipper seal

for 5 minutes in an oil bath warmed to 150° - 180°C (302° -
356°F). Use special slipper seal jig (third item in list of
specialized tools at the beginning of this procedure) to
attach seal. Cool seal by pushing a retracting jig against
seal for several minutes. Apply a strip of clean,
see-through sealing tape around slipper seal to keep it free
of dust.
Figure 39
Cylinders DX210WA
7-3-32
5. Immobilize piston rod on solid support blocks. Assemble
O-ring (21) and backup ring (22). Prepare to attach rod
cover assembly to piston rod. Push rod cover by tightening
piston nut (23).
Figure 40
6. Assemble cushion ring (16) and attach piston assembly to

piston rod.
Figure 41
7. Use specially fabricate or factory sourced tool to tighten

piston nut (23).
Figure 42
8. Assemble wear ring (19), slide ring (20) and set screw (24)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 43
DX210WA Cylinders
7-3-33
9. Immobilize body of cylinder before reassembly.
Figure 44
Preapply fastener locking compound (Loctite #242 or #243 or an

alternate manufacturer's equivalent product) to all end cover
retaining bolts. Wrap a protective cushion around end of rod
while tightening fasteners, to prevent possible damage to
polished surface of rod, should a wrench slip during retightening.
Figure 45
Cylinders DX210WA
7-3-34
TROUBLESHOOTING
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches to dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in seal O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratches on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing.
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Oil leaking between Foreign material in U-packing. Remove foreign material.
cylinder head and piston Scratches in U-packing. Replace U-packing.
rod. Damage to U-packing. Replace U-packing.
Foreign material in dust wiper. Remove foreign material.
Scratches in dust wiper. Replace dust wiper.
Damage to dust wiper. Replace dust wiper.
Foreign material in O-ring. Remove foreign material.
Scratches in O-ring. Replace O-ring.
Damage to O-ring. Replace O-ring.
Scratch on sealing surface of piston If scratches are not deep, hone with an
rod. oil stone and lubricate.
If scratches are deep, replace piston
rod.
Deep scratches on inner surface of Replace bushing
bushing.
Oil leaking between Damage to O-rings. Replace O-rings.
cylinder head and cylinder
tube.
Oil leaking from welded Damage to welded area. Replace cylinder tube.
area of cylinder tube.
Cylinder drops from pull of Light scratches on sealing surface of Hone out scratches with oil stone.
gravity. cylinder tube.
Deep scratches on sealing surface of Replace cylinder tube.
cylinder tube.
Deep scratches on sealing surface of Replace O-rings.
piston O-rings.
Foreign material in U-packing. Remove foreign material.
DX210WA Cylinders
7-3-35
Cylinder drops from pull of Scratches in U-packing. Replace U-packing.
gravity. Damage to U-packing. Replace U-packing.
Wear rings twisted. Replace wear rings.
Wear rings scratched. Replace wear rings.
Wear rings have other damage. Replace wear rings.
Slow bucket and boom Reduced oil flow due to dirty filter or Disassemble and clean parts.
movements. dirty intake line.
Air drawn into circuit through loose Tighten intake connections.
connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting incorrect. Adjust relief valve pressure.
Damaged pump shaft or pump drive Replace damaged parts.
sleeve.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect cartridge.
Clean or replace cartridge.
Air in pressure line. Perform cylinder bleeding procedure to
remove air. Tighten or replace
pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low-pressure, shown by Reduced oil flow due to dirty filter or Disassemble and clean parts.
weak upward movement dirty intake line.
of boom and bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting incorrect. Adjust relief valve pressure.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect cartridge.
Clean or replace cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump discharge
discharge pipes. pipes.
Relief valve spring is weak. Relief Replace worn parts.
valve poppet worn.
Cylinder drops when Worn plunger in control valve. Replace plunger.
control valve is in neutral Stuck overload relief valve due to worn Replace worn parts.
seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic cylinder. Replace piston seal.
Vibration or excessive Excessive resistance in pump intake Inspect intake line and clean or replace
noise. line. as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of oil.
Oil level too low. Raise to proper level.
Air trapped in system Perform cylinder bleeding procedure to
remove air.
Frequent rubber hose System pressure too high. Adjust relief valve pressure.
damage. Hoses breaking due to contact with Restrain hoses to prevent contact.
another machine parts.
Cylinders DX210WA
7-3-36
1Hydraulic System
1Hydraulic
System
Edition 1
DX210WA Hydraulic System

8-1-1
MEMO
Hydraulic System DX210WA

8-1-2
Table of Contents
Hydraulic System
Hydraulic System............................................8-1-5
Hydraulic Schematic .......................................8-1-6
General Notes ........................................................... 8-1-6
Hydraulic Component and Oil Flow ................8-1-8
Hydraulic Components .............................................. 8-1-8
Main Oil Circuit ........................................................ 8-1-10
Pilot Oil Circuit......................................................... 8-1-11
Return Oil Circuit ..................................................... 8-1-12
Safety Cutoff Valve Operation ......................8-1-13
Power Up Valve Operation ...........................8-1-14
Swing Brake Release Operation ..................8-1-16
Travel Forward and Backward Operation .....8-1-18
Steering Operation .......................................8-1-19
Boom Up Operation ......................................8-1-20
Boom Down Operation .................................8-1-22
Arm Dump Operation....................................8-1-24
Arm Crowd Operation ...................................8-1-26
Bucket Dump Operation ...............................8-1-28
Bucket Crowd Operation ..............................8-1-30
Combined Bucket Crowd and Boom Up
Operation ......................................................8-1-32
Combined Travel and Boom, Arm, Bucket or Swing
Operation ......................................................8-1-33

8-1-3
8-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
HYDRAULIC SYSTEM
General Description
The hydraulic system has several improvements over
conventional hydraulic systems - including cross sensing total
horsepower control - to maximize output efficiency.
The system features an electronically controlled output
optimization system, which allows the operator to choose
between two, distinctly different power modes: high output/rapid
cycling maximum speed power mode, and a standard power
mode for most types of general operation.
Electronic management of hydraulic control valves assists in
optimizing the application speed and overall operator control of
hydraulic actuators and functions.

8-1-5
HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the "Hydraulic and
Schematic Shop Manual." This chapter is a diagrams and
schematics.
General Notes
When referring to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly is
driven by the engine. Mechanical energy is converted to
hydraulic power, generating the required hydraulic flow
which drives the system. Two main pumps (a drive side
pump and a idle side pump) make up the main pump
assembly.
• Hydraulic output from the drive side pump is transmitted to
the right side of the control valve. Output from the idle side
pump is transmitted to the left side of the control valve.
Hydraulic output from the pilot pump is used to control the
pump and to operate pilot and solenoid valves.
• The right half of the hydraulic control valve, supplied by the
drive side pump in the pump, operates spools for travel,
option, bucket, boom 1 and arm 2 functions. The amount of
oil flow to the actuators at the output end of each of those
circuits is regulated through the movement of each
individual valve spool.
• The left half of the hydraulic control valve, fed by the idle
side pump in the pump, operates spools for dozer, swing,
boom 2 and arm 1 operation.
• Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using the
output of only one half of the hydraulic pump (one pump or
the other), or – since both halves of the control valve have
a spool and available circuit for these functions – the
output of both pumps can be combined, allowing higher
speed operation. Boom up, arm crowd and dumping
functions can operate in any one of the two available
power modes – the standard or general duty mode, the
high speed/rapid cycling mode.
• Whenever the travel control spools are shifted, output from
the main pump passes through the center joint to the travel
motor driving the wheel.
• The transmission control valve is a 3-position type,
consisting of low speed, high speed and neutral positions.
This valve is switched to the neutral position to protect the
transmission when the parking brake is applied or when
the pilot supply pressure is dropped below the preset level.

8-1-6
• When the parking brake is applied by an operator or
system, the transmission control valve is switched to the
neutral position and power to the shuttle solenoid valve
and pilot cutoff valve is cut off, making all actuators
impossible to operate.
• When the parking brake is not applied, the transmission
control valve is switched to the low speed or high speed
position to protect the transmission from external force
occurred during excavating work.
• The hydraulic reservoir return line and the pilot circuit both
have 10 micron full flow filters. The disposable elements in
these two canister type filters trap and remove impurities
from the oil in the system. An 80 mesh, 177 micron
reservoir intake strainer also helps maintain system
cleanliness and should be cleaned each time hydraulic
fluid is drained and replaced. An oil cooler in the hydraulic
system helps maintain the operating temperature of the
system at approximately 50°C (122°F).
• The arm cylinder operating circuit includes anticavitation
valves which protect the hydraulic system from vacuum
that could result from external shocks or other unusual
conditions. Boom, Arm, and Bucket cylinder circuit are also
protected by overload relief valves. Whenever high-
pressure is generated as a result of a shock or overload,
excess pressure is dumped to the hydraulic oil tank
through the relief valve.

8-1-7
HYDRAULIC COMPONENT AND OIL FLOW
Hydraulic Components
PILOT CIRCUIT
64 OPT. PEDAL
59 OPT. PEDAL 71 OPT. PEDAL
16 14
LH (RO) (TWOWAY) LH (ARTI. BOOM) DOZER ARM/SWING BOOM/BUCKET MAIN CIRCUIT
HIGH
2
HIGH
2
DOWN
2 1 2 15 2
A3
4.6 bar 1 3 1 3 RETURN CIRCUIT

1
RH
1
RH
1
UP
2 4 4 2 1.2 bar 3.5 bar
HIGH 1 T P 2 1 T P 2 HIGH 1 T P 2 1 P T 2
XAd XBd
1 P 3 2 T 4 1 P 3 2 T 4
1.7 bar
10 SUCTION CIRCUIT
(DN) (UP)
A1 B1
R3
S1 R1
SOCKLESS
A2 B2 VALVE
A2 A1
41 7 26 bar
to ONE SPOOL T P1 W TRANSMISSION
M2 PRESSURE
T P
B2 S1 B1 4.6 bar SWING ARM BOOM BUCKET VALVE
A2 4 WARNING
6 1 2 3 4 5 6 P2
W
P2
C1 HO Pa1
(UP)
Pb1
(DN)
17 M
C5
(Front) EPPR
ROTATING V/V P3 T GP P1
7 13 8 14 9 15 10 16 11 17 12 18 Vgmax X1
PUMP
C6
PAR
XAt Ø0.7
XBs XAs ENGINE Vgmin A
CH C1 M 11
(R) (L) XAa2 XBa2 XBb2 XAk XBk DB58
3 5
C5 PBR
XBt Xak2
XAa1 XBa1 XBb1 XAb1
(CR) (DU) (UP) (DN) (CR) (DU) 63 IC C2 C1
2x0.7 L
M3 C4 GTS 30 bar
PZ PBP
43 0.75 L PB
B
(HIGH)
C6
103 bar
C3
PSA
PL X3 10 bar
C2 Vgmax P 125 bar
Vgmin C3 K
Fl
PS (LOW) C4 ACC A 12
C7 X1 C2 160 bar ACC B
C5
TS (Rear) T
T BLOCK
BRAKE
P BLOCK PSD
M SUPPLY W
P1 P1
A1 VALVE
1 R2 S
M1
G1 AC AB 65 bar
Front Rear LOW
T Axle Axle PRESSURE
A
WARNING
P
42
W
19 bar
AUTO IDLE
ACCEL PEDAL VALVE
0.5 bar
LH HIGH RH HIGH
Hammer Select
A
XAo XBo
26 27 13
A B SWING MOTOR SH
24 23
A2 ARTI V/V P A1
W
T 60 T 19 bar
R TRAVEL MODE P2 Py Pg Px P3 P4 P1 Pz
PL
Rs DB
PG
1.5 bar
BR1
4.6 bar
P1
T1
TANK
W
CRUISE BL1
A MRV 265 bar 265 bar
19
2.5 bar A2 A1 RELEASE
P2
P P 56 XBt
C
PB 25 2.0 bar 28 B2 S1 B1
BR2
4.6 bar
323 bar@90L/min PA W T2
W
from JOYSTICK(R) SWITCH 343 bar@90L/min CRUISE BL2
from SELECT SWITCH Bt to ONE SPOOL VALVE 65±4 bar
XAt TRAVEL RELEASE
Hammer Select operating AUTO RAM BRAKE VALVE
T2 OPERATE 80 bar
At A(LH) B(RH)
T1 P DOZER/STAB.
58 XBo 353 bar@20L
XAd Left Turn Right Turn
57
L
T2 73 Bo OPTION ROD Bd
Rear
Axle
Front
Axle L STEERING VALVE R
A B
22 BUCKETT1 P XAo
Ao HEAD Ad
XBd 225 +20
0 bar
8
R.H C Ck2 353 bar@20L
EPPR VALVE 353 bar@20L
55 P A
40 XBk Ø0.9
XAs
Bs
X
T
Fr
XAk
Bk1 ROD
353 bar@20L
BUCKET SWING Ø0.9
XBs CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1 29
XAb1 Ak1 HEAD As 8 8 2 2 8 8 4 4 8 8 2 4 4
JOINT
L X1 SOCKLESS 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2 35
57 53 (Front) VALVE
XBb1 BOOM2
Xop
L.H A Bb1 HEAD BOOM1 op
215 bar
Bar Pi 353 bar@20L XBb2
T Dr1 C Ab1 ROD
B ARM1
G B(HIGH) 34 GP 175 +10
0 bar
353 bar@20L
K(LOW)
X 54 XBa2 ARM2
BP 353 bar@20L
XBa1 31
RH HIGH ROD Ba1 CHOCK
XAa1
XAa2 Aa1
LH HIGH HEAD P T LS
BOOM X1(IC)
E D 353 bar@20L G 3 bar

Pa A B
18 F BC ARM Dr4 U T1 MB GEXT B
61 20 HOLDING GP
GP
J (FWD) Pi BL
ROTATING
PUMP
PA PA
M
qmax
39 STEER DOZER CF EF
E E S
P
EPPR VALVE qmin
A Y BR
CYLINDER
9
78 bar A (REV) LS
X1
CHOCK P
OIL COOLER MA
(RETURN ROOM) Pi1 Pi1 T2 M3
T
Pb
98 bar
T
PC
T
PC 51 X2
M2
30 GP
(TU) TRAVEL MOTOR
LOCK VALVE REAR AXLE
36 BRAKE
FRONT AXLE
BRAKE
LH HIGH
QUICK COUPLER VALVE XAa1
21 38C1 V2 T T
PC T Pil E V2
C2
V1
37
RH HIGH A B
33 32
ø1.0
V3
T P A V1 V1 A
P3 PA
67 ARTICULATED BOOM V3 V3
A
V2
SLOW C
52 RETURN
T
B LOCK VALVE 69 VALVE
62 ARM A B
P
from JOYSTICK(L) SWITCH

65 66 P.B A1 B1 T2 AO ONE WAY
70 57
PC T Pil E
275 bar 275 bar
72 L.H
Pb1 Pa1
(DN) (UP) T A
PA ARTI. SHUTTLE
ARTI. VALVE B2
SHUTTLE
68 VALVE B1 B A
LOCK VALVE P T1 R.H
C/V P4 OIL COOLER
EX1400796
Figure 1

8-1-8
Reference Reference
Number Number
1 Main Pump 38 2-solenoid Valve (For RE-OR.)
2 Pilot Filter 39 Chocking Valve
3 Accumulator (For Pilot) 40 Shockless Valve for Boom Down
4 Solenoid Valve (For Lower) 41 Shockless Valve for Arm Dump
5 Solenoid Valve (For TM) 42 Accelerator Pedal Valve
6 Solenoid Valve (For Upper) 43 Auto Idle Cylinder
7 Steering & Brake Pump 51 Lock Valve for Boom
8 Steering Unit 52 Lock Valve for Arm
9 Priority Valve Proportional Valve
53
10 Brake Filter (for Flow Control)
11 Brake Supply Valve 54 Select Valve with Relief
12 Accumulator (For Brake) 55 Select Valve
13 Brake Pedal 56 2-solenoid Valve for PE3C
14 Joystick Valve (LH) 57 Stop Valve
15 Joystick Valve (RH) 58 Breaker Filter
16 Joystick Valve (Dozer) 59 Option Pedal Valve for PE3C
17 Joint Plate 60 1-solenoid Valve for PE3C
18 Control Valve 61 Rotating Valve
19 Swing Device 62 2-solenoid Valve for Pero
20 Boom Cylinder 63 Rotating Pump
21 Arm Cylinder 64 Option Pedal Valve for Pero
22 Bucket Cylinder 65 Quick Coupler Valve
23 Oil Cooler 66 Quick Coupler
24 Restriction Valve 67 Arti. Boom Cylinder
25 Restriction Valve 68 Lock Valve for Arti. Boom
26 Full Flow Filter 69 Slow Return Valve for Arti. Boom
27 Air Breather 70 Control Valve for Arti. Boom
28 Hydraulic Tank 71 Option Pedal Valve for Arti. Boom
29 Center Joint 72 Relief Valve for Breaker
30 Travel Motor 73 Switch Valve (for Clamshell)
31 Transmission A Main Relief Valve
32 Front Axle B Boom Priority Valve
33 Rear Axle C Boom Holding Valve
34 Chocking Cylinder D Arm Holding Valve
35 Dozer Blade (Front) E Foot Relief Valve
36 Stabilizer (Rear) F Foot Relief Valve
37 1-solenoid Valve (For FR-DZ.) G Arm Regeneration Valve

8-1-9
Main Oil Circuit
While engine is running, oil is supplied to actuator depending on actuator operation signal as oil path changes
when oil is supplied to parking brake release line, etc. of main control valve (18), pilot package valve (4),
accumulator (3), and swing device (19) with main pump (1) and pilot pump operating.
Load condition of actuator will cause a change to oil flow and pressure of main control valve (18) and foot relief
valve (E, F) detects the pressure and transfers to X1 (drive), X1 (idle) of main pump (1).
Flow of oil supplied from main pump (1) changes depending on the actuator pressure transferred to the main
pump (1).
64 OPT. PEDAL
16 14
LH (RO) (TWOWAY) LH (ARTI. BOOM) DOZER ARM/SWING BOOM/BUCKET
HIGH
2
HIGH
2
DOWN
2 1 2 15 2
A3
4.6 bar 1 3 1 3
1
RH
1
RH
1
UP
2 4 4 2 1.2 bar 3.5 bar
XAd XBd
1 P 3 2 T 4 1 P 3 2 T 4
1.7 bar
10
(DN) (UP)
A1 B1
R3
S1 R1
SOCKLESS
A2 B2 VALVE
A2 A1
41 7 26 bar
to ONE SPOOL T P1 TRANSMISSION
M2 PRESSURE
T P
A2 4 WARNING
6 1 2 3 4 5 6 P2
W
P2
C1 HO Pa1
(UP)
Pb1
(DN)
17 M
C5
(Front) EPPR
7 13 8 14 9 15 10 16 11 17 12 18 Vgmax X1
PUMP
C6
PAR
XAt Ø0.7
CH C1 M 11
3 5
C5 PBR
XBt Xak2
XAa1 XBa1 XBb1 XAb1
2x0.7 L
M3 C4 GTS 30 bar
PZ PBP
43 0.75 L PB
B
(HIGH)
C6
103 bar
C3
PSA
PL X3 10 bar
C2 Vgmax P 125 bar
Vgmin C3 K
Fl
C5
TS (Rear) T
T BLOCK
BRAKE
P BLOCK PSD
M SUPPLY
P1 P1
A1 VALVE
1 R2 S
M1
G1 AC AB 65 bar
Front Rear LOW
A
WARNING
P
42
W
19 bar
AUTO IDLE
ACCEL PEDAL VALVE
0.5 bar
LH HIGH RH HIGH
Hammer Select
A
XAo XBo
26 27 13
A B SWING MOTOR SH
24 23
A2 ARTI V/V P A1
W
T 60 T 19 bar
PL
Rs DB
PG
1.5 bar
BR1
4.6 bar
P1
T1
TANK CRUISE BL1
19
P2
P P 56 XBt
C
PB 25 2.0 bar 28 B2 S1 B1
BR2
4.6 bar
323 bar@90L/min PA T2
XAt TRAVEL RELEASE
T2 OPERATE 80 bar
At A(LH) B(RH)
T1 P DOZER/STAB.
58 XBo 353 bar@20L
57
L
Rear
Axle
Front
A B
22 BUCKETT1 P XAo
Ao HEAD Ad
XBd 225 +20
0 bar
8
55 P A
40 XBk Ø0.9
XAs
Bs
X
T
Fr
XAk
Bk1 ROD
353 bar@20L
BUCKET SWING Ø0.9
XBs CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1 29
XAb1 Ak1 HEAD As 8 8 2 2 8 8 4 4 8 8 2 4 4
JOINT
L X1 SOCKLESS 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2 35
57 53 (Front) VALVE
XBb1 BOOM2
Xop
215 bar
T Dr1 C Ab1 ROD
B ARM1
G B(HIGH) 34 GP 175 +10
0 bar
353 bar@20L
K(LOW)
X 54 XBa2 ARM2
BP 353 bar@20L
XBa1 31
XAa1
XAa2 Aa1
LH HIGH HEAD P T LS
BOOM X1(IC)

Pa A B
61 20 HOLDING GP
GP
J (FWD) Pi BL
ROTATING
PUMP
PA PA
M
qmax
E E S
P
EPPR VALVE qmin
A Y BR
CYLINDER
9
78 bar A (REV) LS
X1
CHOCK P
OIL COOLER MA
T
Pb
98 bar
T
PC
T
PC 51 X2
M2
30 GP
(TU) TRAVEL MOTOR
36 BRAKE
FRONT AXLE
BRAKE
LH HIGH
21 38C1 V2 T T
PC T Pil E V2
C2
V1
37
RH HIGH A B
33 32
ø1.0
V3
T P A V1 V1 A
P3 PA
A
V2
SLOW C
52 RETURN
T
62 ARM A B
P

70 57
PC T Pil E
275 bar 275 bar
72 L.H
Pb1 Pa1
(DN) (UP) T A
PA ARTI. SHUTTLE
ARTI. VALVE B2
SHUTTLE
68 VALVE B1 B A
LOCK VALVE P T1 R.H
C/V P4 OIL COOLER
EX1400797
Figure 2

8-1-10
Pilot Oil Circuit
Pilot pump receives oil supply from hydraulic tank (28) which is linked to engine rpm and for improvement of
response to operation, accumulator (3) is first filled with the oil after it passes through pilot filter (2), and the oil is
supplied to solenoid package valve (4).
After passing through solenoid package valve (4), pilot oil is used for signal pressure control, for spool control of
main control valve (18) as it is connected to joystick valve (14, 15) and accelerator pedal valve (42) and as a
signal for parking brake release of swing device (19).
64 OPT. PEDAL
16 14
HIGH
2
HIGH
2
DOWN
2 1 2 15 2
A3
4.6 bar 1 3 1 3
1
RH
1
RH
1
UP
2 4 4 2 1.2 bar 3.5 bar
XAd XBd
1 P 3 2 T 4 1 P 3 2 T 4
1.7 bar
10
(DN) (UP)
A1 B1
R3
S1 R1
SOCKLESS
A2 B2 VALVE
A2 A1
41 7 26 bar
M2 PRESSURE
T P
A2 4 WARNING
6 1 2 3 4 5 6 P2
W
P2
C1 HO Pa1
(UP)
Pb1
(DN)
17 M
C5
(Front) EPPR
7 13 8 14 9 15 10 16 11 17 12 18 Vgmax X1
PUMP
C6
PAR
XAt Ø0.7
CH C1 M 11
3 5
C5 PBR
XBt Xak2
XAa1 XBa1 XBb1 XAb1
2x0.7 L
M3 C4 GTS 30 bar
PZ PBP
43 0.75 L PB
B
(HIGH)
C6
103 bar
C3
PSA
PL X3 10 bar
C2 Vgmax P 125 bar
Vgmin C3 K
Fl
C5
TS (Rear) T
T BLOCK
BRAKE
P BLOCK PSD
M SUPPLY
P1 P1
A1 VALVE
1 R2 S
M1
G1 AC AB 65 bar
Front Rear LOW
A
WARNING
P
42
W
19 bar
AUTO IDLE
ACCEL PEDAL VALVE
0.5 bar
LH HIGH RH HIGH
Hammer Select
A
XAo XBo
26 27 13
A B SWING MOTOR SH
24 23
A2 ARTI V/V P A1
W
T 60 T 19 bar
PL
Rs DB
PG
1.5 bar
BR1
4.6 bar
P1
T1
TANK CRUISE BL1
19
P2
P P 56 XBt
C
PB 25 2.0 bar 28 B2 S1 B1
BR2
4.6 bar
XAt TRAVEL RELEASE
T2 OPERATE 80 bar
At A(LH) B(RH)
T1 P DOZER/STAB.
58 XBo 353 bar@20L
57
L
Rear
Axle
Front
A B
22 BUCKETT1 P XAo
Ao HEAD Ad
XBd 225 +20
0 bar
8
55 P A
40 XBk Ø0.9
XAs
Bs
X
T
Fr
XAk
Bk1 ROD
353 bar@20L
BUCKET SWING Ø0.9
XBs CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1 29
XAb1 Ak1 HEAD As 8 8 2 2 8 8 4 4 8 8 2 4 4
JOINT
L X1 SOCKLESS 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2 35
57 53 (Front) VALVE
XBb1 BOOM2
Xop
215 bar
T Dr1 C Ab1 ROD
B ARM1
G B(HIGH) 34 GP 175 +10
0 bar
353 bar@20L
K(LOW)
X 54 XBa2 ARM2
BP 353 bar@20L
XBa1 31
XAa1
XAa2 Aa1
LH HIGH HEAD P T LS
BOOM X1(IC)

Pa A B
61 20 HOLDING GP
GP
J (FWD) Pi BL
ROTATING
PUMP
PA PA
M
qmax
E E S
P
EPPR VALVE qmin
A Y BR
CYLINDER
9
78 bar A (REV) LS
X1
CHOCK P
OIL COOLER MA
T
Pb
98 bar
T
PC
T
PC 51 X2
M2
30 GP
(TU) TRAVEL MOTOR
36 BRAKE
FRONT AXLE
BRAKE
LH HIGH
21 38C1 V2 T T
PC T Pil E V2
C2
V1
37
RH HIGH A B
33 32
ø1.0
V3
T P A V1 V1 A
P3 PA
A
V2
SLOW C
52 RETURN
T
62 ARM A B
P

70 57
PC T Pil E
275 bar 275 bar
72 L.H
Pb1 Pa1
(DN) (UP) T A
PA ARTI. SHUTTLE
ARTI. VALVE B2
SHUTTLE
68 VALVE B1 B A
LOCK VALVE P T1 R.H
C/V P4 OIL COOLER
EX1400798
Figure 3

8-1-11
Return Oil Circuit
While engine is running, oil is supplied to actuator depending on the operation signal as oil path changes when oil
is supplied to parking brake release line, etc. of main control valve (18), pilot package valve (4) and accumulator
(3) with main pump (1) and pilot pump operating.
If no operation signal is input, oil bypasses and returns to hydraulic tank (28) after passing through full flow filter
(26) or oil cooler (23).
64 OPT. PEDAL
16 14
HIGH
2
HIGH
2
DOWN
2 1 2 15 2
A3
4.6 bar 1 3 1 3
1
RH
1
RH
1
UP
2 4 4 2 1.2 bar 3.5 bar
XAd XBd
1 P 3 2 T 4 1 P 3 2 T 4
1.7 bar
10
(DN) (UP)
A1 B1
R3
S1 R1
SOCKLESS
A2 B2 VALVE
A2 A1
41 7 26 bar
M2 PRESSURE
T P
A2 4 WARNING
6 1 2 3 4 5 6 P2
W
P2
C1 HO Pa1
(UP)
Pb1
(DN)
17 M
C5
(Front) EPPR
7 13 8 14 9 15 10 16 11 17 12 18 Vgmax X1
PUMP
C6
PAR
XAt Ø0.7
CH C1 M 11
3 5
C5 PBR
XBt Xak2
XAa1 XBa1 XBb1 XAb1
2x0.7 L
M3 C4 GTS 30 bar
PZ PBP
43 0.75 L PB
B
(HIGH)
C6
103 bar
C3
PSA
PL X3 10 bar
C2 Vgmax P 125 bar
Vgmin C3 K
Fl
C5
TS (Rear) T
T BLOCK
BRAKE
P BLOCK PSD
M SUPPLY
P1 P1
A1 VALVE
1 R2 S
M1
G1 AC AB 65 bar
Front Rear LOW
A
WARNING
P
42
W
19 bar
AUTO IDLE
ACCEL PEDAL VALVE
0.5 bar
LH HIGH RH HIGH
Hammer Select
A
XAo XBo
26 27 13
A B SWING MOTOR SH
24 23
A2 ARTI V/V P A1
W
T 60 T 19 bar
PL
Rs DB
PG
1.5 bar
BR1
4.6 bar
P1
T1
TANK CRUISE BL1
19
P2
P P 56 XBt
C
PB 25 2.0 bar 28 B2 S1 B1
BR2
4.6 bar
XAt TRAVEL RELEASE
T2 OPERATE 80 bar
At A(LH) B(RH)
T1 P DOZER/STAB.
58 XBo 353 bar@20L
57
L
Rear
Axle
Front
A B
22 BUCKETT1 P XAo
Ao HEAD Ad
XBd 225 +20
0 bar
8
55 P A
40 XBk Ø0.9
XAs
Bs
X
T
Fr
XAk
Bk1 ROD
353 bar@20L
BUCKET SWING Ø0.9
XBs CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1 29
XAb1 Ak1 HEAD As 8 8 2 2 8 8 4 4 8 8 2 4 4
JOINT
L X1 SOCKLESS 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2 35
57 53 (Front) VALVE
XBb1 BOOM2
Xop
215 bar
T Dr1 C Ab1 ROD
B ARM1
G B(HIGH) 34 GP 175 +10
0 bar
353 bar@20L
K(LOW)
X 54 XBa2 ARM2
BP 353 bar@20L
XBa1 31
XAa1
XAa2 Aa1
LH HIGH HEAD P T LS
BOOM X1(IC)

Pa A B
61 20 HOLDING GP
GP
J (FWD) Pi BL
ROTATING
PUMP
PA PA
M
qmax
E E S
P
EPPR VALVE qmin
A Y BR
CYLINDER
9
78 bar A (REV) LS
X1
CHOCK P
OIL COOLER MA
T
Pb
98 bar
T
PC
T
PC 51 X2
M2
30 GP
(TU) TRAVEL MOTOR
36 BRAKE
FRONT AXLE
BRAKE
LH HIGH
21 38C1 V2 T T
PC T Pil E V2
C2
V1
37
RH HIGH A B
33 32
ø1.0
V3
T P A V1 V1 A
P3 PA
A
V2
SLOW C
52 RETURN
T
62 ARM A B
P

70 57
PC T Pil E
275 bar 275 bar
72 L.H
Pb1 Pa1
(DN) (UP) T A
PA ARTI. SHUTTLE
ARTI. VALVE B2
SHUTTLE
68 VALVE B1 B A
LOCK VALVE P T1 R.H
C/V P4 OIL COOLER
EX1400799
Figure 4

8-1-12
SAFETY CUTOFF VALVE OPERATION
Oil from the hydraulic tank (28) fills accumulator (3) first after passing through pilot pump and pilot filter (2) and is
supplied to the solenoid package valve (4).
If an electric signal is inputted to safety cutoff valve (3) installed to the solenoid package valve (5), the oil sent to
main control valve (18), accelerator pedal valve (42) and joystick valve (14, 15) is returned to hydraulic tank
installed to inside of pilot pump through relief valve.
Once safety cutoff valve is operated, any operation of machine is switched to safety mode and actuator will not
operate even if joystick lever is moved.
64 59 71 16 14 15
OPT. PEDAL OPT. PEDAL OPT. PEDAL
LH
HIGH
(RO) (TWOWAY) LH
HIGH
(ARTI. BOOM)
DOWN
DOZER ARM/SWING BOOM/BUCKET
2 1.2 bar
2 2 2 1 2 2
1.7 bar
1 3 1 3
1 1 1 2 4 4
RH RH UP 1 P T 2
HIGH 1 T P 2 1 T P 2 HIGH 1 T P 2 1 P 3 2 T 4 1 P 3 2 T 4
T P1
4 P2
C5
P3
CH
C1
3
IC C2
A3 GTS
C4
0.75 L PB Safety Cut-off
10 bar PS Valve
C3
R3
T
42 T BLOCK P BLOCK R1
A
P
7
ACCEL PEDAL VALVE
M2
to ONE SPOOL A2
VALVE M
R P2 Py Pg Px P3 P4 P1 Pz Rs (Front)
ROTATING Vgmax
PUMP ENGINE Vgmin X1
DB58
A MRV
63
M3
XBt 323 bar@90L/min
343 bar@90L/min
43
Vgmax X3
Bt TRAVEL Vgmin
XAt
At X1
DOZER/STAB. (Rear)
353 bar@20L
XBo XAd M
Bo
XAo
OPTION ROD Bd
XBd 1 A1
M1
Ao Ad R2 S
HEAD
Ck2 353 bar@20L
353 bar@20L
XBk XAs
Bk1 ROD BUCKET SWING Bs
XAk 353 bar@20L XBs
Ak1 HEAD As
XAb1
XBb1 BOOM2 0.5 bar
Bb1 Xop
Dr1 HEAD BOOM1 op 27
353 bar@20L XBb2
Ab1 ROD
B ARM1 G
353 bar@20L
BP 353 bar@20L
26
XBa2 XBa1 TANK
ARM2
ROD Ba1
XAa2 XAa1
Aa1
28
HEAD
E D 353 bar@20L
F BC ARM Dr4
18 HOLDING
EX1400800
Figure 5

8-1-13
POWER UP VALVE OPERATION
Pilot oil that passes through solenoid package valve (6) inside is supplied to main relief valve PZ port of main
control valve (18) the following the signal of power up button of RH joystick (15).
Once the oil is supplied to PZ port of main control valve (18), the setting pressure of main relief valve (A) is
changed from 323 to 343 bar, increasing power of actuator.
A3
2 1.2 bar
T P 1.7 bar
R3
6 R1
C1 HO 15
7 T P1
PAR to ONE SPOOL
VALVE M2
C6
A2
P2
4 P2
PBR M
C5
C5 ROTATING (Front) P3
PUMP Vgmax
ENGINE Vgmin X1
PL DB58 CH
C2 C1
63 3
M3
43 X3
IC C2
GTS
C7 Vgmax C4
Vgmin
0.75 L PB
TS X1 10 bar
C3
(Rear) PS
P1
M
A1 P1
1 S
M1
R2
0.5 bar
A MRV 27
XBt 323 bar@90L/min
343 bar@90L/min
Bt TRAVEL
XAt 26 TANK
At
DOZER/STAB.
XBo
353 bar@20L
XAd
28
Bo OPTION ROD Bd
XAo XBd
Ao HEAD Ad
Ck2 353 bar@20L
353 bar@20L
XBk XAs
Bk1 ROD BUCKET Bs
SWING
XAk 353 bar@20L XBs
Ak1 HEAD As
XAb1
XBb1 BOOM2
Xop
HEAD BOOM1 op
353 bar@20L XBb2
Ab1
ROD
B ARM1
G
353 bar@20L
BP 353 bar@20L
XBa2 XBa1
ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
E D 353 bar@20L
F BC ARM
Dr4
18 HOLDING
EX1400801
Figure 6

8-1-14
If pressure is applied to the voltage step-up pilot port "PZ",
Piston “E”
piston "E" moves to pilot poppet. As a result, spring force of pilot
poppet will increase, causing setting pressure increase of "HP"
(From 323 to 343 bar).
PZ
“HP”
“LP”
WE1400887
Figure 7

8-1-15
SWING BRAKE RELEASE OPERATION
Oil that passed through solenoid package valve (4) inside moves swing spool of main control valve (18) the
following the operation of joystick valve (14).
Once swing spool moves, pressure of oil supplied from pilot pump to main control valve's (18) PG port increases
and the oil is supplied to swing device's (19) SH port causing brake release spool to move.
Then oil is supplied to swing device's (19) PG port connected to solenoid valve (4) P3 port and swing parking
brake is released.
A3
2 1.2 bar
1.7 bar
ARM / SWING R3
14 R1
2
1 3
7
to ONE SPOOL T P1
4
VALVE M2
1 P 3 2 T 4 A2
P2
4 P2
M
C5
ROTATING (Front) P3
PUMP Vgmax X1
ENGINE Vgmin CH
C1
DB58
3
63 IC C2
GTS
43 M3
C4
Safety
X3 0.75 L PB Cut-off
SWING Vgmax 10 bar Valve
Vgmin C3
PS
X1
(Rear)
XBs P BLOCK
(Right) M
A1
1 S
M1
R2
A2
SWING MOTOR SH
A MRV PG
323 bar@90L/min DB
XBt 343 bar@90L/min
0.5 bar
Bt TRAVEL
XAt 265 bar 265 bar 27
At 19
DOZER/STAB. C
353 bar@20L PB
XBo XAd PA
Bo
XAo
OPTION ROD Bd
XBd
26 TANK
Ao HEAD Ad
Ck2
353 bar@20L 353 bar@20L XAs
28
XBk A(LH) B(RH)
Ø0.9 Bs
Bk1 ROD BUCKET SWING Ø0.9
XAk 353 bar@20L XBs
Ak1 HEAD As
XAb1
XBb1 BOOM2
Xop
HEAD BOOM1 op
353 bar@20L XBb2
Ab1
ROD
B ARM1
G
353 bar@20L
BP 353 bar@20L
XBa2 XBa1
ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
E D 353 bar@20L
F BC ARM
Dr4
18 HOLDING

EX1400802
Figure 8

8-1-16
Load Check Valve
As(LH) Bs(RH)
XAs(LH) XBs(RH)
Swing Center Bypass
Swing Motor
As
XBs
Bs Swing
XAs
P1 WE1400486
Figure 9

8-1-17
TRAVEL FORWARD AND BACKWARD OPERATION
When placing the right combination switch to the forward (backward) position, an electric signal is applied to the
C6 (C5) solenoid of the solenoid valve (6) to switch the C6 (C5) solenoid spool.
After oil is passed through the pilot filter (2), it is delivered to the port XAt (XBt) of the main control valve (18)
through the port PAR (PBR) of the solenoid valve (6) to switch the travel spool. Oil being ready at the travel spool
under high pressure is supplied to the port B (A) of the travel motor to drive the axle through the transmission for
forward (backward) operation.
A3
2 1.2 bar
R3 1.7 bar
R1
T P
6 to ONE SPOOL
7
C1 VALVE M2
HO A2
PAR M
C6 EPPR
ROTATING (Front)
PUMP Vgmax V/V
X1 A
PBR ENGINE Vgmin
C5 DB58
63
43 M3
PL Vgmax X3
C2 Vgmin
Fl
X1
(Rear)
C7
M
TS
1 A1
M1
P1 R2 S
0.5 bar
23 27
24
2.5 bar
26 TANK
R TRAVEL MODE P2 Py Pg Px P3 P4 P1 Pz Rs
28
A MRV
XBt 323 bar@90L/min

343 bar@90L/min
Bt TRAVEL
XAt
At 29
DOZER/STAB. 353 bar@20L CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1
XBo XAd 8 8 2 2 8 8 4 4 8 8 2 4 4
JOINT 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
Bo OPTION ROD Bd
XAo XBd
Ao Ad
HEAD
B(HIGH)
Ck2
353 bar@20L 353 bar@20L K(LOW)
XBk XAs 31
XAk 353 bar@20L XBs
Ak1 HEAD As
X1(IC)
XAb1
XBb1 G
BOOM2 U T1 MB GEXT B
Xop
HEAD BOOM1 op J (FWD)
353 bar@20L XBb2 M
Ab1
ROD
B ARM1
G qmax
S
353 bar@20L
353 bar@20L qmin
BP A
XBa2 XBa1
ARM2 (REV)
ROD Ba1
XAa2 XAa1 T2 MA
HEAD Aa1 M3
M2 30
E D 353 bar@20L X2
F BC ARM
Dr4 (TU) TRAVEL MOTOR
18 HOLDING
EX1400803
Figure 10

8-1-18
STEERING OPERATION
Hydraulic oil delivered from the gear pump, which is connected to the PTO (Power Take-Off) of the main pump (1),
is transferred to the port P of priority valve (9) which then delivers the oil to the port CF.
Then, this oil is supplied to the port P of the steering unit (8) to build up pressure in the steering unit (8).
This hydraulic oil in the steering unit (8) built up by driver's operation of the steering wheel is delivered to the port
"L" or port "R". Then, it passes through the port "8" or "9" of the center joint (29) to be delivered to the steering
cylinder of the front axle (32) in order to complete the steering operation.
If load is generated during the steering operation, the spool in the priority valve (9) is switched to open the port
EF. Then, oil led into the steering unit (8) is returned to the tank to protect the steering system circuit. (Load
sensing function)
A3
R3
R1
7
to ONE SPOOL
VALVE M2
A2
P2
M
ROTATING (Front)
PUMP Vgmax
ENGINE Vgmin X1
DB58
63
M3
43 0.5 bar
X3
Vgmax
Vgmin 27
X1 26
(Rear)
M
TANK
A1 P1
1 M1
28
R2 S
CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1 29
JOINT 8 8 2 2 8 8 4 4 8 8 2 4 4
4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
Left Turn Right Turn
L STEERING VALVE R
225+20
0 bar
8
B(HIGH) 34 GP
K(LOW)
31
CHOCK
X1(IC)
G
U T1 MB GEXT B
GP J (FWD) Pi BL
GP
M 39
qmax STEER DOZER
S 175+10
0 bar
qmin CYLINDER
A Y BR
(REV)
CHOCK
MA
T2 M3
M2
X2 30 GP
P T LS
3 bar
(TU) TRAVEL MOTOR
REAR AXLE FRONT AXLE
36 BRAKE BRAKE
T T CF EF
38 V2 V2 V1 37
C1 C2
32 35 9
33 V1 V1 A
V3
LS
V3 V3
V2 P
A
C
EX1400819
Figure 11

8-1-19
BOOM UP OPERATION
Oil supplied from hydraulic tank (28) passes through pilot pump connected to main pump (1) and pilot filter (2) and
is supplied to solenoid package valve (4) after accumulator (3) is first filled with the oil.
If the pilot oil is supplied to boom spool of main control valve (18) by the operation of joystick valve (15), the spool
is moved and oil passage of main pump (1) and the one on the boom cylinder (20) head side open.
Oil supplied from main pump (1) is supplied to boom cylinder (20) head, causing the moving to take place.
If boom up operation is stopped, the oil in boom cylinder is obstructed by check of boom holding valve (C) and the
moving of boom is blocked.
A3
BOOM / BUCKET
15 2
2 1.2 bar
1 3
1.7 bar
4 R3
R1
1 P 3 2 T 4
7
to ONE SPOOL
VALVE M2
A2
M
ROTATING (Front)
PUMP Vgmax
ENGINE Vgmin X1
DB58 T P1
63 4 P2
ARM BOOM BUCKET M3
1 2 3 4 5 6 43 X3 C5
17 UP Vgmax
Vgmin P3
X1 CH
C1
7 13 8 14 9 15 10 16 11 17 12 18 P BLOCK
(Rear)
3 IC
M 0.75 L C2
XAa2 XBa2 XAk XBk GTS
A1 10 bar C4
XAa1 XBa1 XAb1 1 M1
R2 S PB Safety
PBP Cut-off
C3 Valve
PS
PL 0.5 bar
23 27
20 20 A MRV
24
BOOM 2.5 bar
XBt 323 bar@90L/min
343 bar@90L/min 26 TANK
Bt TRAVEL
XAt
At 28
PA PA DOZER/STAB.
E E 353 bar@20L
XAo XAd
Bo OPTION ROD Bd
XBo XBd
Ao HEAD Ad
Pi1 Pi1
Ck2 353 bar@20L
T T 353 bar@20L
51 PC PC 51 XBk XAs
LOCK VALVE LOCK VALVE Bk1 ROD BUCKET SWING Bs
XAk 353 bar@20L XBs
Ak1 HEAD As
XAb1
XBb1 BOOM2
Bb1 Xop
HEAD BOOM1 op
Pi 353 bar@20L
XBb2
Dr1
C Ab1 ROD
B ARM1
G
353 bar@20L
XBa2 BP 353 bar@20L
XBa1
ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
D 353 bar@20L
E F BC ARM
Dr4
18 HOLDING

A
X1
EX1400804
Figure 11

8-1-20
Ab1
Pi Dr1
Bb1
1
Boom Cylinder
2 (Pc)
3 (Pv)
XBb1 XAb1
(up) (down)
Tank Passage
Boom Cylinder
ROD Ab1
353bar@20L
Dr1
HEAD
Boom 1 Pi
Bb1
XBb1
XAb1
P2 WE1400476
Figure 12

8-1-21
BOOM DOWN OPERATION
If the pilot oil is supplied to boom spool of main control valve (18) by the operation of joystick valve (15), the spool
is moved and oil passage of main pump and the one on the boom cylinder (20) rod side open.
Oil passage supplied from main pump (1) is supplied to boom cylinder (20) rod side after passing through
shockless valve (40), causing the moving to take place.
Rapidly occurring boom down causes short supply of oil in the cylinder rod side, in which case the oil in cylinder
head side is supplied to rod side so oil cavitation may be prevented.
If boom down operation is stopped, the oil in boom cylinder is obstructed by check of boom holding valve (C) and
the moving of boom is blocked.
A3
BOOM / BUCKET
15 2
2 1.2 bar
1 3
1.7 bar
4 R3
R1
1 P 3 2 T 4
7
to ONE SPOOL
VALVE M2
A2
M
ROTATING (Front)
PUMP Vgmax
ENGINE Vgmin X1
DB58 T P1
63 4 P2
ARM BOOM BUCKET M3
1 2 3 4 5 6 43 X3 C5
17 DOWN Vgmax
Vgmin P3
X1 CH
7 13 8 14 9 15 10 16 11 17 12 18 C1
P BLOCK
(Rear)
3 IC
XAa2 XBa2 XBb2 M 0.75 L C2
XAk XBk GTS
A1 10 bar C4
XAa1 XBa1 XBb1 1 M1
R2 S PB Safety
PBP Cut-off
C3 Valve
PS
PL 0.5 bar
23 27
20 20 A MRV
24
BOOM 2.5 bar
XBt 323 bar@90L/min
Bt TRAVEL
XAt
51 51 At 28
PA PA DOZER/STAB.
E E 353 bar@20L
XAo XAd
Bo OPTION ROD Bd
XBo XBd
Ao HEAD Ad
Pi1 Pi1
Ck2 353 bar@20L
T T 353 bar@20L
PC PC XBk XAs
LOCK VALVE LOCK VALVE Bk1 ROD BUCKET SWING Bs
XAk 353 bar@20L XBs
XAb1 Ak1 HEAD As
SOCKLESS
VALVE
Bb1
XBb1 BOOM2
Xop
HEAD BOOM1 op
Pi 353 bar@20L XBb2
Dr1
C Ab1 ROD
B ARM1
G
353 bar@20L
XBa2 BP 353 bar@20L
XBa1
ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
D 353 bar@20L
E F BC ARM
Dr4
18 HOLDING

A
X1
EX1400805
Figure 13

8-1-22
Ab1
Pi Dr1
Bb1
1
Boom Cylinder
4
d1
d2
2 (Pc)
3 (Pv)
XBb1 XAb1
(up) (down)
Boom Cylinder
Tank Passage
ROD Ab1
353bar@20L
Dr1
HEAD
Boom 1 Pi
Bb1
XBb1
XAb1
P2 WE1400477
Figure 14

8-1-23
ARM DUMP OPERATION
If pilot oil is supplied to arm 1 and arm 2 spool of main control valve (18) by the operation of joystick valve (14),
then spool is moved and main pump oil passage and arm cylinder rod oil passage open.
Oil supplied from idle side pump and drive side pump of main pump is put together and is supplied to arm cylinder
(21) rod direction after passing through arm holding valve (D), causing arm moving to take place.
If arm dump action is stopped, the oil in arm cylinder is obstructed by check of arm holding valve (D) and the arm
moving is blocked.
A3
ARM/SWING 2 1.2 bar
14 2
1.7 bar
1 3
4 R3
R1
1 P 3 2 T 4
T P1
SWING
7 4
XBs XAs
41
41 to ONE SPOOL
VALVE M2
P2
(R) (L) SOCKLESS A2 C5
VALVE
VALVE M P3
ROTATING (Front)
Vgmax CH
ARM BOOM
BOOM BUCKET
BUCKET PUMP C1
ENGINE Vgmin X1
1 2 3 4 5 6 DB58 3
DUMP
17 63 IC C2
GTS
C4
M3
7 13 8 14 9 15 10 16 11 17 12 18 43 0.75 L PB Safety
X3 Cut-off
Vgmax 10 bar
Vgmin Valve
XAa2 XBb2 XAk XBk C3
XAa1 XBb1 XAb1 PS
X1
(CR) (UP) (DN) (CR) (DU)
(Rear)
P BLOCK M
PBP
A1
1 S
M1
R2
0.5 bar
23 27
R P2 Py Pg Px P3 P4 P1 Pz Rs 24
A MRV
2.5 bar
323 bar@90L/min
26 TANK
XBt
343 bar@90L/min
Bt TRAVEL
XAt
At
28
DOZER/STAB.
XBo 353 bar@20L
XAd
Bo OPTION ROD Bd
XAo XBd
Ao HEAD Ad
Ck2 353 bar@20L
353 bar@20L
XBk XAs
XAk 353 bar@20L XBs
Ak1 HEAD As 21
PC T Pil E
XAb1
XBb1 BOOM2
Xop
HEAD BOOM1 op PA
353 bar@20L
Ab1
ROD B XBb2
BP ARM1 G
353 bar@20L
353 bar@20L
XBa2 ARM2 XBa1 52 LOCK VALVE
ROD Ba1 ARM
XAa2 XAa1
HEAD Aa1
E D 353 bar@20L
F BC ARM Dr4
18 HOLDING
EX1400806
Figure 15

8-1-24
A(Piston) B(Poppet)
Dr4 Tank
pal
d1
Pc
D(Poppet)
Orifice
Pv
d2
XBa1 XAa1
(dump) (crowd)
High Pressure
Tank
WE1400480
Figure 16

8-1-25
ARM CROWD OPERATION
If pilot oil is supplied to arm 1 and arm 2 spool of main control valve (18) by the operation of joystick valve (14),
then spool is moved and main pump (1) oil passage and arm cylinder (21) head oil passage open.
Oil passage supplied from main pump (1) is supplied to arm cylinder (21) head after passing through arm holding
valve (D), causing the arm moving to take place.
Rapidly occurring arm crowd causes short supply of oil in the arm cylinder head, in which case the oil in arm
cylinder rod is supplied to arm cylinder head so cavitation may be prevented.
If arm crowd action is stopped, oil in arm cylinder is obstructed by check of arm holding valve (D), and the moving
of arm is blocked.
A3
ARM/SWING 2 1.2 bar
14 2
1.7 bar
1 3
4 R3
R1
1 P 3 2 T 4
T P1
SWING
7 4
XBs XAs
41
41 to ONE SPOOL
VALVE M2
P2
(R) (L) SOCKLESS A2 C5
VALVE
VALVE M P3
ROTATING (Front)
Vgmax CH
ARM BOOM
BOOM BUCKET
BUCKET PUMP C1
ENGINE Vgmin X1
1 2 3 4 5 6 DB58 3
CROWD 17 63 IC C2
GTS
C4
M3
7 13 8 14 9 15 10 16 11 17 12 18 43 0.75 L PB Safety
X3 Cut-off
Vgmax 10 bar
Vgmin Valve
XBa2 XBb2 XAk XBk C3
XBa1 XBb1 XAb1 PS
X1
(UP) (DN) (CR) (DU)
(Rear)
PBP P BLOCK M
A1
1 S
M1
R2
0.5 bar
23 27
R P2 Py Pg Px P3 P4 P1 Pz Rs 24
A MRV
2.5 bar
26 TANK
XBt 323 bar@90L/min
343 bar@90L/min
Bt TRAVEL
XAt
At
28
DOZER/STAB.
XBo 353 bar@20L
XAd
Bo OPTION ROD Bd
XAo XBd
Ao HEAD Ad
Ck2 353 bar@20L
353 bar@20L
XBk XAs
XAk 353 bar@20L XBs
Ak1 HEAD As 21
PC T Pil E
XAb1
XBb1 BOOM2
Xop
HEAD BOOM1 op PA
353 bar@20L XBb2
Ab1
ROD
B G
353 bar@20L 353 bar@20L
BP ARM1
XBa2 XBa1 52 LOCK VALVE
XAa2 ARM2 ROD Ba1 ARM
XAa1
HEAD Aa1
E F D 353 bar@20L
ARM Dr4
BC
18 HOLDING

EX1400807
Figure 17

8-1-26
Arm Cylinder
Parallel line
C1
Ba1 Aa1
XBa1 XAa1
(Dump) (Crowd)
Arm 1
B 1 2 A C2 Center Bypass
Arm Cylinder
Dr4 Pal
Arm
Holding
Valve
Aa1 HEAD
353bar@20L
XAa1
Ba1 ROD
Arm 1
353bar@20L
XBa1
P1
WE1400482
Figure 18

8-1-27
BUCKET DUMP OPERATION
If pilot oil is supplied to bucket spool of main control valve (18) by the operation of joystick valve (15), then spool is
moved and main pump oil passage and bucket cylinder rod oil passage open.
Oil supplied from drive side pump of main pump (1) is supplied to bucket cylinder (22) rod side, causing bucket
moving to take place.
If boom operation takes place during bucket dump operation, oil is supplied to boom spool, and as a result,
composite action in which boom operation has a priority takes place.
A3
BOOM / BUCKET
15 2
2 1.2 bar
1 3
1.7 bar
4 R3
R1
1 P 3 2 T 4
7
to ONE SPOOL
VALVE M2
A2
M
ROTATING (Front)
PUMP Vgmax
ENGINE Vgmin X1
DB58 T P1
63 4
ARM BOOM BUCKET
BUCKET M3
P2
1 2 3 4 5 6 43 X3 C5
17 DUMP Vgmax
Vgmin P3
X1 CH
C1
7 13 8 14 9 15 10 16 11 17 12 18 P BLOCK
(Rear)
3 IC
M 0.75 L C2
XAa2 XBa2 XBb2 XAk GTS
A1 10 bar C4
XAa1 XBa1 XBb1 XAb1 1 M1
R2 S PB Safety
PBP
Cut-off
C3 Valve
PS
PL 0.5 bar
23 27
A MRV
24
2.5 bar
XBt 323 bar@90L/min
Bt TRAVEL
XAt
At 28
T2 DOZER/STAB.
353 bar@20L
XBo XAd
T1 P
Bo OPTION ROD Bd
XAo XBd
Ao
T2
73 HEAD Ad
22 BUCKET T1 P
Ck2
XBk 353 bar@20L
353 bar@20L
XAs
Bk1 ROD Bs
BUCKET SWING
XAk 353 bar@20L XBs
Ak1 HEAD As
XAb1
XBb1 BOOM2
Xop
HEAD BOOM1 op
353 bar@20L XBb2
Ab1
ROD
B ARM1
G
353 bar@20L
BP 353 bar@20L
XBa2 XBa1
ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
D 353 bar@20L
E F BC ARM
Dr4
18 HOLDING
EX1400808
Figure 19

8-1-28
Bk1 C1 Ak1
Bucket
XBk XAk
(Dump ) ( Crowd)
Bucket Cylinder
353bar@20L
HEAD Ak1
XAk
353bar@20L
ROD Bk1
Bucket
XBk
P2 WE1400485
Figure 20

8-1-29
BUCKET CROWD OPERATION
If pilot oil is supplied to bucket spool of main control valve (18) by the operation of joystick valve (15), then spool is
moved and main pump oil passage and bucket cylinder head oil passage open.
Oil supplied from drive side pump of main pump (1) is supplied to bucket cylinder (22) head side, causing bucket
crowd moving to take place.
If boom operation takes place during bucket crowd operation, oil is supplied to boom spool, and as a result,
composite action in which boom operation has a priority takes place.
A3
BOOM / BUCKET
15 2
2 1.2 bar
1 3
1.7 bar
4 R3
R1
1 P 3 2 T 4
7
to ONE SPOOL
VALVE M2
A2
M
ROTATING (Front)
PUMP Vgmax
ENGINE Vgmin X1
DB58 T P1
63 4
ARM BOOM BUCKET M3
P2
1 2 3 4 5 6 43 X3 C5
17 CROWD Vgmax
Vgmin P3
X1 CH
C1
7 13 8 14 9 15 10 16 11 17 12 18 P BLOCK
(Rear)
3 IC
M 0.75 L C2
XAa2 XBa2 XBb2 GTS
A1 10 bar C4
XAa1 XBa1 XBb1 XAb1 1 M1
R2 S PB Safety
PBP
Cut-off
C3 Valve
PS
PL 0.5 bar
23 27
A MRV
24
2.5 bar
XBt 323 bar@90L/min
Bt TRAVEL
XAt
At 28
T2 DOZER/STAB.
353 bar@20L
XBo XAd
T1 P
Bo OPTION ROD Bd
XAo XBd
Ao
T2
73 HEAD Ad
22 BUCKET T1 P
Ck2
353 bar@20L
353 bar@20L
XBk XAs
Bk1 ROD BUCKET Bs
SWING
XAk XBs
Ak1 HEAD As
XAb1 353 bar@20L

XBb1 BOOM2
Xop
HEAD BOOM1 op
353 bar@20L XBb2
Ab1
ROD
B ARM1
G
353 bar@20L
BP 353 bar@20L
XBa2 XBa1
ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
D 353 bar@20L
E F BC ARM
Dr4
18 HOLDING
EX1400809
Figure 22

8-1-30
Bk1 C1 Ak1
Bucket
XBk XAk
(Dump ) ( Crowd)
Bucket Cylinder
353bar@20L
HEAD Ak1
XAk
353bar@20L
ROD Bk1
Bucket
XBk
P2 WE1400484
Figure 21

8-1-31
COMBINED BUCKET CROWD AND BOOM UP OPERATION
If pilot oil is supplied to bucket spool and boom spool of main control valve (18) by operation of joystick valve (15),
each spool is moved and main pump (1) oil passage, bucket cylinder (22) oil passage and boom cylinder (20) oil
passage open.
Drive side pump oil from main pump (1) is supplied to bucket and boom 1 of main control valve (18) and oil from
idle side pump passes through boom 2, is put with oil from boom 1, and finally supplied to boom cylinder (20)
through boom holding valve (C).
Oil being supplied to bucket cylinder (22) is preferably supplied to boom cylinder (20) by boom priority valve (B),
causing bucket-and-boom composite action in which boom operation has a priority to take place.
A3
BOOM / BUCKET
15 2
2 1.2 bar
1 3
1.7 bar
4 R3
R1
1 P 3 2 T 4
7
to ONE SPOOL
VALVE M2
A2
M
ROTATING (Front)
PUMP Vgmax
ENGINE Vgmin X1
DB58 T P1
ARM BOOM BUCKET

63 4 P2
M3
1 2 3 4 5 6 43 X3 C5
17 UP CROWD Vgmax
Vgmin P3
X1 CH
C1
7 13 8 14 9 15 10 16 11 17 12 18 P BLOCK
(Rear)
3 IC
M 0.75 L C2
XAa2 XBa2 XBk GTS
A1 10 bar C4
XAa1 XBa1 XAb1 1 M1
R2 S PB Safety
PBP Cut-off
C3 Valve
PS
PL 0.5 bar
23 27
A MRV
24
2.5 bar
XBt 323 bar@90L/min
Bt TRAVEL
XAt
At 28
DOZER/STAB.
353 bar@20L
XAo XAd
T2 Bo OPTION ROD Bd
XBo XBd
T1 P Ao HEAD Ad
Ck2 353 bar@20L
353 bar@20L
T2
73 XBk
Bk1
XAs
ROD Bs
22 BUCKET T1 P XAk
BUCKET SWING
XBs
Ak1 HEAD As
XAb1 353 bar@20L
XBb1
BOOM2
Bb1 Xop
HEAD BOOM1 op
Pi 353 bar@20L
XBb2
Dr1
C Ab1 ROD
B ARM1
G
353 bar@20L
XBa2 BP 353 bar@20L
XBa1
20 20 ARM2
ROD Ba1
XAa2 XAa1
HEAD Aa1
BOOM D 353 bar@20L
E F BC ARM
Dr4
18 HOLDING
PA PA
E E Fr PBP Dr3 Fl XAk2 Par Ck1 Pal
A
X1
Pi1 Pi1
T T
51 PC PC 51
LOCK VALVE LOCK VALVE
EX1400810
Figure 22

8-1-32
COMBINED TRAVEL AND BOOM, ARM, BUCKET OR
SWING OPERATION
is supplied to Pg port of main control valve (18) through pilot package valve (4) P3 port.
Drive side oil of main pump (1) is supplied to travel spool of main control valve (18).
The oil of main control valve (18) is supplied to travel motor (30) by operating of the right side combination switch.
Idle side oil from main pump (1) is supplied to swing and arm 1 spools of main control valve (18).
The oil of main control valve (18) is supplied to swing motor (19) and arm cylinder (21) by operating of the joystick
(14).
ARM / SWING A3
14 2
3
1
2 1.2 bar
4
R3 1.7 bar
1 P 3 2 T 4 R1
T P
SWING 7
6 to ONE SPOOL T P1
C1 HO XBs
41
41 VALVE M2
A2 4 P2
(R) SOCKLESS M
PAR C5
C6 VALVE
VALVE (Front)
ROTATING P3
PUMP Vgmax
ENGINE Vgmin X1
CH C1
PBR ARM BOOM
BOOM BUCKET
BUCKET DB58
C5 1 2 3 4 5 6 63 3
IC C2
GTS
DUMP 17 43 M3 C4
X3 0.75 L PB
PL Vgmax 10 bar
C2 7 13 8 14 9 15 10 16 11 17 12 18 Vgmin C3
PS
X1
XAa2 XBb2 XAk XBk
XAa1 XBb1 XAb1 (Rear)
C7 P BLOCK M
PBP
TS
1 A1
M1
R2 S
P1
23 0.5 bar 27
24
2.5 bar
26 TANK
28
A MRV
XBt
SWING MOTOR SH 29
323 bar@90L/min
343 bar@90L/min PG
CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1
8 8 2 2 8 8 4 4 8 8 2 4 4
Bt TRAVEL JOINT 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
DB
XAt
At B(HIGH)
DOZER/STAB. 265 bar 265 bar
353 bar@20L 19 K(LOW)
XBo XAd
C 31
Bo OPTION ROD Bd PA PB
XAo XBd
Ao Ad
HEAD
X1(IC)
Ck2
353 bar@20L 353 bar@20L XAs G
XBk MB GEXT B
U T1
Bs A(LH) B(RH)
Bk1 ROD BUCKET J (FWD)
XAk 353 bar@20L SWING XBs
Ak1 M
HEAD As qmax
XAb1 S
XBb1 qmin
BOOM2 A
Xop (REV)
HEAD BOOM1 op
353 bar@20L MA
Ab1 B XBb2 21 T2
M3
ROD
BP ARM1 G PC T Pil E M2 30
353 bar@20L X2
353 bar@20L
XBa2 XBa1 (TU) TRAVEL MOTOR
ARM2 PA
ROD Ba1
XAa2 XAa1
HEAD Aa1
E D 353 bar@20L
52 LOCK VALVE
F BC ARM
Dr4
18 HOLDING ARM

EX1400811
Figure 25

8-1-33
8-1-34
1Hydraulic
System Testing
and Adjustment
Edition 1
DX210WA Hydraulic System Testing and Adjustment

8-2-1
MEMO
Hydraulic System Testing and Adjustment DX210WA

8-2-2
Table of Contents
Hydraulic System Testing and Adjustment

Procedural Troubleshooting Baseline
Recommendations..........................................8-2-6
Initial Checks and Tests to Establish Operating Condition
of the Excavator ........................................................ 8-2-6
Pilot Pressure .................................................8-2-8
Adjustment and Testing............................................. 8-2-8
Power Mode Valve .........................................8-2-9
Current Signal and Hydraulic Pressure Adjustments 8-2-9
Pressure Up Valve........................................8-2-10
Checks and Adjustments......................................... 8-2-10
Pump Input Power Control ...........................8-2-12
Pump Regulator Adjustment ................................... 8-2-12
Flow Meter and Flow Meter Kit Installation and
Testing ..........................................................8-2-15
Swing System Troubleshooting ....................8-2-17
Precautions/Initial Checks ....................................... 8-2-17
Swing Relief Valve Checking and Adjustment ........ 8-2-18

8-2-3
8-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

8-2-5
PROCEDURAL TROUBLESHOOTING BASELINE
RECOMMENDATIONS
Initial Checks and Tests to Establish Operating Condition of the Excavator
Troubleshooting Recommendations
An excavator that fails to deliver designed performance must be
checked for the following:
• First hydraulic flow.
• Then hydraulic pressure in a specified order of priority
through different points of the system.
To verify adequate available hydraulic flow, before any other
tests are performed through the circuit:
Check engine operation -
• at 1,880 rpm with no load.
• at 1,800 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,800 rpm), performance problems may be
because of inadequate hydraulic flow caused by lagging
rotational speed.
NOTE: Verify actual flow on the excavator against rated
performance, with a flow meter.
If engine tests meet specifications and adequate torque and
horsepower are available at the pump drive flex coupling, pull
out the electrical tray under the operator's seat to inspect the
self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic
functions in the following sequence:
• Pilot pressure.
• Negacon, negative control pressure.
• Main relief pressure (drive side and idle side pump)
• Swing pressure.
• Port relief pressure (individual control functions; boom,
arm, bucket, swing, and travel)
• Power boost circuit.
• Standard performance tests; cylinder speed, hydraulic
motor (travel and swing) speed, cylinder oil tightness
"permissible drift" test.

8-2-6
NOTE: System specification performance tests of
individual activator function are determined by
flow rate through the component or circuit, not
the control pressure or system pressure
available to the actuator. Poor flow through the
individual circuit may indicate that component is
worn beyond tolerance limits, while all other
hydraulic functions are adequate.
IMPORTANT
It is suggested that troubleshooter maintain the testing
sequence of the preceding list. Checks and adjustments
nearer the middle or the end of the list may depend on
adequate functioning of systems tested nearer the top of
the list.

8-2-7
PILOT PRESSURE
Adjustment and Testing
WARNING
This procedure must be done with two people. To reduce
the chance of accidental movement of the excavator, one
person should properly seated at the operator's control
stand while checks and adjustments are made.
Vent hydraulic pressure from the reservoir before breaking the

seal on fittings to install two in-line "T-style" adapters and test
gauges (60 bar/1,000 psi) at the gear pump outlet port, and at
the joystick control valve pilot line.
Start the engine and turn the engine speed control dial to the
maximum setting. After the excavator has been operated long
enough to reach normal operating temperature, back off the
engine control dial to minimum rated rpm speed. With all
controls in neutral, make sure the left safety lever is in the up
(UNLOCK) position and check pressure at the gear pump outlet
port and at the joystick.
If gear pump pressure is outside the tolerance specified in the
table, adjust gear pump relief pressure by loosening the locknut
and turning the set screw in (clockwise) to increase pressure, or
turning it out to decrease it.
NOTE: Be aware that serial number changes and variation in
the joystick assemblies used on different excavators
could produce slight change in actual performance
characteristics. Comparison of part numbers to serial
numbers stamped on your assembly may be
required, if questions or doubt exists.
IMPORTANT
Refill the hydraulic fluid reservoir if there is any measurable
loss of hydraulic oil during test gauge and adapter fitting
installation.
Engine rpm Pilot Pressure @ Pump Pilot Pressure - Joystick

Minimum Speed Setting (full left) 40 ±5 bar 40 ±5 bar
on Speed Control Dial (40 ±5 kg/cm2, 569 ±71 psi) (40 ±5 kg/cm2, 569 ±71 psi)

8-2-8
POWER MODE VALVE
Current Signal and Hydraulic Pressure
Adjustments
WARNING
The electromagnetic pressure proportioning control (EPPR)

"power mode" valve is on the underside of the pumps (not visible
in the harness connections drawing, because it is underneath
the assembly), near the engine/pump flexible coupling, adjacent
to the pump return line. To test and adjust power shift current
and pressure through the power mode valve a multilead jumper
harness is required. The jumper harness (which is available
through DOOSAN After Sales Service, or could be spliced
together from commonly available, purchased parts) has extra
leads so a VOM meter can be connected to the circuit. To set up
the testing equipment, stop engine and disconnect the single
electrical lead from the power mode valve. Attach the jumper
harness to the terminal on the valve, connect the test leads of
the multimeter to the extra leads on the harness and reconnect
the valve electrical lead.
Vent the lever on top of the hydraulic tank to relieve pressure
and connect an in-line "T-style" adapter to the valve pressure
port. Install a 60 bar (1,000 psi) test gauge in the adapter.
Restart the engine and increase engine rpm by turning the
speed control to the maximum speed setting. Warm up the
engine and hydraulic system until hydraulic oil temperature is at
least 45°C (113°F). Select Power Mode on the Instrument
Panel. Check current readings (in milliamps) on the VOM meter
and hydraulic pressure gauge readings and make sure both
conform to the values in the table below.
NOTE: If recorded values do not conform to the specified
current or pressure in the table, back off the locknut
on the end of the valve, turn the adjusting screw 1/4
turn and recheck current and pressure. Repeat
adjustment as required to obtain specified
performance and retighten the valve locknut.
Mode Engine (rpm) Current (mA) Pressure

280
Midrange value corresponding to 3.8 ±3 bar
Power High Idle: 1,950 (3.8 ±3 kg/cm2, 55 ±44 psi)
engine rpm for both current and
hydraulic pressure readings.
Standard 1,850 310 4.5 ±3 bar
(4.6 ±3 kg/cm2, 65 ±44 psi)
Economic 1,750 340 6.6 ±3 bar
(6.7 ±3 kg/cm2, 96 ±44 psi)
Auto Idle 1,400 650 22 ±4.5 bar
(22.4 ±4.6 kg/cm2, 319 ±65 psi)

8-2-9
PRESSURE UP VALVE
Checks and Adjustments
WARNING
Vent hydraulic pressure from the reservoir to install an in-line

"T-style" adapter and test gauge (60 bar/1,000 psi) at the pilot
pump signal port relief valve outlet.
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached:
• Check pilot pressure and readjust it, if required:
• Select the Instrument Panel rear pump "pressure display".
• Select Power Mode.
• Stall the boom cylinder (towards the extend side).
• Read rear pump pressure on the Instrument Panel display.
Repeat all tests with and without "pressure up" selected through
the console rocker switch and joystick button.
If the two-stage main relief valve was not set correctly and main
relief high stage pressure ("pressure up") is outside the
tolerance range, begin valve adjustment by loosening the
outside (widest diameter) locknut on the relief valve. Turn the
adjusting screw clockwise to increase pressure, or
counterclockwise to decrease it. Pressure must be 343 bar
(350 kg/cm2, 4,975 psi), or up to 10 bar (10 kg/cm2, 145 psi)
higher.
Because one adjustment can affect the other, check low stage
main relief pressure by repeating the cylinder stall test without
"pressure up". Readjust standard relief pressure by turning the
innermost (smallest diameter) screw clockwise to increase the
setting, or counterclockwise to decrease it. Pressure must be at
least 323 bar (330 kg/cm2, 4,684 psi), but less than 329 bar
(335 kg/cm2, 4,772 psi).
IMPORTANT
Pressure adjustments and checks cannot be made if pilot
pressure is outside the specified range. Refer to the pilot
pump adjustment procedure if required, then proceed with
any necessary adjustments to main relief pressure settings.

8-2-10
Mode Operation Main Pressure and Tolerance Pilot Pressure and Tolerance
Neutral, No 20 ~ 40 bar
Power Mode
Operation (20 ~ 40 kg/cm2, 290 ~ 580 psi)
323 ±5 bar 40 ±10 bar
Power Mode Cylinder Stall
(330 ±5 kg/cm2, 4,684 ±72 psi) (40 ±10 kg/cm2, 290 ±145 psi)
Power Mode W/ 343 ±5 bar
Cylinder Stall
Pressure Up (350 ±5 kg/cm2, 4,974 ±72 psi)
NOTE: The electrical pressure up (power boost) solenoid

valve alongside the arm speed control solenoid, in
compartment rear of the operator's cabin, must be
operating correctly, or pressure tests and further
adjustments cannot be made.

8-2-11
PUMP INPUT POWER CONTROL
Pump Regulator Adjustment
WARNING
To perform these adjustments accurately the use of a flow meter

is strongly recommended, as is consulting the factory (before
starting work) to validate the need for making regulator
adjustments. Vent hydraulic pressure from the reservoir before
breaking the seal on fittings to install the flow meter kit. (Refer to
"Flow meter Installation and Testing" procedure.)
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
• Verify engine output to the rated speed –
1,900 ±50 rpm.
• Permanently mark setscrew positions at the current
regulator control setting.
Use a scribe or other permanent marker to identify a reference point

on adjusting screws with a corresponding reference on the body of
the valve. The adjustment process affects a complex balance and
could require some time to complete. If adjustment has to be
interrupted or postponed, reference marks at the adjustment point
allow immediate restoration of original performance.
This adjustment procedure is normally performed:
• If the engine is being consistently overloaded (and engine
troubleshooting shows engine performance to be at or
above rated output).
• If reduced cylinder speed and diminished work
performance provide an indication that rated, maximum
pump flow may not be available (and all other
troubleshooting gives no indication of other flaws or
hydraulic system defects).
• If pump output is out of balance and one pump is failing to
keep up with the output flow of the other.

8-2-12
To check pump imbalance without a flow meter, travel the
excavator forward on flat, level terrain. If the machine veers off
despite neutral control input and even, balanced track
adjustment, the pump which supplies output to the track frame
toward which the excavator is veering is weak.
Refer to the illustration of the pump regulator control valve (Figure
2
1) for the location of adjustment screws. There are two different 2
adjustments, with the Negacon, negative control, adjustment
screw. Each one of the adjustment procedures could affect the 3
setting of the others.
3
Check and record the arm dump speed performance test before
and after input power adjustment, whether or not a flow meter is
used.
NOTE: Regulator adjustments affect total cumulative
horsepower, since each regulator compensates for
the output of the other. It is not necessary to adjust
both regulators at the same time, but after checking
or adjusting one of them, the remaining unit should
also be checked.
1
Figure 1 1 EX1403918
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached, loosen the
largest diameter locknut around the adjustment screw for the
outer regulator spring. Tightening the screw shifts the P/Q
(Pressure/Flow) control curve to the right, and increases
compensating control pressure.
On the other hand, if the persistent cause of performance
problems is engine overloading, decreasing the adjustment by
turning the larger diameter adjusting screw out will decrease
pump input horsepower. 1/4 turn on the adjusting screw is equal
to approximately 17 horsepower.
Figure 2
IMPORTANT
Because changing the position of adjusting screw also
affects the setting of the adjustment for the inner spring,
the smaller diameter adjusting screw, turn in the inner
screw 198° (slightly more than 1/2 turn, 180°) before screw
is backed out 1/4 turn (90°).
NOTE: For each full turn of adjustment on the larger

diameter screw, the square-tipped adjusting screw
must be turned in the opposite direction 2.2 turns to
avoid changing inner spring adjustment.

8-2-13
Pump input power adjustments are normally made in small
increments, 1/4 turn (90°) or less, each time.
Turning the square-tipped, smaller diameter screw clockwise
moves the flow curve up, increasing flow and then input
horsepower.
Figure 3
The adjusting screw (Figure 1) affects the delivery rate (Q) of the
pump. Tightening the adjusting screw decreases the maximum
cut flow (as shown in Figure 4) while backing out the screw
increases cut flow delivery rate.
Balance both pumps for equal output.
Q
P
HDA3008L
Figure 4

8-2-14
FLOW METER AND FLOW METER KIT INSTALLATION
AND TESTING
Checking regulator and pump output, to assess the output
balance between the front and rear pumps and to verify
operating adjustment of each regulator, will require installation of
a flow meter.
The After Sales Service department of the nearest local
DOOSAN dealer can assist you with these tests or, if you prefer
performing your own testing, they must be able to help in putting
together a hose and fitting kit (or the required dimensions and
specifications for hoses and fittings) to allow you to install a flow
meter downstream from the main pump assembly.
Installation and Testing Procedure

• Stop engine and operate controls to release hydraulic
pressure from the accumulator.
• Vent the reservoir to release all pressure from the
hydraulic system.
• Remove guard panels from around the main pump
assembly.
• Disconnect the main pump discharge output line. Install the
input flange of the flow meter on the pump end of the
output line.
• Cap off the unused (input) end of the pump discharge line
with a blocking flange.
• Connect a premeasured length of hydraulic hose, between
the output end of the flow meter assembly and the top of
the reservoir. Use appropriate fittings and adapter flanges
to guarantee a pressure tight seal.
NOTE: Be sure to maintain even tightening torque on
all flange fittings. Use Loctite brand "PST 545"
(or an alternate manufacturer's hydraulic
system joint seal) if required, to give an airtight
seal.
• An assistant – who must remain at the operator's control
station always – should restart the engine and run it long
enough (at minimum rpm) to deaerate the system and
warm up the engine and hydraulic system to operating
temperature.
Record the values of all test results in three columns, comparing
1) pump pressure (from the instrument panel display) with 2)
measured flow, in gallons or liters per minute, from the installed
flow meter. The third column of test results should provide a
record of engine rpm measured during each of the following
tests – with the engine speed control dial set at maximum, the
power mode selector at Power Mode and the work mode
selector at digging mode:

8-2-15
• Unloaded maximum engine speed baseline test (all
controls in neutral).
• Front pump test – operate "travel right" lever. Record
values at all specified pressures.
• Rear pump test – operate "travel left" lever. Record values
at all specified pressures.
Record the values for each of the three tests (neutral, travel right
and travel left) at the following pump pressure levels, with travel
speed control set at "high-speed".
Engine rpm Pressure Flow

98 bar (100 ±5 kg/cm2,1,422 psi)
147 bar (150 ±5 kg/cm2, 2,133 psi)
196 bar (200 ±5 kg/cm2 , 2,844 psi)
294 bar (300 ±5 kg/cm2, 4,267 psi)
343 bar (350 ±5 kg/cm2, 4,975 psi)
*See below note.
Compare recorded values with output shown in the P-Q curve in

the specifications section of this book.
If test results do not meet specified values, pump output tests
can be repeated using different control levers. Recheck front
pump operation while stroking the bucket cylinder out lever, and
the rear pump by actuating the swing control lever.

8-2-16
SWING SYSTEM TROUBLESHOOTING
Precautions/Initial Checks
1. Stop work. Release all weight or any load safely before
proceeding. Avoid risking injury or adding to damage.
2. Stop engine and disengage control functions until initial
tests are ready to be made.
WARNING
Stop operation and park excavator whenever these
problems are noticed:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the inoperative
(overnight park) position and begin by making the fastest,
simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record for
prior repair/service work.
• Drain some tank oil into a clean, clear container. Look
for metal shavings/grit, cloudiness/water or foam/air
bubbles in the oil.
NOTE: Dispose of drained fluids in compliance
with all applicable environmental laws and
regulations.
• Check for wobble through the engine/pump flex
coupling. Run engine with the pump input hydraulic
power control nut turned to the lowest power to check
the engine.
• Investigate unusual operating noises or vibration.
Check for loose bolts, connections.

8-2-17
Swing Relief Valve Checking and Adjustment
Make a check of operating pressures through the swing relief
valve if:
• The swing motor fails to turn.
• Swings in one direction only.
• Swings but continues to coast.
• There is drifting on a slope.
1. Check operation by connecting:
A. Two 500 bar (510 kg/cm2, 7,252 psi) pressure gauges
to the inlet and outlet measuring ports on top of the
swing motor.
Pressure must be between 260 bar and 280 bar
(3,771 psi and 4,061 psi), with both swing locks
engaged. With swing locks released, during full
acceleration and deceleration, pressure should
approach 275 bar (280 kg/cm2 (3,989 psi) in each
direction.
B. Connect a 100 bar (102 kg/cm2, 1,450 psi) pressure
gauge at the "SH" port of the hydraulic brake.
Pressure should always stay at or above 13 bar
(189 psi) when operating swing, boom or arm.
C. Connect a 10 bar (10 kg/cm2, 145 psi) gauge at the
motor makeup valve.
Pressure should stay consistently above 2.5 bar
(2.5 kg/cm2, 36 psi). If pressure drops below the
recommended minimum level, forceful acceleration of
the swing motor could lead to cavitation of the circuit
and stalling, slowed rotation, noise and possible
damage.
2. If main inlet and outlet pressures were off in the preceding
tests in Step 1, adjust swing relief valve pressure.
Following adjustment, repeat the operating pressure tests
(with gauges connected to the inlet and outlet test ports on
top of the swing motor) and check pressures with the swing
locks engaged and released.
If pressure adjustment fails to restore adequate
performance, proceed to the Troubleshooting – Swing table.
3. If pressure tests were at recommended levels through the
main inlet and outlet ports, and through the "SH" port of the
swing brake, the causes of poor swing performance could
include a faulty swing motor, drivetrain overloading or
gearbox defect, or a problem in the brake assembly or
swing control valve. Proceed to the troubleshooting
information in the next procedure.
If pressure through the "SH" port was tested below the
minimum 13 bar (13 kg/cm2, 189 psi) level, check the
shuttle valve in the rear compartment behind cabin. When
pressure through the port is at the recommended level, the
brake release valve should disengage the swing brake,
allowing the swing motor to rotate the excavator. If pressure
adjustment to the valve has been restored but the brake still

8-2-18
fails to release, the brake piston or friction plate may be
frozen, requiring disassembly of the motor and parts repair/
replacement.
4. If pressure tested at the motor makeup valve drops below
recommended minimum level, and consequent problems
with cavitation, stalling and surging are observed, check
the restriction valve. If pressure adjustment to the valve
has been restored but if problems with cavitation
continues, disassemble the upper swing motor housing
and clean or replace assembly components as required.
NOTE: If all tested pressures are at or above
recommended levels, and there are no
mechanical problems in the drivetrain or in the
motor/brake assembly, the problem will require
further hydraulic troubleshooting. It's also
possible that a defective joystick, an intermittent
short in an electrical control circuit or a problem
in the EPOS circuit is causing diminished swing
performance. Pull out the EPOS indicator panel
from underneath the operator's seat and
perform the self-diagnostic test. Refer to the
Electrical section of this book for more
information.

8-2-19
8-2-20
1Electrical System
Electrical
System
Edition 1
DX210WA Electrical System

9-1-1
MEMO
Electrical System DX210WA

9-1-2
Table of Contents
Electrical System
Safety Instructions ................................................ 7
Introduction ........................................................... 7
Electrical Supply System ...................................... 8
Engine Starting Circuit ........................................ 10
Start Operation .............................................................. 10
After Start ...................................................................... 12
Engine Preheating System ................................. 13
Engine Stop ........................................................ 14
Charging System ................................................ 15
Monitoring System .............................................. 16
Instrument Panel ........................................................... 17
Monitoring System Schematic....................................... 18
Operation ............................................................ 20
Instruments.................................................................... 20
Warning and Indicator Lights .............................. 21
Indication of Warning Lights .......................................... 21
Indication of Multifunction Gauge and Letter Information
Area............................................................................... 22
Initial Operation .................................................. 24
Mode Selector Switch ......................................... 25
Graphic Information Area Display....................... 26
Overview ....................................................................... 26
Main Menus for the Graphic Display Area..................... 26
Menu Selector Buttons .................................................. 26
User Menu .......................................................... 27
User Menu - Access and Escape Methods ................... 27
Special Menu ...................................................... 50
Entering/Accessing and Exiting/Escaping Menus ......... 50
Special Menu Selections ............................................... 51
Electronic Hydraulic Control System (EPOS) ..... 68

9-1-3
Control System Schematic ............................................ 68
Power Mode Control ........................................... 70
Operation....................................................................... 71
Power Mode Control - Circuit Diagram.......................... 74
Engine Control System ....................................... 75
Engine Control Dial ....................................................... 76
Engine Control Motor .................................................... 77
Engine Control Circuit Diagram ..................................... 78
Automatic Deceleration Control
(Auto Idle Control) .............................................. 79
Engine Overheat Protection System .................. 80
Adjust Engine Speed .......................................... 81
How To Adjust The Engine Control Device ................... 82
Engine Throttle Controller ............................................. 85
Power Boost Mode ............................................. 87
Operation....................................................................... 87
Power Boost Control - Circuit Diagram ......................... 88
Cruise control ..................................................... 89
Operation....................................................................... 89
Cruise Control Circuit .................................................... 91
Self-diagnostic Function ..................................... 92
EPOS Controller............................................................ 92
Wiper System ..................................................... 94
Wiper Circuit.................................................................. 94
Wiper Operation ............................................................ 95
Lighting System .................................................. 96
Lighting System Circuit Diagram ................................... 96
Type .............................................................................. 97
Operation....................................................................... 97
Overload Warning Device................................... 98
Overload Warning Device Circuit Diagram.................... 98
Audio Controller .................................................. 99

9-1-4
Audio Controller Circuit Diagram................................... 99
Ram lock device ............................................... 100
Ram Lock Control Circuit ............................................ 100
Operation..................................................................... 101
Air Conditioner System ..................................... 102
Outline ......................................................................... 102
Internal and External Filters ........................................ 103
Air-Conditioning System Layout .................................. 104
Air Conditioner/Heater Circuit Diagram ....................... 105
Air Conditioner/Heater Unit ......................................... 106
Relay - Blower ............................................................. 110
Relay - A/C .................................................................. 110
Duct Sensor................................................................. 110
Water Temp Sensor .................................................... 111
Internal Air Temp Sensor ............................................ 111
Ambient Air Temperature Sensor................................ 111
Sun Sensor.................................................................. 112
Control Panel............................................................... 112
Compressor................................................................. 119
Receiver Dryer ............................................................ 119
Troubleshooting ................................................ 120
Refrigerant System Repairs ............................. 122
Refrigerant Safe Handling Procedures........................ 122
Repair and Replacement Procedure ........................... 123
Refrigerant Recovery .................................................. 125
Vacuuming Refrigerant System................................... 125
Leakage Check ........................................................... 127
Refrigerant Charging ................................................... 127
Inspecting System For Leakage.................................. 129

9-1-5
9-1-6
SAFETY INSTRUCTIONS
WARNING
or serious injury.
INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
Electric Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color
NOTE: 0.85G: Nominal sectional area of wire core less
insulator = 0.85 mm2

9-1-7
ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1) → fusible link (3) → fuse box (6).
1. Terminal "1" of DC-DC converter (for memory backup of
stereo)
2. Terminal "B" of starter switch
3. Hour meter
4. Fuel feeder pump switch
5. Terminal "6" of wiper motor
6. Terminal "13" of wiper controller
7. Terminal "CN7-5, CN7-6" of instrument panel
8. Terminal "CN9-6" of air conditioner panel
9. Pilot buzzer
10. Light switch
When the starter switch (5) is in the "ON or START" positions,
the current flows from the battery (1) → fusible link (3) → fuse
box (6) → "B" terminal of starter switch (5) → "BR" terminal of
starter switch (5) → "BR" terminal of battery relay (2) which
activates the coil of the battery relay and the electric supply
system is energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator (7).

9-1-8
ACC C
B 5
R2 BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
1
R(I) P(R) B(B+)
0.5 uF
Starter Switch Connection B+
PST TML B BR R1 R2 C ACC I(L)
OFF REG. 7
TRIO DIODE
PREHEAT FIELD
F+
ON F-
E
START
GRD
WE1400665
Figure 1 Electric Power Circuit Diagram
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

9-1-9
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to the "START" position, the
"S" and "E" terminals of the starter controller (7) are connected.
At this time the contacts in the starter relay (8) are closed by the
current flow from the battery (1) → fusible link (3) → fuse box (6)
→ "B" terminal of starter switch (5) → "C" terminal of starter
switch (5) → "30" terminal of starter relay 2 (12) - "87a" terminal
→ "C" terminal of starter relay (8) - "D" terminal → "S" terminal of
starter controller (7) - "E" terminal → ground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) → "A" terminal of the battery relay (2) → "B"
terminal of the battery relay (2, Figure 3) → "30" terminal of the
starter (9). The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED," a four-digit
Owner Password
password will be required to start the engine. If the
system is "UNLOCKED," no password will be
required and this display screen will not appear.
In the event the security system is locked, current
flows from battery (1) → fusible link (3) → fuse box
(6) → "B" terminal of starter switch (5) → "ACC" 3 4 5 6 7 8 9 : ; <
terminal of starter switch (5) → "86" terminal of starter Enter Owner Password
relay (12) → "85" terminal of starter relay (12) →
"CN1-15" terminal of EPOS (13) → ground. This
current flow causes the coil in starter relay (12) to be EX1301416
activated, opening contacts at "87a" terminal. This Figure 2
prevents starter relay (8) from functioning.

9-1-10
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1 3
CN1-15
6
4
B A
CN2-1
BR
E
13 11
R(I) P(R) B(B+)
2
0.5 uF
OFF 10 - + - +
REG.
TRIO DIODE 12V 150AH 12V 150AH
PREHEAT
F+ FIELD
1
ON F-
E
START
GRD
WE1400666
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller

9-1-11
After Start
Once the engine has been started, the belt driven alternator (10) generates a current.
The output generated by the alternator (10) is a square wave pulse voltage through the "R" terminal and the
frequency of the pulse voltage is proportional to the rotation of the alternator.
The starter controller (7) monitors the frequency of the output current. Once the frequency is equivalent to 500
rpm, it is sensed and the connection between "S" and "E" terminals and the connection between "B" and "PP"
terminals are opened. As a result the rotation of the starter (9) is stopped. Once the engine is running, the starter
(9) will not operate even if the starter switch (5) is moved to the start position, preventing possible damage to the
starter.
7 8 9
N S D PP C
P C B B
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1 3
CN1-15
6
4
B A
CN2-1
BR
E
13 11
R(I) P(R) B(B+)
2
0.5 uF
OFF 10 - + - +
REG.
TRIO DIODE 12V 150AH 12V 150AH
PREHEAT
F+ FIELD
1
ON F-
E
START
GRD
WE1400666
Figure 4 Operation of Starter Circuit (1) - Immediately After Starting
Reference Reference
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller

9-1-12
ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of the engine. When the starter switch (5) is turned to
"PREHEAT" the current flows from the battery (1) → fusible link (3) → "B" terminal of starter switch (5) → "R1"
terminal of starter switch (5) → "C" terminal of preheat relay (7) → ground. This current flow causes the coil in the
preheat relay (7) to be activated, closing contact.
When the contacts of the preheat relay (7) are closed, the heating coils of the air heating device are heated by
current flowing from the battery (1) → battery relay (2) → preheat relay (7) → air heater (8) → ground.
The duration of the heating time is approximately 20 seconds. After 20 seconds later to start preheating, the
preheat indicator light will be turned "OFF" by the timer in the EPOS controller.
If the starter switch (5) turns to "START", the heating process will go on because the current flows into the coil in
preheat relay (7) through "R2" terminal of starter switch (5).
4
9
CN6-4 2
ACC C B A
Preheat CN6-12,13,14
B 5
L5 R2 BR
R1 BR 10
E
CN4-4,5,6
CN2-13 10
CN2-1 - + - +
12V 150AH 12V 150AH
11 1
C B
-
200A
Starter Switch Connection
PST TML B BR R1 R2 C ACC

7
8 OFF
PREHEAT
D H + ON
START
WE1400667
Figure 5 Engine Preheat Circuit
Reference Reference
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
5 Starter Switch 11 EPOS Controller
6 Fuse Box

9-1-13
ENGINE STOP
Engine stop circuit consists of starter switch (5), engine stop motor (9), engine stop relay (8). The current flowing
into the "ACC" terminal of starter switch allows the engine’s start and stop function.
The stop motor is decelerated by the worm gear by itself and converts the rotary motion into a back-and-forth
motion to pull and push the engine stop lever.
If the starter switch turns "ON", the motor will stop automatically after revolving 0° → 180°, and if the starter switch
turns "OFF", the motor will stop at the engine stop position by revolving 180° → 360°
A
Starter Switch Connection
P1 87 1
30 TML B
P2 87a 3 PST BR R1 R2 C ACC
9 OFF
A B 85 86 4
PREHEAT
E
11 ON
8 START
6
3
ACC C
B 5
R2 BR 2
4
R1 B A
BR
E
10
7
CN2-13
- + - +
12V 150AH 12V 150AH
1 WE1400669
Figure 6 Engine Stop Circuit
Reference Reference
Number Number
1 Battery 7 Diode
2 Battery Relay 8 Injector Solenoid
3 Fusible Link 9 Engine Stop Motor
4 Circuit Breaker 10 EPOS Controller
5 Starter Switch 11 Engine Time Delay
6 Fuse Box

9-1-14
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of the
alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition
the alternator (7) starts charging. The current flows from the "B(B+)" terminal of alternator (7) → circuit breaker (4)
→ battery relay (2) → battery (1).
The alternator also supplies electric current to other electrical components. When the alternator (7) starts to
operate, a current flows from the "I (R)" terminal of alternator → diode (8) → battery relay (2) coil securing a path
for the charging current to the battery (1). Thus preventing the possibility of a high voltage build up and possible
damage to the electric system.
ACC C
B 5
R2 BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
1
R(I) P(R) B(B+)
0.5 uF
OFF REG. 7
TRIO DIODE
PREHEAT FIELD
F+
ON F-
E
START
GRD
WE1400665
Figure 7 Charging Circuit
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box

9-1-15
MONITORING SYSTEM
5
7
1 4
2
3
9
AM
H H 8
16
E F 10
C C 6
rpm
s
SPC
USB
20 11
17
15
14 12
13
19 18
WE1400670
Figure 8
Reference Reference
Number Number
1 Instrument Panel 12 Air Cleaner Indicator
2 Battery 13 Parking Brake Sensor
3 Light Switch 14 Brake Oil Pressure Switch
4 Return Filter Switch 15 Pilot Relay
5 Pilot Filter Switch 16 Parking Brake Switch
6 EPOS Controller 17 Steering Console
7 Alternator 18 Right Side Combination Switch
8 Warning Buzzer 19 Left Side Combination Switch
9 Pump Discharge Pressure Sensor 20 Ram Lock Switch
10 Oil Temperature Sensor
11 Fuel Sensor
The monitoring system displays the various data and warning

signals onto the instrument panel by processing the information
gathered from the EPOS controller. It displays information
selected by the operator.

9-1-16
Instrument Panel
7 6
5 1
AM
1
H H
3
2
E F
< Connector and Terminal No.>
C C 4
AMP 040 28P
rpm
s
SPC
USB 6 5 4 3 2 1 8 7 6 5 4 3 2 1
10 12 11 10 9 8 7 16 15 14 13 12 11 10 9
9 (CN7) (CN6)
WE1400671
Figure 9
Reference Reference
Number Number
1 Fuel Gauge 5 Hour Meter
Engine Coolant Temperature 6 Digital Clock
2
Gauge 7 Display Warning Symbols
Hydraulic Oil Temperature 8 Warning Light
3
Gauge
9 Function Buttons
Multifunction Gauge and Graphic
4 10 Selector Function Display
Information Area
When the engine starter switch is turned to "I" (ON) position, all
gauge bands, switch/button indicator lights and warning lights
will turn "ON" and the alarm buzzer will sound for about two
seconds.
During this functional check, a LOGO will appear on the
multifunction gauge in the graphic information area (3 and 4,
Figure 34).

9-1-17
Monitoring System Schematic
1
22
87a
CN6-1 30
87
85 86
0.5B 17
3
CN6-4
-
CN7-6 +
CN7-5
2 15A
15
CN7-16 4 10A
R2 B 14 B
CN7-3
CN7-4 BR
12 E
CN2-1 A
16
+ CN5-7 13
CN3-1
5 SIG
CN3-2
9
LCD DISPLAY PANEL -
WATER TEMPERATURE CN2-17
FUEL LEVEL + 10
CN3-3
6 SIG
GRAPHIC DISPLAY CN3-4
-
CN6-12 CN4-4
CN6-13 CN4-5 CAN
CN6-14 CN4-6
CN3-7
GND
CN3-8 8
CN4-3
CN4-2 RxD
CN4-1 TxD CN3-9
CN3-10 7
1
2 CN5-13
3 CN5-14 19
4 18
5 CN5-15
6 CN5-16 20
14
CN4-7 CN5-5
R(I) CN2-14 21
11 3 I
2
CN2-7 1 O 27
+ 7 8
CN3-11
23 SIG
CN3-12
-
CN2-3 1 (T) O 2 2H
2
CN2-18
3 (W) I
54AA 8
28
7
24
CN5-3
25 CN5-1 3 O
2
CN5-6
1 (P) I 29
8
26 7
WE1400668
Figure 10

9-1-18
Reference Reference
Number Number
1 Instrument Panel 15 Circuit Breaker
2 Pilot Buzzer 16 Fusible Link
3 Light Switch 17 Fuse Box
4 Starter Switch 18 Check Connector
Drive Side Pump Pressure 19 Coolant Temperature Sensor
5
Sensor 20 Engine Speed Sensor
6 Idle Side Pump Pressure Sensor 21 Engine Oil Pressure Switch
Hydraulic Oil Temperature 22 Alarm Relay 2
7
Sensor
23 Parking Brake Sensor
8 Fuel Sensor
24 Pilot Filter Switch
9 Pedal Pressure Switch (Optional)
25 Return Filter Switch
10 Air Cleaner Indicator
26 Brake Oil Pressure Switch
11 Alternator
27 Ram Lock Switch
12 EPOS Controller
28 Work/Travel Switch
13 Battery
29 Parking Brake Switch
14 Battery Relay

9-1-19
OPERATION
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
0% (34°C)
98% 100% 17% (46°C)

33% (59°C)
81%
H 50% (72°C)
65%
Coolant CN5-13 51% (86°C)
Temperature 50% CN5-14 65% (90°C)
33% 81% (96°C)

C
17% 95 % (103°C)
0% WE1401047 98 % (107°C) (Warning Start)
100 % (110°C)
White 4,700 Ω / 3,460 mV / 0%

4,450 Ω / 3,390 mV / 11%
(Warning Start)
CN3-7 3,350 Ω / 3,070 mV / 33%
Fuel Level
11% CN3-8
Red Full
2,250 Ω / 2,590 mV / 55%
E F 1,100 Ω / 1,720 mV / 77%
WE1401048 645 Ω / 1,170 mV / 100%
0% (34°C)
100% 98% 17% (46°C)
81% 33% (59°C)

H
50% (72°C)
65%
Hydraulic Oil CN3-9 65% (85°C)
50%
Temperature CN3-10 81% (91°C)
C 33% 95% (97°C)

17% 97% (98°C)
WE1401049 98% (99°C) (Warning Start)
100% (101°C)
CN5-15
Tachometer rpm CN5-16
EX1301378

9-1-20
WARNING AND INDICATOR LIGHTS
Indication of Warning Lights

Input
Description Symbol Operation Remarks
Terminal
It lights in case of no
charge [voltage of
Normally, it lights
CN2 - 14 "R(I)" terminal is
when starting engine
Charge below 12 ±1V] or
CN1 - 8 (9) and is out after engine
overcharge [voltage
starts.
of "R(I)" terminal is
HAOA610L above 33(V)].
After starting engine,

CN5 - 5 It lights when engine if engine oil pressure
Engine Oil
oil pressure is below is insufficient after 8
Pressure CN1 - 8 (9) the reference. seconds, a warning
buzzer will sound.
HAOA620L
It lights when engine

CN5 - 13 coolant temperature
Coolant
sensor resistant is
Temperature CN5 - 14 below about 128
ohms.
HAOD350L
It lights during
preheating and turns
"OFF" after
CN2 - 13
Preheating completion of
CN1 - 8 (9) preheating.
(After 20 sec
preheating)
HAOA639L
CN2 - 6 It lights when work

Work Light light turns "ON" (24V
CN1 - 8 (9) applied).
HB4O2003

9-1-21
Input
Terminal
- Symbol up when
the parking brake
switch is placed in
Parking CN5-1 the park position.
Brake
Indicator
Light
P CN3-11
CN3-12
- Symbol up when
parking brake
pressure decrease
BCS0790L
below 26.0 kg/cm2
(377 psi)
Indication of Multifunction Gauge and

Letter Information Area
Input
Terminal
CN3 - 9 When hydraulic oil

Hydraulic Oil
temperature is above
Temperature CN3 - 10 about 96°C.
FG000056
Fuel CN3 - 7 When fuel is almost

Exhausted CN3 - 8 exhausted.
FG000057
CN2 - 17 When air cleaner is

Air Cleaner
CN1 - 8 (9) clogged.
FG000053
When return filter

CN5 - 3 pressure is above
Return Filter
CN1 - 8 (9) about 1.50 kg/cm²
(21 psi)
FG000054

9-1-22
When pilot filter
CN2 - 18 pressure is above
Pilot Filter
CN1 - 8 (9) about 1 kg/cm² (14
psi)
FG000055
Warning buzzer also

It flickers in case of
starts when boom
2.71V and above and
CN3-5 pressure sensor
Overload lights continuously in
output voltage is
Warning CN3-6 case of 2.8V and
about 2.7V while
above (and warning
overload warning
buzzer also starts).
FG000253 switch is "ON."
It lights when boost is

Boost CN2-2
selected.
FG000554
It lights when breaker

Breaker CN2-10
is selected.
FG001470
It lights when shear is

Shear CN2-9
selected.
FG001471
Lights up when quick

Quick Clamp CN2-11
clamp was release.
FG002195

9-1-23
Lights up when travel
Travel CN2-3
was selected.
WE1400672
This symbol appears

when the water
separator is full.
Water CN3-19
Separator This symbol appears
CN3-20
when water separator
sensor output voltage
FG010520
is about 1.5V below.
INITIAL OPERATION
Item Input (Terminal) Output (Operation and Initial Setting Mode)
• Warning buzzer is activated and turned "OFF" after
about 3 seconds.
• Power mode: When Fuel Saving Mode is disabled,
the power mode is the previous mode. When Fuel
When "CN7-16" is applied
Initial Saving Mode is enable, the power mode is standard
battery voltage (starter switch)
Operation mode or economy mode.
shifts from "OFF" to "ON"
• Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, fuel level,
hydraulic oil temperature, engine speed.
• Clock: Current time display.
NOTE: Refer to method for setting clock in operation manual

for setting time.

9-1-24
MODE SELECTOR SWITCH
EPOS Output
Output Check
Operation Mode Electromagnetic Proportional Pressure 7-Segment
(Operation Mode Display)
Reducing Valve (E.P.P.R Valve) Current (mA) Display
No-load: 280 ± 20mA
Power Mode
P Load: Variable output
(Max. current: 400 ± 20mA)
9x

Standard Mode
S Load: Variable output
7x

Economy Mode
E Load: Variable output
5x
NOTE: When the engine speed is below 1,000 rpm, the

output current of E.P.P.R valve is fixed to be
600 ± 60mA.
Auto Idle Switch
Operation Mode Output Check (Operation mode display LED)

Activation ON
Auto Idle
Cancellation OFF

9-1-25
GRAPHIC INFORMATION AREA DISPLAY
Overview
Machine condition is displayed in the letter information display
department. The information display department is divided into
two menus. One is main menu for the user and the other is a
special menu for the specialist. These menus can be changed
from normal display mode by the combination of selector button.
AM
H H
E F
C C
rpm
s
SPC
USB
1
WE1400673
Figure 11
Main Menus for the Graphic Display Area

1. User menu: Language setting, Time setting, Filter/Oil
information, Brightness adjustment, Password
2. Special menu: Information of machine status, fault
information, Information of machine operation.
Menu Selector Buttons

1. Proceed to the user menu using the menu/esc (1, Figure
11) button on the front of the panel.
2. Escape Button (1, Figure 11): Move a screen to previous
menu or main menu.

9-1-26
USER MENU
User Menu - Access and Escape Methods
Access Method
1. Proceed to the user menu using the menu/esc button on
the front of the dashboard.
2. Select the user menu from the launch menu.
AM PM
User Menu
H H
E F
C C Vehicle GP
Vehicle State Configuration Configuration
rpm
s
SPC SPC
USB S USB
<Normal Indication Monitor> <Main Menu Monitor>

WE1400674
Figure 12
Escape Method
1. Press the ESC button to move to the normal display screen.
2. If 20 seconds have passed without the operation of the
button, the normal display screen will be displayed.
3. Turning "OFF" the starter switch to cut off power, you will
move to the normal display screen.
User Menu
PM
Use the and buttons and move the cursor to see a User Menu
reversed display on the desired menu. Then, press the
button to select the menu.
Vehicle State ↔ Vehicle Configuration ↔ GP Configuration
Press the ESC button to return to the previous screen. Vehicle GP
Vehicle State Configuration Configuration
s
SPC
WARNING
USB
WE1400704
Figure 13
Do not use vehicle state menu when traveling or operating.

9-1-27
1. Vehicle State
PM
This is used to check the current vehicle state, filter/oil Vehicle State
information, vehicle information, etc.
Monitoring
Use the and buttons and move the cursor to see a
Filter/Oil Information
button to select the menu. Vehicle Information
Monitoring ↔ Filter/Oil Information ↔ Vehicle

Information
s
SPC
USB
Press the ESC button to return to the previous screen. WE1400705

Figure 14
A. Monitoring
Monitoring
The monitoring screen displays the information on Front Pump Pressure Rear Pump Pressure Battery Voltage
vehicle pump pressure, voltage, fuel level, etc.
bar bar bar
At the vehicle state, if the cursor is placed on 0 500 0 500 0 500
Monitoring, press the button to display the Engine Dial Voltage Fuel Level Engine Speed
Monitoring screen.
bar v %
Press the ESC button to return to the previous 0 50 0 40 0 100
screen.
FG018483
Figure 15
B. Filter/Oil Information
PM
The screen displays the information on filter/oil use Vehicle State
time, replacement period, and remaining time.
Monitoring
At the vehicle state, if the cursor is placed on the
filter/oil information, press the button to display
the filter/oil information. Vehicle Information
s
SPC
USB
WE1400706
Figure 16

9-1-28
Reset Method/Replacement Period Change Method
Move the cursor over the filter/oil item you wish to Fuel Filter
change using the and buttons on the front of TIME: 40hr
REMAIN: 1960hr
CHANGE: 2000hr
2 %
the dashboard and press the button on the front Air Cleaner
TIME: 0 hr CHANGE: 2000hr
of the dashboard. A window for resetting/changing REMAIN: 2000hr 0 %
the filter/oil time will pop-up. Engine Oil Filter

To reset the use time, move the cursor over 'clear' REMAIN: 100hr 0 %
and press the button on the front of the TIME: 41 hr

Return Filter
CHANGE: 1400hr
dashboard. REMAIN: 1359hr 2 %
Use the and buttons to locate it at YES. Then, EX1301406
press the button to reset the operation hour. Figure 17
Use the and buttons to locate it at NO. Then,

press the button to allow the pop-up window to
Fuel Filter
disappear without resetting the operation hour. TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
TIME:
Fuel Filter
0 hr CHANGE: 2000hr
REMAIN: 2000hr 0 %
TIME: 40 Engine CHANGE:

Oil Filter 2000
TIME:CLEAR
0 hr CHANGE
CHANGE: 100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301407
Figure 18
– The filter/oil use time shows the hours of

operation after initializing the engine. It begins
again with 0 hr after initialization the following TIME: 40hr
Fuel Filter
CHANGE: 2000hr
the replacement of filter/oil. REMAIN: 1960hr 2 %
Air Cleaner
Reset Operation
TIME: 0 hr
Hour?
CHANGE: 2000hr
REMAIN: 2000hr 0 %
Engine Oil Filter

TIME: 0 hr \HV QR
CHANGE: 100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301408
Figure 19
Fuel Filter
TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
TIME:
Fuel Filter
0 hr CHANGE: 2000hr
CHANGE:
REMAIN: 2000hr 2000 hr 0 %
Engine Oil Filter

1000 hr
TIME: CHANGE: 2000hr
100hr
REMAIN: 100hr 0 %
Return Filter
REMAIN: 1359hr 2 %
EX1301409
Figure 20

9-1-29
In order to change the filter/oil exchange period,
move the cursor over 'change' in the window for
Fuel Filter
resetting/changing the filter/oil time and press the TIME: 40hr CHANGE: 2000hr
button on the front of the dashboard.

REMAIN: 1960hr 2 %
Air Cleaner
Change Period?
After the exchange period change screen pops up,
TIME: 0 hrCHANGE: 2000hr
REMAIN: 2000hr 0 %
press the button on the front of the dashboard Engine Oil Filter
\HV QR
and the exchange time will start flashing. REMAIN: 100hr 0 %
Return Filter
Next, change the exchange period using the and TIME: 41 hr
REMAIN: 1359hr
CHANGE: 1400hr
2 %
buttons on the front of the dashboard.
EX1301410
With the replacement period change being
Figure 21
completed, press the button to create a pop-up
window to select the period change.
Use the and buttons to locate it at YES. Then,
press the button to change the replacement
period.
Use the and buttons to locate it at NO. Then,
press the button to allow the pop-up window to
disappear without the replacement period not being
changed.
Filter/Oil Period Setup Table Unit: time (hr)
Replacement Period
Kind Minimum Available Change Value By
Basic Setup Value
Setup Value Step
Fuel Filter 500 100 50
Air Cleaner 2,000 1,000 50
Engine Oil Filter 500 100 50
Return Filter 1,000 100 50
Pilot Filter 1,000 100 50
Engine Oil 500 100 50
Hydraulic Oil 2,000 1,000 50
Coolant Water 4,000 1,000 50
Symbol Description
Filter/ ENG Oil Return Coolant

Fuel Filter Air Cleaner Pilot Filter ENG Oil HYD. Oil
Oil Name Filter Filter Water
Icon
EX1300858
Figure 22

9-1-30
If the remaining time for filter/oil replacement is less
than 10 hours, this pop-up window will be created. PM
Press the ESC button or the button to allow the H Caution H

pop-up window to disappear.
Return Filter
F
E period starts!
Replacement
C E F C
rpm
s
SPC
USB
WE1400707
Figure 23
If the filter/oil replacement period is exceeded, this

pop-up window will be created. Press the ESC button PM
or the button to allow the pop-up window to H Caution H

disappear.
Return Filter
WARNING
F
E period is exceeded!
Replacement
C E F C
rpm
AVOID DEATH OR SERIOUS INJURY SPC
s USB
Do not use vehicle state menu when traveling or WE1400708

operating. Figure 24
C. Vehicle Information
PM
This is used to check the vehicle name, engine type Vehicle State
and attachment options.
Monitoring
At the vehicle state, if the cursor is placed on the
vehicle information, press the button to access
the vehicle information screen. Vehicle Information
Click the ESC button to return to the previous screen.

s
SPC
USB
WE1400721
Figure 25
Vehicle Information
Engine
Attachment Option Not Available
Vehicle Number 001001
EX1301411
Figure 26

9-1-31
2. Vehicle Configuration
PM
This is used when selecting the functions such as User Menu
attachment setting, camera setting, forced dial input, auto
shut-off setting and option motion setting.
Turn the jog switch and move the cursor to see an
reversed display on the desired menu. Then, click the jog
Vehicle GP
switch to select the menu. Vehicle State Configuration Configuration
s
SPC
USB
WE1400722
Figure 27
Attachment Setting ↔ Camera Setting ↔ Forced Dial

Input ↔ Auto Shut-off Setting ↔ Option Motion Setting PM
↔ Other Setting Vehicle Configuration
Press the ESC button to return to the previous screen. Attachment Setting
Camera Setting
Forced Dial Input
Option Motion Setting
s
SPC
USB
WE1400723
Figure 28
A. Attachment Setting (Optional)

PM
In this menu, performance of the breaker and Attachment Setting
two-way can be set and set items can be selected.
Breaker Select
Breaker Select ↔ Two-way Select ↔ Breaker
Two Way Select
Setting ↔ Two-way Setting
Breaker Setting
Press the ESC button to return to the previous
Two way Setting
screen.
s
SPC
USB
WE1400724
Figure 29
How to Select Attachments (Breaker/Two-way)

Breaker Select
After proceeding to attachment setting items, breaker 1. 1800 rpm 95 lpm 140 bar
select and two-way select will appear. 2. 1800 rpm 95 lpm 140 bar
Operate the jog switch clockwise/counterclockwise to 3. Not in Use
select breaker/two-way select. Then, click on the jog 4. Not in Use
switch to move the cursor to the selectable lists. 5. Not in Use
When the cursor is placed on the list, operate the jog

switch clockwise/counterclockwise to move the
cursor. Then, click on the jog switch to select
attachments to use. EX1301413
Figure 30

9-1-32
When the selection is completed, the "Select
Breaker Select
Complete!" pop-up window is displayed for 3
seconds, and the checkbox of the selected list is 1. 1800 rpm 95 lpm 140 bar
updated. 2. 1800 rpm 95 lpm 140 bar

3. Not in Use
The cursor can only be moved from the selectable 4. Not in Use
Select Complete!
lists. The selectable list items at the attachment 5. Not in Use
setting are set as "Available" in the use or non-use of
attachments in the attachment setting.
EX1301414
Figure 31
B. Breaker Setting/Two-way Setting

PM
The breaker setting/two-way setting screen is used to Attachment Setting
set up the use or non-use of attachments, max.
engine limit, and max. attachment flow rate, etc. Breaker Select
Two Way Select

At the vehicle configuration, when the cursor is
placed on attachment setting, click on the jog switch Breaker Setting
to access the Breaker setting or Two-way setting list Two way Setting
screen.
s
SPC
If the system is set up as the owner's password

USB
locked, access the attachment setting list screen by WE1400725

using owner's password input screen. Figure 32
On the owner's password input screen, press the

Owner Password
ESC button to return to the previous screen.
3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301416
Figure 33
If you access the breaker setting or two-way setting

Breaker Setting
list screen, the initial screen locates the cursor at the
top. 1. 1800 rpm 95 lpm 140 bar
2. 1800 rpm 95 lpm 250 bar
3. 1800 rpm 95 lpm 140 bar
4. 1800 rpm 95 lpm 140 bar
5. 1800 rpm 95 lpm 140 bar
EX1301417
Figure 34

9-1-33
Operate the jog switch clockwise/counterclockwise to
Two Way Setting
select breaker/two-way. Then, click on the jog switch
on the list, operate the jog switch clockwise/ 1. 1800 rpm 95 lpm 250 bar
counterclockwise to move the cursor. Then, click on 2. 1800 rpm 95 lpm 340 bar
the jog switch to select the attachments to be set up 3. 1800 rpm 95 lpm 250 bar
and move to the attachment setting screen. 4. 1800 rpm 95 lpm 250 bar
5. 1800 rpm 95 lpm 250 bar
On the attachment setting list screen, when cursor is
placed on the list, press the ESC button to locate the
cursor at breaker/two-way at the top. When the
cursor is placed at breaker/two-way at the top, press
the ESC button to return to the previous screen. EX1301418
Figure 35
How to Set Up Attachments

Breaker 1 Setting
Attachment setting items include attachment use,
Attachment Use Dydlodeoh Button Type Wrjjoh
max E/G limit, max pressure (ATT), max flow (ATT), Max E/G Limit 4;33 usp Max Press.(ATT) 473 edu
min flow (ATT), and user setting max flow. Operate Max Flow(Pump) 7<3 osp Max Flow(ATT) 573 osp
the jog switch clockwise/counterclockwise to locate 2 Pump Option Dydlodeoh Min Flow(ATT) 63 osp
the cursor. Then, click on the jog switch to set up
relevant items. User Setting Max Flow <8 osp
0 .
The cursor movement order goes like this: 63 573
1) Breaker Setting
EX1301419
Attachment Use ↔ Toggle ↔ Max E/G Limit
Figure 36
↔ Max Pressure ↔ Max Flow ↔ Min Flow ↔
User Setting Max Flow
2) Two-way Setting
Attachment Use ↔ Max E/G Limit ↔ Max
Pressure ↔ Max Flow ↔ Min Flow ↔ User
Setting Max Flow
Attachment Use
Breaker 1 Setting
The attachment use is designed to determine Attachment Use Dydlodeoh Button Type Wrjjoh
whether relevant attachments are used or not. Max E/G Limit 4;33 usp Max Press.(ATT) 473 edu
If set up as enable, the relevant attachment can be Max Flow(Pump) 7<3 osp Max Flow(ATT) 573 osp
2 Pump Option Dydlodeoh Min Flow(ATT) 63 osp
used. Currently Selected Item!
If set up as disable, the relevant attachment cannot User Setting Max Flow <8 osp
be used. 0
63 573
.
Locate the cursor at the attachment use. Then, click

on the jog switch to set up enable/disable. EX1301420
NOTE: If you select an attachment set up as Figure 37
disable, the pop-up window "Currently
Selected Item!" is displayed for three (3)
seconds disabling the setup.
NOTE: If an attachment is enabled it can be a
selectable attachment in the attachment
select.

9-1-34
Toggle
This item sets the applicability of the toggle of the
breaker button.
If toggle is selected, the breaker will continue
operation when the breaker button is pressed once,
and reset when pressed again.
If toggle is not selected, the breaker is only actuated
while the breaker button is being pressed and held.
Max E/G Limit
The max E/G Limit is set up to define the flow rate
limit discharged when using attachments.
Operate the jog switch to move the cursor to the max
E/G limit. Then, click on the jog switch to convert into
the editing mode.
At the editing mode, operate the jog switch clockwise/
counterclockwise to determine the desired max.
engine limit. Then, click the jog switch to complete
setup.
At the editing mode, press the ESC button to disable
the editing mode and save the current setup value.
The change value by stage in the jog switch
operation is 100 rpm.
Max Pressure (ATT)
The max pressure (ATT) can be set up as the max
pressure of the attachment by the user according to
the attachment’s specifications.
Max Flow (Pump)
The max flow (pump) is the pump's max. flow rate
discharged when using attachments.
It needs not to be set up by the user, and it is
automatically determined according to the max.
engine limit setup value.
Max Flow (ATT)/Min Flow (ATT)
The max flow (ATT) /min flow (ATT) can be set up as
the max/min flow rate value of the attachment by the
user according to the attachment's specifications.
For instance, if the relevant attachment's use
capacity is 90 - 120 lpm (23.8 - 31.7 gpm), the user
can set up 120 lpm (31.7 gpm) for the max. flow rate,
and 90 lpm (23.8 gpm) for the min. flow rate.
The setup method is the same as the above max.
engine limit setup method. The change value by
stage in the jog switch operation is 10 lpm (2.6 gpm).

9-1-35
User Setting Max Flow
The user setting max flow is designed to set up the
flow rate segment of the attachment to be used by
the user.
Within the above setup max. flow rate (pump), max.
flow rate (ATT), and min. flow rate (ATT) scope, the
user can set up the max. flow rate value of the
attachment to be used.
The setup method is the same as the above max.
engine limit setup method. The change value by
stage in the jog switch operation is 10 lpm (2.6 gpm).
When setting up all above items, the setup limits are
outlined as follows.
• Breaker (One Way) Setting
Max. Limit Min. Limit
Max. E/G Limit 2,200 rpm -
Max. Press. 220 bar 140 bar
• Two-way Setting
Max. Limit Min. Limit
Max. E/G Limit 2,200 rpm -
Max. Press. 220 bar 140 bar

9-1-36
C. Camera Setting
PM
The camera setting screen is designed to set up Vehicle Configuration
various cameras "ON/OFF" and normal/mirror.
Attachment Setting
From the vehicle configuration, select camera setting
Camera Setting
to access the camera setting list screen.
Forced Dial Input
s
SPC
USB
WE1400726
Figure 38
The camera setting list screen displays various

PM
camera states (ON/OFF, NORMAL/MIRROR).
Camera Setting
Select a camera and click the jog switch to access
the relevant camera setting screen. No 1 Camera
Press the ESC button to return to the previous No 2 Camera
screen. No 3 Camera
s
SPC
USB
WE1400727
Figure 39
On the camera setting screen, set up the camera

No 1 Camera
state (ON/OFF, NORMAL/MIRROR).
Also, see the actual image of the currently installed No 1 Camera
camera.
On Off
Normal Mirror
EX1301421
Figure 40
If a camera is not installed, the camera image section

No 1 Camera
is shown as a blue screen.
If the cursor is placed on "ON/OFF", click on the jog No 1 Camera
switch to set up "ON" ↔ "OFF".
On Off
Turn the jog switch to locate the cursor at normal/ Normal Mirror
mirror. Then, click on the jog switch to set up normal
↔ mirror.
EX1301422
Figure 41

9-1-37
D. Forced Dial Input
PM
The forced dial input screen provides a method Vehicle Configuration
whereby to use the gauge panel's jog switch and
control the engine rpm, replacing the engine control Attachment Setting
dial. Camera Setting

Forced Dial Input
From the vehicle configuration, select the jog shuttle Option Motion Setting
for dial to access it.
s
SPC
USB
WE1400728
Figure 42
If you access the jog shuttle for dial screen, the initial
# Input
Forced Dial
cursor is located at the using jog shuttle for dial.
If the using jog shuttle for dial is shown as disable,
Using Jog Shuttle for Dial Available
the cursor cannot be moved.
Current Engine Speed 0
40 %
Setting RPM Dial
EX1301423
Figure 43
When the cursor is placed at the using jog shuttle for

# Input
Forced Dial
dial, if you click on the jog switch, a pop-up window
will be created, saying "Do you want to use manual
Dial Control for Engine rpm?". Using Jog Shuttle for Dial Available
Do you want to use
Operate the jog switch and select "YES/NO" to manual Dial Control for
Current Engine Speed
RPM? 0
determine whether to use jog shuttle for dial. Engine
\HV QR
0%
If you select "YES", then using jog shuttle for dial is Setting RPM Dial
enabled, causing the pop-up window to disappear.
If you select "NO", then using jog shuttle for dial
remains disabled, causing the pop-up window to EX1301424
disappear. Figure 44
If the using jog shuttle for dial is shown as enable,

# Input
Forced Dial
operate the jog switch clockwise and move the cursor
to the setting rpm dial. When the cursor is placed at
the setting rpm dial, click on the jog switch to cause Using Jog Shuttle for Dial Available
the cursor to flicker, changing into an editing mode to
set up the rpm dial. When the cursor is placed at the Current Engine Speed 0
editing mode, operate the jog switch clockwise/
40 %
counterclockwise, thus setting up the engine rpm. Setting RPM Dial
When the cursor is at the editing mode, press the

ESC button to disable the editing mode. When the
cursor is not at the editing mode, press the ESC EX1301425
button to return to the previous screen. Figure 45
Before keying off the gauge panel or disabling the
using jog shuttle for dial, control the engine rpm only
with the shuttle of the gauge panel's jog shuttle.

9-1-38
E. Option Motion Setting (Option)
PM
When the PE3C option is installed, the motion input Vehicle Configuration
signal of the attachment can be set to be used
through either the joystick or the hydraulic pedal in Attachment Setting
the option motion setting screen. Camera Setting

Forced Dial Input
Select option motion setting in the vehicle settings Option Motion Setting
and proceed to the settings screen.
s
SPC
USB
WE1400729
Figure 46
'Joystick Thumb Wheel' and 'Option Pedal' can be

# Setting
Option Motion
selected in option motion settings.
Joystick Thumb Wheel
Joystick Thumb Wheel
The breaker/two-way motion signal can be input as a Option Motion
Option Pedal
joystick manipulation signal.
If this item is selected in a vehicle in which a hydraulic
pedal is installed, the hydraulic pedal will be
deactivated.
Option Pedal (Option) EX1301429
This option is available only in vehicles with the PE3C Figure 47
option with a hydraulic pedal installed.
The breaker/two-way motion signal can be input as a
hydraulic pedal manipulation signal.
If this item is selected, the input signal of the joystick
thumb wheel is deactivated.

9-1-39
F. Other Settings
PM
The auto idle rpm is adjusted according to the Vehicle Configuration
ambient temperature to enhance heater performance
in winter. Camera Setting
Forced Dial Input
Other Setting
s
SPC
USB
WE1400730
Figure 48
The default value is "Enable." When the ambient

temperature is below 10°C, the auto idle rpm is set to Other Setting
1100 rpm. It is set to 800 rpm with the ambient
temperature over 10°C. Change Auto Idle RPM as the Enabled
Temperature
When disabling this menu item, the auto idle rpm is

fixed to 800 rpm regardless of change in the ambient
temperature.
EX1402175
Figure 49
3. GP Configuration
PM
This menu is used to set up password, brightness, default User Menu
screen and time, and to input service phone number. Use
the and buttons and move the cursor to see an
button to select the menu.
Vehicle GP
Password Setting ↔ Brightness Setting ↔ Default Vehicle State Configuration Configuration
Power Mode Setting ↔ Time Setting ↔ Service Phone

s
SPC
Number Setting ↔ Unit Setting ↔ Notification Setting USB
↔ Entertainment Use Setting WE1400731
Press the ESC button to return to previous screen. Figure 50
A. Password Setting
PM
Password Setting GP Configuration
An owner passwords and user passwords can be set Password Setting
(Only the owner password is selected in the default Brightness Setting
shipment state). Default Power Mode Setting
By using the password setting function, you can Time Setting
manage usage of operations and functions of the Service Phone Number Setting
vehicle.
s
SPC
USB
WE1400732
Figure 51

9-1-40
Owner Password Setting
PM
1) Selection Password Setting
An owner password can be set for managing Owner Password Setting
functions of equipment and use privileges of the
User Password Seeting
equipment for different users.
To set an owner password, place the cursor
over Owner Password Setting in the settings
screen and press the button.
s
SPC
USB
WE1400733
Figure 52
2) Password entry
Owner Password
When the password entry screen appears, use
the keypad to enter the password and move to
the settings screen.
The default password is "1111".
How to enter the password 3 4 5 6 7 8 9 : ; <
Use the and buttons to select digits from 0 Enter Owner Password
to 9 below, and press the button to input the
password.
EX1301416
If the password is input incorrectly, use the
Figure 53
button on the lower right to delete the input
password.
Owner Password
IMPORTANT
If the password is input incorrectly three
times in a row, you will be redirected to the Password Error!
main screen and the system will not start for
the next 10 minutes. 3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301433
Figure 54
3) Structure
Password Setting
Owner password settings include password
change, start-up restriction settings, function Password Change
item settings, user password use settings, and Owner Engine Startup Lock has not been set!
user password change.
Item Setting
Use
User
Password Change
EX1301434
Figure 55

9-1-41
Password change
Owner Password Change
To change the owner password, select
password change with the keypad.
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301435
Figure 56
When the owner password has been changed,

Password Setting
"Password Set!" will pop-up.
Password Change
Owner Engine Startup Lock has not been set!

Password
Item Setting Set!
Use
User
Password Change
EX1301436
Figure 57
Item setting
Item Setting
User privileges and settings for engine start-up,
attachment settings, and entertainment use Item Use Permission
settings can be set.
Engine Startup
NOTE: Permission, which gives certain
Attachment Setting
users permission touse certain
features, can only be checked when
use is checked.
In this case, the user has the same
privileges as the owner, and the
WE1400699
user’s settings take precedence in
equipment settings. Figure 58
NOTE: This setting is off by default.

a) Engine startup
Setting of password input upon operation
of equipment.
b) Attachment setting
Setting of password input for attachment
setting.

9-1-42
Engine start-up setting
Password Setting
By selecting "Engine Start-up" among item
settings the reentry time for password entry Password Change
upon start-up of the equipment can be set. Owner Always 1min 5min
NOTE: No password for start-up of the Item Setting

equipment is setby default. Use
User
a) Always Password Change
Password is entered with each start-up.

b) 1 min EX1301438
If the system is started again within 1
Figure 59
minute from key-off after the password is
input, the password is not requested
again.
c) 5 min
minutes from key-off after the password is
again.
User password setting
Password Setting
a) User password use setting
Sets use of the user password. Password Change
b) User password change Owner Engine Startup Lock has not been set!
After setting use privileges for the user Item Setting

password, the owner can change the user Use
password. User
Password Change
EX1301439
Figure 60
User Password Setting

PM
1) Selection Password Setting
If the owner checks user password use in owner Owner Password Setting
password setting, user password setting will
User Password Seeting
appear in the password setting screen so user
password can be set. (refer to “Owner
Password Setting” on page 1-41).
To set a user password, place the cursor over
s
SPC
User Password Setting in the Password Setting USB
screen and press the button. WE1400734

Figure 61
2) Password entry
When the password input screen appears, input
the password with the keypad and move to the
settings screen. (refer to "Owner Password
Setting 2" on page 2-71.)
The default password is "1111".

9-1-43
3) Structure
Password Setting
User password settings include password
change, start-up restriction settings, and Password Change
function item settings. User Always 1min 5min
Item Setting
EX1301441
Figure 62
Password change
User Password Change
To change the user password, select password
change, and change the user password using
the keypad.
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301442
Figure 63
When the user password is changed,"Password

Password Setting
Set!" will pop-up.
Password Change
Owner Engine Startup Lock has not been set!

Password
Item Setting Set!
Use
User
Password Change
EX1301436
Figure 64
Item setting
Item Setting
Use of engine start-up, attachment setting, and
entertainment use setting can be set. Item Use
NOTE: This is only possible when permitted Engine Startup

by the owner.
Attachment Setting
a) Engine startup
Setting of password input upon operation
of equipment.
b) Attachment setting
WE1400700
Setting of password input for attachment
Figure 65
setting.

9-1-44
Engine start-up setting
Password Setting
By selecting "Engine Start-up" among item
settings the reentry time for password entry Password Change
upon start-up of the equipment can be set. User Always 1min 5min
a) Always Item Setting

Password is entered with each start-up.
b) 1 min
minute from key-off after the password is
input, the password is not requested EX1301444
again. Figure 66
c) 5 min
minutes from key-off after the password is
again.
NOTE: If the owner uses the engine start-up
feature but does not permit the user
to use it, the user cannot select
whether to use the feature, but can
select the password reentry time.
B. Brightness Setting
PM
On the GP configuration screen, when cursor is GP Configuration
placed on brightness setting, press the button to
Password Setting
display the screen brightness setting and camera
Brightness Setting
brightness setting screen.
Default Power Mode Setting
Time Setting
Service Phone Number Setting
s
SPC
USB
WE1400735
Figure 67
If you want to change the screen brightness, select

PM
the screen brightness setting to display the
brightness adjustment screen. Brightness Setting
Screen Brightness Setting
Camera Brightness Setting
s
SPC
USB
WE1400736
Figure 68

9-1-45
Use the and buttons and adjust the brightness
of 0 - 100% at an interval of 10%. Screen Brightness Setting
The screen brightness when manufactured is set as H H
60%.
60 %
screen. C
E F
C
EX1401629
Figure 69
If you want to change the camera screen brightness,

PM
select the camera brightness setting to display the
camera screen brightness adjustment screen. Brightness Setting
Screen Brightness Setting
Camera Brightness Setting
s
SPC
USB
WE1400736
Figure 70
Use the and buttons to adjust the brightness of

0 - 100% at an interval of 10%.
The camera screen brightness at the vehicle release
time is set as 60%. 60 %

screen.
EX1301445
Figure 71
C. Default Power Mode Setting

PM
placed on default power mode setting, press the
Password Setting
button to access the default power mode setting.
Brightness Setting
Fuel Saving Mode is Enable Default Power Mode Setting
Time Setting
ON OFF ON Service Phone Number Setting
P P
s
SPC
USB
PWR PWR
S S WE1400737
STD STD
Figure 72
E E
ECO ECO

9-1-46
Fuel Saving Mode is Disable
ON OFF ON
P P Fuel Saving Mode Enable

PWR PWR
Smart Power Control Enable

S S
STD STD
E E
ECO ECO
EX1301446
Figure 73
D. Time Setting
PM
placed on time setting, press the button to access
Password Setting
the time setting.
Brightness Setting
Use the and buttons and locate the cursor at a Default Power Mode Setting
target of change. Then, press the button to Time Setting
change the target. Service Phone Number Setting
s
SPC
USB
WE1400738
Figure 74
Use the and buttons to change numbers of

Time Setting
each item.
If the setup is completed, press the button to
store the setup details. TIME 09 : 47 : 24 PM
When the time setting is completed, locate cursor to DATE 2013 / 10 / 29 SET
'SET' and press the button.

If the SET button is not pressed, time setting would
not be completed.
Press the ESC button to return to the previous EX1301447
screen. Figure 75
E. Service Phone Number Setting

PM
placed on service phone number setting, press the
Password Setting
button to access the service phone number
Brightness Setting
setting.
Time Setting
s
SPC
USB
WE1400740
Figure 76

9-1-47
Use the and buttons and locate the cursor at a
desired number. Then, press the button to input
the number. If number input is completed, press the 1 2 3
Current Phone Number is
key to enter the input phone numbers. 4 5 6
Use the key and delete erroneously input
Enter Phone Number if you want
to Change. 7 8 9
numbers. 000-0000-0000
0
EX1301448
Figure 77
When you input service phone numbers, if warning/

alarm is issued, check the input phone numbers in PM
the pop-up window. H Warning H

000-0000-0000
Hydraulic Oil
Hydraulic oil overheat. Please check after the
hydraulic oil is cooled off completely. In times of
E F
an emergency situation, turn off the engine after
C
gradually cooling Ethe engine. F C
rpm
s
SPC
USB
WE1400743
Figure 78
F. Unit Setting
PM
placed on unit setting, press the button to access
Brightness Setting
the unit setting.
Time Setting
Unit Setting
s
SPC
USB
WE1400744
Figure 79
On the unit setting screen, change the units of

Unit Setting
temperature, pressure, flow rate, and speed. These
figures at the vehicle release time are set as below:
Temperature 䮎䯘
Temperature: °C
Pressure edu nji2 䶫 svl PSd
Pressure: bar
Flux osp jsp
Flow rate: lpm
Speed np2k psk
Speed: km/h
EX1301449
Figure 80

9-1-48
G. Language Setting
PM
placed on language setting, press the button to
access the language setting.
Time Setting
Unit Setting
Language Setting
s
SPC
USB
WE1400745
Figure 81
On the language selection screen, use the and

Language Setting
buttons and move the cursor to select a language.
Then, press the button to adopt the selected
language.
screen.
Language
Korean, English, Chinese, Persian, Turkish,
Indonesian, Polish, Arabic, Russian, Thai, Hindi,
EX1301062
Japanese, French, German, Nederlands, Italian,
Portuguese, Spanish, Finnish, Swedish, Figure 82
Norwegian, Danish, Vietnamese, Greek
H. Notification Setting
PM
placed on notification setting, press the button to
Time Setting
access the notification setting.
Unit Setting
Language Setting
Notification Setting
s
SPC
USB
WE1400746
Figure 83
Depending on the notification setting screen details,

Notification Setting
pop-ups are created on the main screen when
warning/alarm is issued, when the switch is operated,
and when the supplies replacement period expires. Warning Alarm Pop up Avalible
On the notification setting screen, use the and Maintenance Notification Pop up Avalible
buttons and move the cursor to a desired location.
Then, press the button to select enable or
disable.
All notice items at the vehicle release time are set as
Enable. EX1301450
Figure 84

9-1-49
SPECIAL MENU
In this menu, many types of operating conditions and functions
can be accessed and displayed, including the EPOS controller.
This menu is mainly used for machine testing and fault
diagnostics.
The special menu offers five submenus:
1. Monitoring.
2. Graph.
3. Failure Information.
4. Operating Hour Information.
5. Vehicle Configuration.
Entering/Accessing and Exiting/Escaping

Menus
Entering/Accessing Menus
When normal mode screen is displayed, normal mode screen
(Figure 85) will be changed to special menu screen (Figure 86).
Normal Mode Screen
NOTE: Normal mode screen display fuel gauge, engine
H H
coolant temperature gauge, hydraulic oil temperature
gauge and engine speed (rpm).
E F
C C
rpm
WE1400701
Figure 85
Special Menu Screen

PM
NOTE: Displayed language on the special menu screen Service Menu
consists of Korean and English.
Monitoring
If any language except for Korean is selected during Graph
language selection mode of main menu, only English Failure Information
will be displayed on special menu screen. Operating Hour Information
Vehicle Configuration
s
SPC
USB
WE1400747
Figure 86

9-1-50
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 127) is pressed the
special menu screen will be returned to the normal mode
screen.
2. If this special menu is "ON" without any activity, for more
than 20 seconds, it will return to the normal mode screen.
3. After the turning starter switch to "OFF" position, turn it
back to "ON" position, and the normal mode screen
displayed once again.
Special Menu Selections

Submenu Selection Method
PM
Various submenus can be selected by turning the jog switch and Service Menu
moving the cursor to see a reversed display on the desired
Monitoring
menu. Then, click on the jog switch to select the menu.
Graph
Press the ESC button to return to the previous screen. Failure Information
Entering Submenus: When cursor is located on "Machine Info" Operating Hour Information
of special menu screen, press "Enter ( , 3 on Figure 127)" Vehicle Configuration
button and the "Machine Info" will be displayed.

s
SPC
USB
WE1400747
Figure 87
Monitoring
PM
1. Entering Submenus: When cursor is located on Monitoring
"Monitoring" of special menu screen, press the jog switch
Vehicle Analog
and the "Monitoring" will be displayed.
Vehicle Digital
2. Exiting Submenus: If escape button (ESC, 4 on Figure Engine Signal
127) is pressed display will be turned to previous screen. User Selection Signal
Doosan Connect Information
s
SPC
USB
WE1400748
Figure 88

9-1-51
Vehicle Analog Description
Analog Items Display Remark

1. Front Pump Pressure bar Front Pump Pressure
2. Rear Pump Pressure bar Rear Pump Pressure
3. Boom Cylinder Pressure bar Boom Cylinder Head Pressure
4. Px Pressure bar Px Pressure
5. Py Pressure bar Py Pressure
6. Pilot Gear Pump Pressure bar Pilot Gear Pump Pressure
7. Alternator Voltage V Indicating Alternator Voltage
8. Battery Voltage V Indicating Battery Voltage
9. Engine Dial Voltage mV Indicating Dial Voltage
10. Water in Fuel Voltage V Indicating WIF Sensor Voltage
11. Fuel Level % Fuel Residual Quantity Radio of Fuel Tank
12. Hydraulic Oil Temperature °C Hydraulic Oil Temperature
13. TPS Voltage V E/G Throttle Lever
14. Coolant Temperature °C Coolant Temperature
15. Pump P/V mA Current in Pump Proportional Valve
16. Flow Control P/V mA Current in Pump Proportional Valve
Submenu Selections
Vehicle Analog Vehicle Analog

Front Pump Pressure 0 bar Engine Dial Voltage 216 mV
Rear Pump Pressure 0 bar Water in Fuel Volage V
Boom Cylinder Pressure 0 bar Fuel Level 0%
Px Pressure 0 bar Hydraulic Oil Temperature -40 C
Py Pressure 0 bar TPS Voltage V
Pilot Gear Pump Pressure 0.1 V Coolant Temperature C
Alternator Voltage 24.7 V Pump P/V 0 mA
Battery Voltage 216 mV Flow Control P/V 0 mA
WE1400702
Figure 89

9-1-52
Vehicle Digital Descriptions
Digital Items Remark

1. Alternator Lights up when output at alternator "R (I)" terminal is above 12 ±1 V.
Lights up when the boost button is "ON" with the work mode
2. Power Max Switch
selected to "Boost".
Lights up when the boost button is "ON" with the work mode
3. Breaker Operator Switch
selected to "Breaker".
4. Travel Select SW N.A. (Only for wheel type equipment)
5. Working Light Switch Lights up when the light switch is set to "II" position.
6. One Way Selection Switch Lights up when the selector switch is turned to "Breaker".
7. Two-way Selection Switch Lights up when the selector switch is turned to "Shear".
8. Quick Coupler Lights up when the quick coupler switch is "ON".
9. Parking Brake Switch Lights up when the parking brake switch is "ON".
10. Ram Lock Switch Lights up when the ram lock switch is "ON".
11. Air Cleaner Indicator Lights up when the air cleaner indicator contact is "ON".
12. Pilot Filter Lights up when the pilot filter pressure switch is "ON".
13. Return Filter Lights up when the return filter pressure switch is "ON".
14. OWD Selector Switch Lights up when the overload warning selector switch is "ON".
15. Brake Oil Pressure Switch N.A. (Only for wheel type equipment)
16. Option Pedal Pressure Switch (2 way) Lights up when the option pedal switch is "ON".
17. Water in Fuel Light up when WIF sensor is "ON".
18. Preheat Relay Lights up when the preheat relay is "ON".
19. Start Up Switch Lights up when the starter switch is "Start".
20. Travel Press. SW (Py) Lights up when the pressure switch (Py) is "ON".
21. Work Press. SW (Px) Lights up when the pressure switch (Px) is "ON".
22. E/G Oil Press. SW Light up when E/G oil pressure sensor is "ON".
23. Relief Pressure Up S/V Lights up when the relief press up solenoid valve is "ON".
24. Starter Relay Lights up when the starter relay is "ON".
25. Back Up Relay Lights up when the back buzzer relay is "ON".

9-1-53
Submenu Selections
Vehicle Digital Vehicle Digital

Alternator Parking Brake Switch
Power Max Switch Ram Lock Switch
Breaker Operator Switch Air Cleaner Indicator
Travel Select SW Pilot Filter
Working Light Switch Return Filter
One Way Selection Switch OWD Selector Switch
Two-way Selection Switch Brake Oil Pressure Switch
Quick Coupler Option Pedal Pressure Switch (2 way)
Vehicle Digital Vehicle Digital

Back Up Relay Water in Fuel
Preheat Relay
Start Up Switch
Travel Press. SW (Py)
Work Press. SW (Px)
E/G Oil Press. SW
Relief Press. Up S/V
Starter Relay
WE1400703
Figure 90
User Selection Signal

User can select signals of all monitoring items.
Front Pump Press.
The maximum limit of monitoring signal is 8. Rear Pump Press.
Boom Cylinder Press.
Px Pressure
Py Pressure
Alternator Voltage
Battery Voltage
Engine Dial Volt.
EX1301613
Figure 91

Rear Pump Press. Front Pump Press. 0 bar
Boom Cylinder Press. 0 bar
Px Pressure Boom Cylinder Press. 0 bar
Py Pressure You canPxselect up to 8
Pressure 0 bar
Alternator Voltage items!
Py Pressure 0 bar
Battery Voltage Alternator Voltage 1V
Engine Dial Volt. Battery Voltage 24.7 V
Flow Ctrl Lever LH Volt. Engine Dial Volt. 215 mV
Flow Ctrl Lever LH Volt.
EX1301614
Figure 92

9-1-54
Graph
PM
1. Entering Submenus: When a cursor is located in "Graph" Service Menu
of special menu screen press selector button ( ) on Monitoring
panel and "Graph" screen is displayed. Graph
2. Exiting Submenus: If escape button on panel is pressed, Failure Information
this information screen will be returned to previous screen. Operating Hour Information
s
SPC
USB
WE1400749
Figure 93
Graph Data Monitoring

PM
Real time monitoring of the selected data. Service Menu
Graph Data Setting
s
SPC
USB
WE1400750
Figure 94

Battery Voltage V Current Value : 24.7
40.0
Engine Dial Volt.
Rotating P/V (CCW)
0
1 19 Sec
EX1301616
Figure 95
Graph Data Setting

Graph Data Setting
User can be graph data setting. Front Pump Press.
The maximum limit of the graph data setting is 7. Rear Pump Press.
Boom Cylinder Press.
Px Pressure You can select up to 7
Py Pressure items!
Alternator Voltage
Battery Voltage
Engine Dial Volt.
EX1301617
Figure 96

9-1-55
Failure Information
PM
1. Entering Submenus: When a cursor is located in "Failure Service Menu
Info" of special menu screen press selector button ( ) on
Monitoring
panel and "Failure Info" screen is displayed.
Graph
2. Exiting Submenus: If escape button on panel is pressed, Failure Information
this information screen will be returned to previous screen. Operating Hour Information
s
SPC
USB
WE1400751
Figure 97
* Real-time Failure: Current status of fault is displayed.

PM
* Failure Log: Memorized record of past fault is displayed. Failure Information
Real Time Failure Information
Failure Log Information
s
SPC
USB
WE1400752
Figure 98
A. Current fault information

Real Time Failure Information
Current status of fault is displayed (Failure code, fault NO Code Description
contents). 1 VCO002-11 THUMB WHEEL (LH)
2 VPV001-05 PUMP P/V (A), Current below normal
When several faults are produced, fault information 3 VPV010-05 FLOW CONTROL P/V (F) ROTATIN.
can be checked on this information screen. 4 VSV001-05 BREAKER OPERATING S/V, Curen.
5 VSP011-04 ARM OUT PRESS. SENSOR, Voltag
No: Number of currently occurring failure 6 VSP008-04 BOOM DOWN PRESS. SENSOR, Vo
Description
Code: Display of current failure code Pump P/V (A), Current below normal
VXXyyy-zz: Method of displaying machine related

failure code EX1301618
Figure 99
– V: Display of machine related failure code
– XX: Display of failed part
– yyy: Serial number of failed part
– zz: FMI (Failure Mode Identifier) number
Eyyyyyy-zz: Method of displaying engine related
failure code
– E: Engine related failure code
– yyyyyy: Serial number of failed part
– zz: FMI (Failure Mode Identifier) number
* Method of displaying failed part of machine (VXX)
1) VCO: Communication related failure
2) VPV: EPPR valve related failure

9-1-56
3) VSV: Solenoid valve related failure
4) VRY: Relay related failure
5) VSP: Pressure sensor related failure
6) VSE: Sensor related failure except for pressure
sensor
7) VS5: 5V sensor related failure
8) VAL: Other failures.
Example)
VPV001-05: EPPR valve (A) current is lower than
normal current.
Description: Shows the description of the details of
machine failure.
Refer to the failure information code for unique codes
and FMI numbers.
This example shows one of two faults.
B. Past failure information
Failure Log Information
Memorized record of past failure is displayed (Failure NO Code Count Occurrence Time
code, fault contents). 5 VPV007-05 9 21 Hr 20 Min
6 VCO002-11 25 21 Hr 27 Min
When several faults are produced, failure information 7 VSP011-04 2 21 Hr 56 Min
can be checked on this information screen. 8 VSP008-04 1 21 Hr 56 Min
9 VSV001-05 4 21 Hr 56 Min
NOTE: "Count: xxx": "xxx" means that totally 10 VPV001-05 15 21 Hr 56 Min
Description
counted number of the same fault.
BREAKER OPERATING S/V, Current below normal
"Occurrence Time": It indicates the period
for which machine has operated until a EX1301619
fault takes place. (For more than two Figure 100
occurrences of the same fault, until first
occurrence time.)

9-1-57
Failure Code at Machine
GP Display GP Display Measurin Correct Value Severity

SPN Name FMI Remark
Code Description g Point Active Passive Level
Pump P/V (A), CN1-10 Pump proportional

VPV001 Pump P/V (A) 05 3
Current Below Normal CN1-21 R = 13.5 ±2 Ω pressure reducing valve
Pump P/V (A), CN1-10 (25°C (77°F)) Pump proportional
VPV001 Pump P/V (A) 06 3
Current Above Normal CN1-21 pressure reducing valve
Flow Control P/V (C), CN1-19 Flow control proportional
VPV007 Flow Control P/V (C) 05 3
Current Below Normal CN1-20 R = 13.5 ±2 Ω pressure reducing valve
Flow Control P/V (C), CN1-19 (25°C (77°F)) Flow control proportional
VPV007 Flow Control P/V (C) 06 3
Current Above Normal CN1-20 pressure reducing valve
Breaker/boost/ shear
selector switch has to be
Relief Press. Up S/V, CN1-1 selected as a boost
VSV002 Relief Press. UP S/V 05 3
Current Below Normal CN1-11 function and the boost
switch on the right-hand
joystick is "ON" status
V = V_volt
Breaker/boost/ shear
selector switch has to be
Relief Press. Up S/V, CN1-1 selected as a boost
VSV002 Relief Press. UP S/V 06 3
Current Above Normal CN1-11 function and the boost
switch on the right-hand
joystick is "ON" status.
Breaker Select S/V,
VSV013 Breaker Select S/V 05 3
Current Below Normal CN2-8,
V = V_volt
Breaker Select S/V, CN1-8
VSV013 Breaker Select S/V 06 3
Current Above Normal
Breaker Operating S/V,
VSV001 Breaker Operating S/V 05 3
Current Below Normal CN2-10,
V = V_volt
Breaker Operating S/V, CN1-8
VSV001 Breaker Operating S/V 06 3
Current Above Normal
Starter Relay, CN1-1 It has to be measured in
VRY007 Starter Relay 05 3
Current Below Normal CN1-15 engine start up state.
V = V_volt
Starter Relay, CN1-1 It has to be measured in
VRY007 Starter Relay 06 3
Current Above Normal CN1-15 engine start up state.
After Heat Relay, CN1-16
VSV014 After Heat Relay 05 3
Current below normal CN1-04
V = V_volt
After Heat Relay, CN1-16
VSV014 After Heat Relay 06 3
Current above normal CN1-04
Dial,
VS5005 Dial 03 3
Voltage Above Normal CN3-16 V = 1.0 ±0.1 V
Dial, CN3-17 V = 4.0 ±0.1 V
VS5005 Dial 04 3
Voltage Below Normal
E/G Control Motor
E/G Control Motor
VSE009 03 Sensor, Voltage 3
Sensor
Above Normal CN5-11
E/G Control Motor CN5-12
E/G Control Motor
VSE009 04 Sensor, Voltage 3
Sensor
Below Normal
TPS TPS (Wheel),
VSE006 03 3
(E/G Throttle Lever) Voltage Above Normal CN3-13
TPS TPS (Wheel), CN3-14
VSE006 04 3
(E/G Throttle Lever) Voltage Below Normal
Fuel Level Sensor,
VSE002 Fuel Level Sensor 03 3
Voltage Above Normal CN3-7 Empty: 5 ±0.2 kΩ
Fuel Level Sensor, CN3-8 Full: 500 ±10 Ω
VSE002 Fuel Level Sensor 04 3
Oil Temp. Sensor,
VSE001 Oil Temp. Sensor 00 Signal Above Normal 3
Range R = 2.45 ±0.25 kΩ
CN3-9 (25°C (77°F))
Oil Temp. Sensor,
VSE001 Oil Temp. Sensor 03 CN3-10 R = 320 ±32 Ω 3
Voltage Above Normal
(80°C (176°F))
Oil Temp. Sensor,
VSE001 Oil Temp. Sensor 04 3

9-1-58
GP Display GP Display Measurin Correct Value Severity
SPN Name FMI Remark
Code Description g Point Active Passive Level
Water Temp. Sensor,

VSE010 Water Temp. Sensor 00 Signal Above Normal 3
Range
CN5-13
Water Temp. Sensor,
VSE010 Water Temp. Sensor 03 CN5-14 3
Voltage Above Normal
Water Temp. Sensor,
VSE010 Water Temp. Sensor 04 3
Engine Speed Sensor, CN5-15
VSE011 Engine Speed Sensor 02 3
Incorrect Signal CN5-16
Front Pump Press.
Front Pump Press.
VSP001 02 Sensor, Incorrect 2
Sensor
Signal
Front Pump Press.
Front Pump Press. CN3-1
VSP001 03 Sensor, Voltage V = IV 2
Sensor CN3-2
Above Normal
Front Pump Press.
Front Pump Press.
VSP001 04 Sensor, Voltage 2
Sensor
Below Normal It has to be measured in
Rear Pump Press. engine stop state.
Rear Pump Press.
VSP002 02 Sensor, Incorrect 2
Sensor
Signal
Rear Pump Press.
Rear Pump Press. CN3-3
VSP002 03 Sensor, Voltage V = IV 2
Sensor CN3-4
Above Normal
Rear Pump Press.
Rear Pump Press.
Sensor
Below Normal
Park Brake Press.
Park Brake Press.
Sensor
Above Normal CN3-11
Park Brake Press. CN3-12
Park Brake Press.
Sensor
Below Normal
Alternator Potential,
VAL001 Alternator Potential 03 4
Voltage Above Normal CN2-14
V = 27 ±0.1V
Alternator Potential, CN1-8
VAL001 Alternator Potential 04 4
It is a compositeresistance
CN4-4 of CAN line. This value has
Gauge Panel Gauge Panel Comm.
VCO001 11 CN4-5 R = 60 ±5 Ω 4 to be measured by
Communication Error
CN4-6 connected condition of
CAN line.
WIF Sensor, Signal
VSE004 WIF Sensor 01 3
Below Normal Range
WIF Sensor, CN3-19
Voltage Above Normal CN3-20
WIF Sensor,
NOTE: 1. Active value: Starter switch has to be turned "ON"

Measuring points between component and wire harness have to be connected.
2. Passive value: Starter switch has to be turned "OFF"
Measuring points between component and wire harness have to be disconnected.
3. Measuring points are engine controller's points and passive value is each component's value.
4. V_batt: Source power of equipment.

9-1-59
FMIs (Failure Mode Identifier)
FMI Description
0 Data Valid but Above Normal Operational Range - Most Severe Level
1 Data Valid but Below Normal Operational Range - Most Severe Level
2 Data Erratic, Intermittent or Incorrect
3 Voltage Above Normal, or Shorted to High Source
4 Voltage Below Normal, or Shorted to Low Source
5 Current Below Normal or Open Circuit
6 Current Above Normal or Grounded Circuit
7 Mechanical System Not Responding or Out of Adjustment
8 Abnormal Frequency or Pulse Width or Period
9 Abnormal Update Rate
10 Abnormal Rate of Change
11 Root Cause Not Known
12 Bad Intelligent Device or Component
13 Out of Calibration
14 Special Instructions
15 Data Valid but Above Normal Operating Range - Least Severe Level
16 Data Valid but Above Normal Operating Range - Moderately Severe Level
17 Data Valid but Below Normal Operating Range - Least Severe Level
18 Data Valid but Below Normal Operating Range - Moderately Severe Level
19 Received Network Data in Error
20 Data Drifted High
21 Data Drifted Low
31 Condition Exists

9-1-60
Information of Machine Operation
Accumulated operation hour of each mode and status is
displayed.
Operating Hour Information
PM
1. Entering Submenus: When a cursor is located in Service Menu
"Operating Hrs" of special menu screen (Figure 101)
Monitoring
"Operating Hrs" screen will be displayed (Figure 102).
Graph
Failure Information
s
SPC
USB
WE1400753
Figure 101
2. Operating Hours Screen

4 hr
0 hr
14 hr
0 hr
0 hr
0 hr
0 hr
0 hr
WE1400762
Figure 102
3. Exiting Submenus: If escape button (ESC, on Figure 103)

is pressed, this information screen will be returned to
previous screen.
WE1400760
Figure 103

9-1-61
Information contents of operation hour
Item Information Contents Detection Method

Power Mode Operation hours used Power Mode Power Mode status (Instrument panel)
are displayed. and Alternator signal (CN2-14) is "HI".
Standard Mode Operation hours used standard Standard Mode status (Instrument panel)
mode are displayed. and Alternator signal (CN2-14) is "HI".
Economy Mode Operation hours used economy Economy Mode status (Instrument
mode are displayed. panel) and Alternator signal (CN2-14) is
"HI".
Auto Idle Operation hours used auto idle Auto Idle Mode status (Instrument panel)
status are displayed. and Alternator signal (CN2-14) is "HI".
Operation hours used work mode is Work mode status (Instrument panel)
Work Mode
displayed and alternator signal (CN2-14) is "HI".
Operation hours used travel mode Travel mode status (Instrument panel)
Travel Mode
is displayed and alternator signal (CN2-14) is "HI".
Hydraulic Oil Temperature Temperature of hydraulic oil is The resistance delivered from
Distribution (°C (°F)) classified 6 steps, and operation temperature sensor of hydraulic oil is
hours of each step are displayed. classified 6 steps, and operation hours of
each step are displayed.
Under 30°C (87°F)
(Alternator output "HI" status)
31 ~ 50°C (88 ~ 123°F)
51 ~ 75°C (124 ~ 168°F)
76 ~ 85°C (169 ~ 186°F)
86 ~ 95°C (187 ~ 203°F)
Over 96°C (204°F)
Coolant Temperature Temperature of coolant is classified The resistance delivered from coolant
Distribution (°C (°F)) 6 steps, and operation hours of sensor is classified 6 steps, and
each step are displayed. operation hours of each step are
displayed. (Alternator output "HI" status)
Under 40°C (105°F)
41 ~ 60°C (106 ~ 141°F)
61 ~ 85°C (142 ~ 186°F)
86 ~ 95°C (187 ~ 204°F)
96 ~ 104°C (205 ~ 221°F)
Over 105°C (222°F)

9-1-62
Example of Machine Operation Info Screen
Operating Hour Information Operating Hour Information

Power Mode 0 hr
Standard Mode 0 hr
Economy Mode 0 hr
Auto Idle Mode 0 hr
Travel Mode 0 hr
Work Mode 20 hr

17 hr
1 hr
1 hr
1 hr
0 hr
0 hr
WE1400764
Figure 104

9-1-63
1. Vehicle Configuration
PM
A. Entering Submenus: When a cursor is located in Service Menu
"Vehicle Configuration" of special menu screen
Monitoring
(Figure 105) press selector button ( ) on panel and
Graph
"Vehicle Configuration" screen will be displayed
Failure Information
(Figure 107).
Operation Hour Information
s
SPC
USB
WE1400754
Figure 105
Entering service password is required when

Service Password
accessing the menu.
Q Q
3 4 5 6 7 8 9 : ; <
Enter Service Password
EX1301634
Figure 106
B. Vehicle Configuration Screen (Figure 107).

Option Setting
Program Update
Vehicle Serial Number
Vehicle Information Delete
Version Information
s
SPC
USB
WE1400755
Figure 107
2. Exiting Submenus: If escape button (ESC, on Figure 108)

is pressed, this information screen will be returned to
previous screen.
WE1400760
Figure 108

9-1-64
Option Setting
1. Entering Submenus: When a cursor is located in "Option Vehicle Configuration
Setting" of special menu screen (Figure 151) press
Option Setting
selector button ( ) on panel and "Option Setting screen"
Program Update
will be displayed (Figure 152).
Version Information
s
SPC
USB
WE1400755
Figure 109
2. Option Setting
• Attachment Option Vehicle Configuration
When a cursor is located in check box of breaker or Option Setting
two-way, press selector button ( ) on panel and Program Update
then, the check box light turns "ON". Vehicle Serial Number
Version Information
s
SPC
USB
WE1400755
Figure 110
• Two-way Option Pedal

Option Setting
Place the cursor on the check box for the two-way
option pedal and select a function by pressing the jog
switch. Attachment Option Breaker Two Way
NOTE: Option setting can only be made for those Two Pump Option Enable
vehicles with the option in question.

Selecting a vehicle without the option can Two Way Option Pedal Enable
cause a problem in terms of performance

and safety.
EX1301635
Figure 111

9-1-65
3. Program Update
Entering Submenus: When a cursor is located in "Program Vehicle Configuration
Update" of special menu screen (Figure 112) press
Option Setting
selector button ( ) on panel and "Program Update
Program Update
Screen" will be displayed (Figure 113).
Version Information
s
SPC
USB
WE1400756
Figure 112
Program Update
Be careful not to remove USB or shut down GP. It may

Seriously damage the equipment.
Current Version V 0100 [2013.10.23]
Update Version No Available Update Files!
Insert USB for update!
EX1301636
Figure 113
4. Vehicle Serial Number

Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration
Serial Number" of special menu screen (Figure 114) press
Option Setting
selector button ( ) on panel and "Vehicle Serial Number
Program Update
Vehicle serial number can be input by pressing up/down Vehicle Information Delete
arrow ( , ) and pressing selector button ( ). Version Information
s
SPC
USB
WE1400757
Figure 114
3 4 5 6 7 8 9 : ; <
Enter Serial Number
EX1301638
Figure 115

9-1-66
5. Vehicle Information Delete
Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration
Information Delete" of special menu screen (Figure 116)
Option Setting
press selector button ( ) on panel and "Vehicle
Program Update
Information Delete Screen" will be displayed (Figure 117).
NOTE: When press selector button ( ) on panel in Vehicle Information Delete
the selected menu the menu will be initialized. Version Information
- Delete Failure Log s

SPC
USB
- Reset Operation Hour WE1400758
- GP Setting Reset Figure 116

Delete Failure Log
Reset Operation Hour
GP Setting Reset
EX1301094
Figure 117
6. Version Information
Entering Submenus: When a cursor is located in "Version Vehicle Configuration
Information" of special menu screen (Figure 118) press
Option Setting
selector button ( ) on panel and "Version Information
Program Update
Vehicle Information
s
SPC
USB
WE1400759
Figure 118
Version Information
EPOS S/W Version V 0100 [2014.10.11]
GP S/W Version V 0110 [2014.10.23]
GP OS Version V 0081 [2014.03.25]
WE1400763
Figure 119

9-1-67
ELECTRONIC HYDRAULIC CONTROL SYSTEM (EPOS)
Control System Schematic
6 Main Relief v/v 6
7 11
12
3 8
P
4 5
N
9
15 10
P M
(Pump control signal)
(Potentiometer signal)
(Engine speed sensor signal)

(Drive signal)
(Throttle signal)
(Engine throttle control signal)

13 2
(Throttle signal)
18
14
(Throttle command)
(Switch signal) 1
(Coolant water temp. signal)
(Mode select signal) AM
(Auto idle signal) H H
(Machine information) C
E F
C
rpm
s
SPC
USB
16
UP
19 (Sensor) PO
WER
17
21 PO
WER
20 23
22
WE1400765
Figure 120

9-1-68
Reference Reference
Number Number
1 Instrument Panel 13 Engine Throttle Controller
2 EPOS Controller 14 Engine Control Dial
3 Engine 15 Engine Control Motor
4 Main Pump Breaker/Boost/Shear Select
16
5 Gear Pump (Pilot) Switch
6 Control Valve 17 Work/Travel Select Switch
7 Pressure Switch 18 Boost Switch (Right Work Lever)
8 Pump Pressure Sensor 19 Sensor
9 Engine Speed Sensor 20 Aux Mode Switch
Electromagnetic Proportional 21 Aux Mode Resistance
10
Pressure Reducing Valve 22 Acceleration Pedal
11 Solenoid Valve (Boost) 23 Power Mode Switch
12 Travel Motor

9-1-69
POWER MODE CONTROL
The power mode switch permits the selection of the appropriate engine power depending on the working
condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine starter
switch is turned "ON," the power mode is automatically defaulted to standard mode. The desired mode can be
selected by pressing the power mode switch. When the power mode is selected, the indicator light will turn "ON"
to display the selected mode.
The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the
operator. The pump output in each mode is determined by the mode selection and is listed in the following table.
Mode Standard Mode Power Mode

Output (%) Approximately 85% 100%
6 6
P
4 5
9
17
10
PO
WE
R 1
2
15
16
20
WE1400766
Figure 121
Reference Reference
Number Number
1 Power Mode Switch Electromagnetic Proportional
10
2 EPOS Controller Pressure Reducing Valve
3 Engine 15 Engine Throttle Controller
4 Main Pump 16 Engine Control Dial
5 Gear Pump (Pilot) 17 Engine Control Motor
6 Control Valve 20 Work/Travel Selector Switch
9 Engine Speed Sensor

9-1-70
Operation
1. Power Mode
This mode should be selected for high speed work. In this
mode the engine output is most efficiently utilized due to the
discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The EPOS controller compares the target engine speed with
the actual engine speed and controls the signal to the
E.P.P.R. (Electromagnetic Proportional Pressure Reducing)
valve which in turn varies the pump output quantity.
P
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this
decrease and immediately reduces the pump discharge WE1400767
volume to maintain the engine speed at the rated level. Figure 122
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the EPOS controller receives engine
speed signals from the engine control dial and the engine
speed sensor and converts it to an operating signal current
and is then transferred to the pump's E.P.P.R valve. At this
time the E.P.P.R. valve converts the electric signal to the
corresponding control pressure and sends it to the two
pumps, adjusting the pump discharge volume to the
desired level.
A C
B D
FG000580
Figure 123
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)

9-1-71
2. Standard Mode
Standard Mode is used for general work. When this mode
is selected it will reduce noise and fuel consumption in
comparison with Power Mode. The epos controller
compares the target engine speed with the actual engine
speed and controls the signal to the E.P.P.R. valve which
in turn varies the pump output quantity and it is the same
method with power volume.
A C
B D
FG000581
Figure 124
Reference Reference
Number Number
3. Economy Mode
Economy mode is used for light loading work. When this
mode is selected, it will reduce noise and fuel consumption
in comparison with standard mode.
Engine revolution is changed by engine throttle controller.
The EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. valve which in turn varies the pump output
quantity and it is the same method with power volume.
E
WE1400768
Figure 125

9-1-72
A C
B D FG013633
Figure 126
Reference Reference
Number Number
4. Operation in case of failure in the control system (Aux

mode operation)
Though it is impossible to control current of the E.P.P.R
(Electromagnetic Proportional Pressure Reducing) Valve
controlling the discharge volume of pump due to fault in
control system, the machine can be operated in the aux
mode.
Upon turning "ON" the aux mode switch, the E.P.P.R Valve
controlling the discharge volume of pump comes into
contact with the aux mode resistor to let current of a certain
value flow. At this time, the discharge volume of pump
follow the control by the pump regulator, nearly at quantity
roughly similar to that in the standard mode.

9-1-73
Power Mode Control - Circuit Diagram
15A
26
26 20A
2 26 10A 26 10A
25
CN1-1
CN1-2
19
CN2-3 1
CN5-15 2
CN5-1 3
30 CN5-16
29 CN1-8
24
16 CN3-18 CN1-9
I
15 CN1-3 II
10 CN1-4
23
A/I
14 CN1-5 W/M
17 CN1-6 O/H 22
12 CN1-10 1 10
3 5
P/V-(A)
4 P4 2
(+)
CN1-21 3
M 6
(-) 5 P5 4 31
(+) 8 P3 RETRACT 2
CN5-2
7 P2 3
(-)
6 P1 16
SIG 1
CW LOW
CN5-11 GND CN3-16 2
CN5-12 CN3-17 3
HIGH
1
+(5V)
2
SIG
3
GND
9
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
WE1400769
Figure 127
Reference Reference
Number Number
2 EPOS Controller 23 Aux Mode Resistor
3 Engine Control Motor 24 Battery
E.P.P.R. Valve (Electromagnetic 25 Battery Relay
10
Proportional Pressure Reducing) 26 Fuse
16 Engine Control Dial 29 Engine Throttle Controller
19 Work/Travel Selector Switch 30 Engine Speed Sensor
22 Aux Mode Switch 31 Power Mode Switch

9-1-74
ENGINE CONTROL SYSTEM
(Feedback Signal)
16
P
A B 2 3
15 M
(Command Signal) (Drive Signal)
10A
Batt. Relay
9
10 Auto Idle Command CN1-4
4 4 (+)
EPOS Controller
17 Over Heat CN1-6
M
5 5 (-) Battery
Retract 3 8 (+) 5V 5V (+)
1 1 CW LOW
2 7 2 2
SIG SIG
1 6 3 3
(-) (-)
12 HIGH
2 16
15
WE1400770
Figure 128
Reference Reference
Number Number
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
When the engine control dial is moved, the output voltage

changes according to the dial position, and this signal enters the
engine throttle controller. The engine throttle controller drives
the motor according to the dial command position by comparing
the value of dial voltage and the value of potentiometer voltage
which is used to observe the motor position (Feedback signal)
contained within the engine control motor.
The throttle controller stops the motor by cutting off the motor
drive current when dial command signal and feedback signal are
the same.
A cable is attached to the engine control motor and the end of
this cable is connected with the lever which adjusts fuel injection
of engine. Thus, this lever is always driven with motor, so the
speed of the engine is controlled.

9-1-75
Engine Control Dial
10 x 12 Step = 120 ±1
1th Step 7th Step 13th Step
CCW (10 ) (10 ) CW

Mechanical Mechanical
Stop Stop
2 - Ø4.5
54 ±2
78.5
Knob
(V)
5
4.0V
Output Voltage
3 2.5V
2
1.0V
1
0 Step
1st 2nd 7th 12th 13th
CCW CW
Stop Stop
WE1400771
Figure 129
Output Specification
Knob Location Output

2nd Step 80 ±5 %
7th Step 50 ±10 %
12th Step 20 ±5 %
When the control knob is moved the output voltage (through "2
and 3" terminals) will vary from the 5 V supplied from the EPOS
controller as shown in the graph.

9-1-76
Engine Control Motor
Circuit Diagram
(Green) P4
P1 (Gr) P2 (P) P3 (L) M

(Yellow) P5
(Retract)
(Gray) P1
Accel
P4 (G) P5 (Y) (Pink) P2 + Vs

- (5.0V)
(Blue) P3 Vp
View A Decel
(Extend)
WE1400772
Figure 130
The engine control motor uses the DC motor and has a

potentiometer (a variable resistor) that is used to observe the
position within it. When the engine control motor has unusual
loads (in case of aging of control cable or folded cable), the
engine throttle controller shuts off current to the engine control
motor for protecting the system in the event the engine control
motor does not drive. In this situation, it can drive normally if the
start switch is moved from "OFF" position to "ON" position after
removing the cause of unusual loads.
NOTE: Change or Adjust the engine control motor in
accordance with adjustment way of engine control
device. Wrong adjustment causes unexpected
performance of the equipment.

9-1-77
Engine Control Circuit Diagram
1
15A
CN7-6
CN7-5
26
CN7-3 2 26 20A 26 10A

CN7-4
CN1-1 25
CN6-12 CN4-4 CN1-2
CN6-13 CN4-5 CAN
CN6-14 CN4-6
15 CN1-8 24
16 CN3-18 I CN1-9
15 CN1-3 II
10 CN1-4 A/I
14 CN1-5 W/M
17 CN1-6 O/H
12
17 31
4 P4 Py
(+)
CN2-15
M
5 P5 Px
(-) CN2-16
(+) 8 P3 Retrack
7 P2 32 16
1
(-) 6 P1 CW LOW
SIG CN3-16 2
CN5-11 GND CN3-17 3
CN5-12 HIGH
1
+(5V)
2
SIG
3
GND
9
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
Instrument Panel WE1400773
Figure 131
Reference Reference
Number Number
1 Instrument Panel 24 Battery
2 EPOS Controller 25 Battery Relay
15 Engine Throttle Controller 26 Fuse
16 Engine Control Dial 31 Pressure Switch (Py)
17 Engine Control Motor 32 Pressure Switch (Px)

9-1-78
AUTOMATIC DECELERATION
CONTROL (AUTO IDLE CONTROL)
(Feedback Signal)
16 15
3
(Command Signal) (Drive Signal)
31 1
32 Auto Deceleration Switch Signal
WE1400774
Figure 132
Reference Reference
Number Number
Instrument Panel 15 Engine Throttle Controller
1
(Auto Idle Selector Button) 16 Engine Control Dial
2 EPOS Controller 31 Pressure Switch
3 Engine 32 Pressure Switch
4 Engine Control Motor
If the machine is idling without the controls being operated or is

waiting for a dump truck the engine speed is automatically
lowered. Once the controls are operated and work is being
started the machine will be restored to the previous settings. As
a result, noise and fuel consumption will be reduced. This
function can be selected or cancelled through the auto idle
selector button on the instrument panel.
The initial setting at start-up is with this switch in the select
position. Approximately 4 seconds after this function is selected,
if all work levers are in the neutral position, the EPOS controller
compares the automatic reduction signal with the signal set by
engine control dial. The lower of the two signals is selected, the
EPOS controller sends a signal to the engine controller to
control the engine speed.
The neutral status of the machine is detected by the two
pressure switches in the control valve. When the work levers are
in the neutral position, the switch is in the "OFF" position.

9-1-79
ENGINE OVERHEAT
PROTECTION SYSTEM
Engine
3 3
AM
(Pump Control Signal)
33
H H
(Potentiometer Signal)
10
E F
C C
rpm
s
SPC
USB
(Drive Signal)
15
2
Engine Overheat Signal

Engine Overheat Signal
WE1400775
Figure 133
Reference Reference
Number Number
1 Instrument Panel Electromagnetic Proportional
10
2 EPOS Controller Pressure Reducing Valve
3 Main Pump 15 Engine Throttle Controller
4 Gear Pump (Pilot) 33 Warning Buzzer
When the engine coolant temperature increases to over 107°C

(225°F), the gauge panel detects it from the sensor mounted in
the coolant line of engine and send a signal to the EPOS
controller and turns on the buzzer simultaneously.
The EPOS controller returns an overheat signal to the engine
throttle controller and changes from power mode to standard
mode. The engine speed is then set to a low speed by the engine
throttle controller. That is, when the engine coolant temperature
increases, a warning buzzer turns on, power mode is changed to
standard mode and engine speed set to a low speed.
When coolant temperature falls below 95°C (203°F), normal
operation will resume.

9-1-80
ADJUST ENGINE SPEED
21
C
F
A
H E B
WE1400776
Figure 134
Reference Reference
Number Number
A Engine Governor Lever F Shaft
B Bracket G Bolt
C Lever H Lever
D Engine Speed Limiter I Lever
E Stopper Bolt 21 Engine Speed Adjusting Cable

9-1-81
How To Adjust The Engine Control Device
The engine speed adjustment is done following order.
1. Perform engine rpm setting according to the following
procedure. (Perform the procedure without load.)
A. High idle speed setting (2,200 rpm)
1) After starting the engine, set the travel/work
selection switch in the "Travel" position and
check that the shuttle shift lever is in the neutral
position.
2) Set the engine speed control dial in the
maximum speed position to set the engine
control motor cable (21) in the minimum length
condition.
3) Adjust the motor cable which is installed to the
bracket (B) so that the engine governor lever
(A) touches the stopper bolt in the maximum
position. Then, rotate the cable adjusting nut in
the maximum direction for one turn further to fix
the cable. (Then, the spring built in the cable is
extended for 1 mm.)
4) Depress the accelerator pedal fully and adjust
the engine control motor cable (21) on the
bracket (B).
B. Low idle speed setting (1,200 rpm)
minimum speed position to set the engine
control motor cable (21) in the maximum length
condition. (Then, the stroke of the cable
becomes approx. 40 mm.)
2) Check that the engine governor lever (A)
touches the stopper bolt in the low idle speed
position. Also, check that deflection of the cable
is normal. (It should be minimum.)
3) If the lever (A) does not touch the stopper bolt,
move the motor cable one hole down on lever
C. If deflection of the cable is excessive, move
the motor cable one hole up on the lever (C).
Then, repeat the previous steps 1) and 2).
Adjust the mounting position of the bracket
(B) too as the end of the cable should not be
higher than the horizontal position.
C. Power mode rpm setting
1) Set the travel/work selection switch in the
"Work" position and check that the shuttle shift
lever is in the "Neutral" position.
maximum speed position and turn the power
switch "ON". Then, check if the engine speed is
1,800 ±50 rpm.

9-1-82
3) If the engine speed is not within the specified
range, adjust the variable resistor (VR4) of the
throttle controller to meet the specification.
4) Check if the plunger of the automatic idle
cylinder is operated properly according to the
position of the travel/work selection switch.
(Work mode - maximum extension, travel mode
- maximum retraction) After inspection, keep the
travel/work selection switch in the work position.
5) Depress and hold the accelerator pedal slowly to
set the engine speed to 1,800 rpm.
Then, adjust the length of the stopper bolt (E)
until the head of the bolt touches the plunger (D).
D. Automatic idle speed setting
1) Set the automatic idle switch in the "ON" position
to activate the automatic idle function. Then,
check that the engine speed is 1,400 rpm.
2) If the engine speed does not meet with the
specification, adjust the variable resistor (VR1)
of the throttle controller to meet the
specification.
E. Standard mode RPM setting
1) Set the power switch in the "OFF" position. Then,
check that the engine speed is 1,700 rpm.
2) If the engine speed does not meet with the
specification, adjust the variable resistor (VR1)
of the throttle controller to meet the
specification.
F. Over-heating operation inspection
1) Short the water temperature sensor wiring
(harness side.)
2) Check if the engine speed is lowered to the low
idle speed range (low idle speed + 100 rpm).
2. Set the potentiometer output voltage according to the
following procedure (TPS voltage setting).
A. Connect a test jack and install the multi-tester to the
potentiometer.
Then, set the tester in the DC voltage mode.
B. Set the engine speed control dial to the minimum
speed position. (Low idle speed: 1,200 rpm)
1) Set the output voltage to 3.55 ±0.1 V. Set it
close to 3.55 V if possible. Adjust the shaft (F)
with a flat-bladed screwdriver and fix it with the
bolt G firmly.
2) If the engine speed is not fixed to 1,200 rpm (set
between 1,250 and 1,300 rpm for example),
adjust the potentiometer according to the
voltage characteristics curve diagram so that

9-1-83
the output voltage meets with the theoretical
voltage value for the engine speed. The voltage
tolerance is ±0.05 V.
C. Set the travel/work selection switch in the "Travel"
position and set the engine at the maximum speed.
(High idle speed: 2,200 rpm)
1) Check if the output value corresponds to the
engine speed according to the voltage
characteristics curve diagram. (Check that the
voltage is within the range between 0.9 and
1.1 V at 2,200 rpm.)
2) If the measured voltage is over the standard,
select the hole one step to the right from the
current hole position on the lever (I).
3) Then, repeat the above steps 1) and 2) of (B).
D. Check and record that the correct output voltage is
obtained at 1,200 rpm, 1,700 rpm, 1,800 rpm and
2,200 rpm according to the voltage characteristics
curve diagram.
Dial Position and Set the Mode

Variable Regulated Engine
Mode Power Mode Auto
Resistor Dial Speed (rpm)
Switch Idle
Max Speed ON (Select the
Set Auto Deceleration Speed VR1 ON 1,050 ±50
Position Power Mode)
Max Speed OFF (Select the
Set Standard Mode Speed VR2 OFF 1,600 ±50
Position Standard Mode)
Max Speed ON (Select the
Set Power Mode Speed VR4 OFF 1,700 ±50
Position Power Mode)

9-1-84
Engine Throttle Controller
1 2
VR1
MOTOR
VR2 SIGNAL STATUS R G Y VOLTAGE
VR3
3
VR4
R G
(Red) Y (Green)
- ENGINE RPM SETTING - (Yellow)
RPM VR1
ENGINE THROTTLE CONTROLLER
RPM VR2
PART NO. 300611-00138A
RPM VR3 SERIAL NO.
VR4
RPM WHEEL
TYPE
ONLY
WE1400824
Figure 135
Reference Reference
Number Number
1 VR1 (Set Auto Deceleration Speed) 3 VR4 (Set Power Mode Speed)
2 VR2 (Set Standard Mode Speed)

9-1-85
LED Sign of Throttle Controller
When the rub cap on the upper part of controller is removed,
three LED are shown in it.
LED works following chart with the condition of equipment (start
switch is "OFF").
Input signal of LED sign Control motor

State
throttle controller Red Green Yellow terminal voltage
Dial voltage < motor Control motor is working on
X ◎ O Approximately + 24(V)
potentiometer voltage (RPM is increasing)
Dial voltage > motor Control motor is working on
◎ X O Approximately - 24(V)
potentiometer voltage (RPM is increasing)
Dial voltage = motor
Stop state O O O 0 (V)
potentiometer voltage
Motor overload
- X X O 0 (V)
(cut off current)
Error on controller voltage
- X X X 0 (V)
source (is low or no input)
WARNING
1. " ◎ "turn on brightly, "O" turn on, "X" turn off.
2. Measured terminal of motor voltage, 4(+), 5(-) terminal
of throttle controller.
3. Yellow LED is used to show the Power on.
4. In motor overload current cut off mode, remove the
cause of overload, and turn the start switch off and
then on normal work should resume.

9-1-86
POWER BOOST MODE
Operation
6 6
Main Relief v/v
11
Engine
4 4
5
2
20
1
(Button Signal) H H
AM
E F
C C
rpm
s
SPC
USB
UP
ER
P OW
18 WE1400825
Figure 136
Reference Reference
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Gear Pump (Pilot) Power Boost Switch
20
(Top of Right Work Lever)
6 Control Valve
The Power Boost function is used to temporarily increase the main

relief pressure to enhance excavation ability. When the breaker/
boost/shear selector switch is set to "BOOST" and the power boost
button on the center of the right-hand work lever (joystick) is
pressed during work, the e-EPOS controller will activate the power
boost solenoid valve and increase the relief valve pressure from
323 ~ 343 bar (330 ~ 350 kg/cm2 (4,700 ~ 5,000 psi).
The excavation ability is increased by approximately 6%.
When the power boost function is in activated, a power boost
symbol appears on the information display department of
instrument panel.
NOTE: Do not use this switch for more than 10 seconds.

9-1-87
Power Boost Control - Circuit Diagram
1
15A
CN7-6
CN7-5
26
CN7-3
2 26 20A 26 10A
CN7-4
CN1-1
25
CN6-12 CN4-4 CN1-2 PST SHEAR PRESS BREAKER
CN6-13 CN4-5 CAN UP
CN6-14 CN4-6 TML 1 0 2
9
24
10
11 3
(C2) 14 18
CN1-11 13
11
6
CN2-2 (POWER MAX) 16
15
CN1-8 12
CN1-9
6 3
(POWER MAX / BREAKER) (Center)
20
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
Figure 137 WE1400826
Reference Reference
Number Number
1 Instrument Panel Power Boost Switch
20
2 EPOS Controller (Top of Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse

9-1-88
CRUISE CONTROL
Operation
Cruise control is used for the purpose of reducing operator’s
fatigue during long travel distances.
40
4 35 36
5
15 32 37
38
I II
39
17
WE1400827
Figure 138
Reference Reference
Number Number
3 Engine 35 Cruise Solenoid Valve
4 Main Pump 36 Forward Solenoid Valve
5 Gear Pump (Pilot) 37 Pilot Relay
6 Control Valve 38 Cruise Switch
15 EPOS Controller 39 Brake Pedal
17 Engine Control Dial 40 Travel Motor
32 Pressure Switch (Py)

9-1-89
1. Run Method
F = Forward Travel
Forward/reverse lever is placed at forward position (F),
although accelerator pedal is not stepped on, the unit can
travel. At this time, faster or slower travel speed can be F
obtained by adjusting the engine speed control dial. When F

Cruise
N = Neutral
engine speed control dial is adjusted to desired speed, the
N
I II
R
Switch
unit will travel at a constant speed. If there is a change in R
the load, a change of travel speed can occur. When the

forward/reverse lever is placed in reverse position, this Forward/reverse Lever R = Reverse Travel
function will be not operated.
BCS0811L
Figure 139
2. Cancel
When the brake is applied the cruise control will be
canceled.
Bring the forward/reverse lever back to neutral (N), will
also cancel the cruise control.
If the engine is running at an excessive rpm when the
cruise control is canceled, reduce the engine rpm setting.
NOTE: If the auto idle is "ON" when the cruise control is
canceled, the engine will return to idle in HAOA690L
approximately four seconds. When the cruise Figure 140
control is turned back "ON" the engine will
return to the rpm setting control by the engine
speed control dial.
3. Cruise Operation
Division Run Cancel

Condition 1. Forward/reverse lever is placed in 1. When the brake is applied.
FORWARD.
2. Accelerator pedal is stepped ON. 2. Forward/reverse lever is placed in
NEUTRAL or REVERSE.
3. Cruise switch turns "ON".
Forward Relay Operation Cancel
Forward Solenoid Valve Operation Cancel
Cruise Relay (1) Operation Cancel
Cruise Relay (2) Cancel Operation
Cruise Solenoid Valve Operation Cancel
Speed Control Engine Speed Control Dial Accelerator Pedal

9-1-90
Cruise Control Circuit
3 10A 10A 10A 10A 2
87a
4
30
87
1
85 86
CN15-7 (+)
5
87a I
30 II
11 87
III
85 86 CN15-2 F
R
CN15-8
KD
CN15-1 (+)
1 2 3 Crui
F N R step step step se
6
12 87a 13 8
30
87
87a 85 86
30
87
85 86
10 9
7 WE1400828
Figure 141
Reference Reference
Number Number
1 Battery 7 Cruise Relay (1)
2 Battery Relay 8 Forward/Reverse Lever Switch
3 Fuse 9 Brake Light Switch
4 Pilot Relay 10 Pressure Switch (Py)
5 Forward Run Relay 11 Forward Run Solenoid Valve
6 Cruise Relay (2) 12 Cruise Solenoid Valve
If the cruise switch is turned on during the forward run, the "15/1
(+)" and "49" terminals of the travel speed control switch are
connected. At this time the current flows from the battery (1) →
battery relay (2) → fuse box (3) → "15/1" (+) and "49" terminals of
the travel speed control switch (8) → "86" and "85" terminals of
cruise relay 1 (7) → pressure switch (10) → ground. The other
side, the current flows from the fuse box (3) → "30" and "87a"
terminals of pilot relay (4) and then current flow from fuse box (3)
→ "30" and "87" terminals of forward run relay (5) → "30" and "87"
of cruise relay 1 (7) → cruise solenoid valve (12) and the machine
runs as a cruise state. Also the cruise relay 1 (7) is activated by
the current flows from the "87a" and "30" terminals of cruise relay
2 (6) → diode (13) and it makes self - activated circuit.
If the forward/reverse lever (8) is place in neutral or reverse
position during the cruise, the forward run relay will be
deactivated and cruise function will be cancelled.
Also if the brake pedal is pressed, the brake light switch (9) will
be turned "ON". At this time, the cruise relay 2 (6) will be
activated and the cruise relay 1 (7) will be deactivated. So cruise
function will be cancelled.

9-1-91
SELF-DIAGNOSTIC FUNCTION
EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 142
Reference Reference
Number Number
1 Upper Digit Power Monitor (Stays "ON"
2 Lower Digit 4 While Power Is In Normal
Range)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
e-EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.

9-1-92
3. Normal Operation Display Readout
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L HAOH370L
Normal Operation
Power Mode Standard Mode
Standard Mode
HAOH350L HAOH370L
Normal Operation
Economy Mode
Economy Mode
FG013637 HAOH370L
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Error Code Indication Code Fault Location

Communication error in instrument
V201 01
panel.
Communication error in engine
V202 02
controller.

9-1-93
WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 Continue CN16-10
M +
8 INT1 CN15-9 CN16-9
4 4
10 INT2 CN15-10 CN16-12
5 6 ON
OFF
1 7 J1
J2
11 CN16-11
6 13 12 - + 8
P
1 CN15 CN16
9
9 2
AMP MIC 13P
CN12
15A 15A 4
AMP MIC 13P

1 2 3 4 5 6 4 3 2 1 5 4 3 2 1 6 5 4 3 2 1
10 9 8 7 6 12 11 10 9 8 7
7 8 9 10 11 12 13 9 8 7 6 5
(CN12) (CN13) (CN15) (CN16)
WE1400829
Figure 143
Reference Reference
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay Combination Switch
7
3 Fusible Link (Wiper & Washer)
4 Fuse Box 8 Window Washer
5 Wiper Motor 9 Wiper Cutoff Switch

9-1-94
Wiper Operation
Continuous Operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of
the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0 + 0.5V) and also current flows via the "3" terminal
of the wiper controller (6) → the "2" and "4" terminals of the wiper motor (5) → the "4" terminal of the wiper
controller (6) to run the wiper motor (5) continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper switch panel (7) changes the voltage of the "5"
terminal of the wiper controller (6) from LOW (0 + 0.5V) to HIGH (about 5.5 ±0.5V). As the "5" and "6" terminals of
the wiper motor are connected still that power is supplied to the "6" terminal of the wiper controller (6),
However, the controller (6) runs the wiper motor continuously and then rotates the motor reversely by " letting
current flow via the "4" terminal of the wiper controller (6) → the "2" and "4" terminals of the wiper motor (5) → the
"3" terminal of he wiper controller (6) when the "1" and "6" terminals of he wiper motor (5) are connected and thus
power voltage is supplied to the "7" terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact of a cam switch connected to the "6" terminal of
the wiper motor (5) moves to an insulation area of the cam plate to disconnect the "5" and "6" terminals of the
wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it move to the stop positions of the right pole in the
cabin.
Intermittent Operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7) changes voltage of the "8" terminal in the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0 + 0.5V) and current flows through the "3" terminal in the
wiper controller (6) → the "2" and "4" terminals in the wiper motor (5) → the "4" terminal in the wiper controller (6)
to start the cycle that wiper stops 3 seconds after every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7) changes voltage of the "10" terminal in the wiper
controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0 + 0.5V) and current flows through the "3" terminal in the
wiper controller (6) → the "2" and "4" terminals in the wiper motor (5) → the "4" terminal in the wiper controller (6)
to start the cycle that wiper stops 6 seconds after every operation.
- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel (7) while the wiper is operating stops the action of
the wiper motor.
NOTE: The wiper system does not work when the wiper cutoff switch (9) is "ON".

9-1-95
LIGHTING SYSTEM
Lighting System Circuit Diagram
10A
4 10A
4
10A
30A
B
E
5 7
2 3 10 L
87a
3 2 30
87
11
5 1
2
6 86 85 3
CN17-7
0.5B 7 8
4
5
6 CN17-6
8 7
6
Head Lamp Turn Signal SW 13
TML
1 49a CN16-7
R CN16-3
L CN16-1
56 CN16-4
56b CN16-5
56a CN16-6
30 CN16-8
87a
4 10A 30
87
4 10A 86 85
8 14
4 10A
9
19 15 15 19
*
* 21 21
20 20
12
CN17-2
L2
CN17-1
L1
C A B D F E E F D B A C CN17-5
16 17 18 17 16
WE1400830
Figure 144

9-1-96
Reference Reference
Number Number
1 Battery 12 Console (Steering Column)
2 Battery Relay 13 Diode
3 Fusible Link 14 Reverse Relay
4 Fuse 15 Head Light
5 Light Switch 16 Rear Combination Light
6 Combination Switch 17 Back Up Light
7 Flasher Unit 18 Registration Plate Light
8 Reverse Switch 19 Front Turn Signal Light
9 Stop Light Pressure SW 20 Side Turn Signal Light
10 Head Light Relay 21 Arm Position Light
11 Hazard Switch
NOTE: * indicates optional items.
Type
Lighting system consists of headlamp, work lights, cabin light
(optional), and S/W devices and relays to control them.
Operation
Connected
Activated Relay/
Switch Position Terminal of Lit Light
Operated Switch
Switch
Illumination Light of Switch/
Position Light of Head Light/
1st "2-3" Terminals - Position LIght of Rear
Combination Light
Light Switch (5) Position Light of Arm
"2-3" Terminals - "
2nd Head Light Relay
"5-6" Terminals Low Beam of Head Light (2 ea.)
(10)
"56-56b" Operated Light
Low Beam of Head Light (2 ea.)
Terminals Switch (2nd)
"56-56a" Operated Light
High Beam of Head Light (2 ea.)
Terminals Switch (2nd)
"30-56a"
- High Beam of Head Light (2 ea.)
Combination Terminals
Switch (6) Front Turn Signal Light (LH.)
"49a-L" Terminals - Side Turn Signal Light (LH.)
Rear Combination Light (LH.)
Front Turn Signal Light (RH.)
"49a-R" Terminals - Side Turn Signal Light (RH.)
Rear Combination Light (RH.)
Transmission
Switch (Reverse ON (+) - R Terminals Reverse Relay Back up Light (2 ea.)
Position) (8)
Stop Light Stop Light of Rear Combination
ON ON -
Switch (9) Light (2 ea.)

9-1-97
OVERLOAD WARNING DEVICE
Overload Warning Device Circuit Diagram
10A 20A
4 1
5 CN1-1
1 CN1-2
2 CN5-4
3
7 8
CN1-8
CN1-9
+
CN3-5
6 SIG
CN3-6
-
CN4
CN1 CN2 CN3
WE1400831
Figure 145
Reference Reference
Number Number
1 Battery 4 EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor

9-1-98
AUDIO CONTROLLER
Audio Controller Circuit Diagram
ANTENNA
6 7
3
MODULE
10
15A 2 15 9
Vcc(+5V)
3 16
1 MICOM
8
4 13 (LH) (RH)
10A
Vcc(+5V)
14 + - + -
5
10A 1 2 7
5
DC/DC + 17
3 CONVERTER 1 12V Socket
- 2
3
10
15A 11
4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 2 3 4 5 6 7 8
1
(Audio Control Panel) (Stereo)
WE1400832
Figure 146
Reference Reference
Number Number
1 Battery 6 Audio Control Panel
2 Battery Relay 7 Stereo
3 Fuse Box 8 Speaker
4 Fusible Link 9 Antenna Module
5 Converter 10 Light Switch
Operations Via Audio Control Panel
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 ±0.2V Stereo ON, OFF
1.24 ±0.2V Volume up
"3-4"
0+0.2V Volume down
SCAN 2.49 ±0.2V Frequency selection

9-1-99
RAM LOCK DEVICE
Ram Lock Control Circuit
4
3
2
1 (P)
8
9 5 1 CN17-8 1 (T) 7
2 CN17-10
7 9 3 (W) 3
3
9 8 7 3 CN17-9
12 7 8 CN17-11
87a 4 8
3 30
2 87 9 5
11 1 7 3
0.5B 86 87a
6 8 30 10A
(C2) 7
2 9
10 85 86
DA1-2
6
9 2
9 6
CN15-7 (+)
13 DA1-3
7 3 CN15-2
F
8 4 CN15-3
R
CN2-7
DA1-4
F N R
CN1-8 CN1-1
9
CN1-9 CN1-2 20A
WE1400833
Figure 147
Reference Reference
Number Number
1 Battery 8 Ram Lock Relay
2 Battery Relay 9 Diode
3 Fuse 10 Ram Lock Pressure Switch
4 Parking Brake Switch 11 Ram Lock Solenoid Valve
5 Pilot Relay 12 Ram Lock Switch
6 Combination Switch (F/R) 13 EPOS Controller
7 Work/Travel Switch

9-1-100
Operation
Input Output
Parking Work/ Ram Lock Combination Ram Lock Console Remark
Ram Lock
Brake Travel Pressure Switch (F/R) Solenoid (Ram Lock
Switch (13)
Switch (4) Switch (7) Switch (10) (6) Valve (11) Light) (12)
"2-3"
Terminals - Lock (OFF) ON
(Parking)
"2-1"
Terminals - - Lock (OFF) ON
"2-1" (Lock)
Terminals
(Travel) "2-3"
Release
Terminals - - OFF
(ON)
(Release)
"2-1"
Terminals - Lock (OFF) ON
(Lock) OFF
(below
"2-3" 47 bar) Release
Terminals - OFF
(ON)
"2-3" (Release)
Terminals - OFF Lock (OFF) ON
(Work) "2-1"
Terminals ON ON Lock (OFF) ON
(Lock) (above
"2-3" 47 bar)
Release
Terminals ON OFF
(ON)
(Release)
NOTE: "-" is don’t-care condition.

9-1-101
AIR CONDITIONER SYSTEM
Outline
Figure 148 FG016933
Solid-type heater and air conditioner are installed in the cover behind the driver's seat.
Temperature of the driver's room is adjusted automatically to the temperature set by operator.
Please refer to the Operation Manual for detailed whole automatic control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C

9-1-102
Internal and External Filters
Internal and external air purification filters are installed for the
driver's room.
Filters should be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters should be cleaned more frequently and if
necessary, replaced with new ones.
How to check Indoor air filter

1. Press both levers on the left and right side at the top of the
filter installed at the rear of the driver's seat.
FG016045
Figure 149
How to check outdoor air filter

1. Open the front door at the left side of machine and loosen
four marked bolts to remove the cover (Figure 150).
FG016043
Figure 150
2. Turn marked knobs (Figure 151) at the rear side of the

cabin to open the cover.
3. Remove the filter attached to the cover and clean the
contaminated filter using compressed air.
4. Close the cover, replace the knobs, and secure the cover
to the support with butterfly bolts.
FG016044
Figure 151

9-1-103
Air-Conditioning System Layout
10
11
2
5
6
5
7
4
1
6
8
9 FG016941
Figure 152
Reference Reference
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose

9-1-104
Air Conditioner/Heater Circuit Diagram
15A
0.5RW
FUSIBLE LINK
LAMP SWITCH
20A
A/C CONTROL PANEL AIRCON UNIT BATT.

1.25LR CN11-2 42C 24V
LED 1~12 130C CN9-6
0.85LR CN10-8 42D
54E CN9-11 0.5WR
CN10-18 46B
ILL 42B CN9-5 1.25LR
0.85BW
0.85LR
RECEIVER DRIER
BLOWER A/C
42E 46A
RELAY RELAY
COMPRESSOR
168B CN8-10 0.5LG CN10-16 168A
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
106B CN8-11 CN10-6 106A 47A 47B

0.5LY
FET
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
108A CN9-13 0.5GrG CN10-2 108B FRE (P1)

INTAKE
109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
M
110A CN9-15 0.5OrR CN10-12 110B DEF (P1)

111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
M
MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
ACTUATOR
44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
99 CN9-10 1.25B
112A CN9-1 0.5LgW CN10-19 112B WARM (P1)

113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
114A CN9-3 0.5YR CN10-7 114B Vref MIX MIX
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
167C CN9-2 1.25BL CN10-4 167A GND
116A CN8-2 0.5OrB CN10-15 116B

DUCT
SENSOR
45A CN8-1 0.5LgR CN10-14 45B

WATER
SENSOR
2
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
SENSOR
SUN LOAD SENSOR
0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P

142A CN8-3
142B 0.5YR
114C 0.85BL 167B 2
49A CN8-4 0.85YG 0.85YG 49B 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P
AMP 040-III 20P

KET 4P AMP 070 18P AMP 070 12P
2 1 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN11) (CN10) (CN9) (CN8)

WE1400856
Figure 153

9-1-105
Air Conditioner/Heater Unit
Air Flow Diagram
External Air Inlet
Internal Air Inlet
External Air
VENT
COOL
DOOR
-INTAKE
DOOR
DEF -MIX
Internal Air
WARM
Evaporator Fan
Heater
FOOT Core
FG016942
Figure 154

9-1-106
Door Open by Vent Modes
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Air Sensor
Blower
Motor
Actuator
- Internal/external
Air Exchanger
Internal
Air Filter
FG016943
Figure 155

9-1-107
Actuator - Wind direction control: change of discharged air flow
according to selected wind direction mode - Change of wind
direction: Direction changes in the order of VENT→ BI-LEVEL
→ FOOT → FOOT/DEF → VENT.
Actuator - Temp control: Change of discharged air temperature
by controlling the position of temp control door.
N P2
c
b
e
P2 P1
b c e
FG001361
Figure 156
Actuator - Wind direction control
Wind Direction Mode Output Terminal Voltage

Vent 0.5 ±0.2V
Bi-level 1.3 ±0.2V
c(+): CN10-10
Foot 2.45 ±0.2V
b(-): CN10-4
Foot/def 3.5 ±0.2V
Def 4.5 ±0.2V
Actuator - Temp control
Set Temp Output Terminal Voltage

Max cooling c(+): CN10-9 Below 0.4V
Max heating b(-): CN10-4 Above 4.5V

9-1-108
Actuator - Internal/external air exchange
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 157
Sel mode Output Terminal Output

Moving of exchange door
Internal Air P1(+), P2(-)
by selecting external air
Moving of exchange door
External Air P1(-), P2(+)
by selecting internal air
Air Flow Control Module

Air flow is controlled through the control of voltage between
GATE and SOURCE.
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 158
Air flow Output Terminal Output

1st 10 ±0.5V
2nd 12.5 ±0.5V
3rd 15 ±0.5V
4th CN11-2 CN10-1 17.5 ±0.5V
5th 20.0 ±0.5V
6th 22.0 ±0.5V
7th More than 25V
Applied voltage: Standard voltage is 27.5V.

Basically, air flow is set manually.

9-1-109
Relay - Blower
Power is supplied to the blower motor when the system is turned 87 85(-)
on. 87
Specifications 86 85
Rated voltage 24V 30

Rated current 20A
30 86(+)
FG001057
Figure 159
Relay - A/C
Power is supplied to the magnetic clutch of the compressor.
Specifications
L S1 (+)
Rated voltage 24V
Rated current 10A
B S2
(-)
FG001058
Figure 160
Duct Sensor
It is inserted in the core of the evaporator to prevent freezing of
the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
Temp (°C) Resistance (KΩ)

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2 Figure 161
3 9.95 ±0.2
3.5 9.73 ±0.2
4 9.52 ±0.2
5 9.12 ±0.2
10 7.36 ±0.15
25 4.02 ±0.08
30 3.33 ±0.07

9-1-110
Water Temp Sensor
It senses the temperature of coolant water in the heater core.

-10 55.8 ±1.7
0 32.9 ±0.9
15 15.76 ±0.5
25 10.0 ±0.3
35 6.5 ±0.2
Figure 162
Internal Air Temp Sensor

Built in the internal air filter, it senses the internal temperature.

-15 218.2 ±7.5
0 97.83 ±0.9
15 47.12 ±0.7
25 30.0 ±0.36
35 19.60 ±0.3
Figure 163
Ambient Air Temperature Sensor

Built at the bottom of the cockpit, it senses the temperature of
external air.

-10 163 ±4.9
0 96.9 ±2.9
10 59.4 ±1.8
20 37.4 ±1.1
25 30 ±0.9
30 24.2 ±0.7 FG001064
Figure 164

9-1-111
Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to optimize discharge temperature and air flow
as set by driver.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0

LUX(x10,000)
FG001062
Figure 165
Control Panel
Appearance and Terminal Arrangement
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
AMP 070 18P AMP 070 12P

8 7 6 5 4 3 2 1 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CN9) (CN8) FG001063

Figure 166
Refer to "Air Conditioner and Heater" of operation manual.

9-1-112
Terminal Terms
CN Term No. Terms CN Term No. Terms

Temperature Control Water Temperature
1 1
(Warm) Sensor
2 Sensor Ground 2 Duct Sensor
Temperature Control
3 3 Sun Sensor
Power (5V)
Ambient Air temperature
4 Mix Feedback 4
sensor
Internal Air Temperature
5 Power (Key "ON") 5
CN8 Sensor
6 Back-up 6 -
7 - 7 -
8 A/C Output (Low) 8 -
9 - 9 -
10 Ground 10 D.P.S CHECK
CN9 11 Illumination 11 Air Flow Module (Gate)
Intake/Recirculate
12 12 Blower Motor (Feedback)
(Recirculate)
Intake/Recirculate
13
(Intake)
Wind Direction Control
14
(VENT)
15
(DEF.)
16
Power (5V)
17
(Feedback)
Temperature Control
18
(Cool)
Control Logic
Categories Inputs System Operation

AUTO Set temperature 1. Automatically adjust room temperature as set and then
next items.
Internal air temperature
sensor Temperature, Wind direction, Recirculate/Intake, Air flow,
Compressor
Ambient air temperature
sensor 2. Auto mode is released when manually setting any switch
except, Temperature Control switch in Auto mode.
Water temperature sensor
3. Upon the releasing of Auto mode, all of functions except
Sun sensor
selected switch are controlled automatically.

9-1-113
Sensor Set temperature 1. In case of sensor failure, following defaults are applied:
compensation
Internal air temperature Internal air temperature sensor: 25°C, Ambient air
sensor temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature Temperature control actuator:
sensor
- Set Temperature 17 - 24.5°C: Max cooling, Set
Water temperature sensor Temperature 25 - 32°C: Max heating
Wind direction mode actuator
- VENT: VENT fix, modes other than VENT: Fixed to DEF
* Sun sensor is not compensated.
Max cooling/ Auto Setting 1. Set Temperature 32°C: Max heating
heating
2. Set Temperature 17°C: Max cooling
control
Max Cooling (17 C) Max Heating (32 C)
Temp Control
FULL COOL FULL HOT
Actuator
Air Flow MAX HI AUTO HI
Compressor Forced ON OFF
Intake/Recircle Recircle Intake
Wind Direction Mode VENT FOOT
* Max cooling/heating control is possible only in Auto mode.

Starting Auto mode 1. Prevention of discharge of hot air before discharge
Control of temperature drops enough in hot summer weather
Duct sensor
Cooling
2. Start conditions (AND condition)
(1) A/C on (AUTO or manual)
(2) Temperature sensed by the duct sensor is above 30°C
(3) Air flow: Auto mode
3. One time control in the cycle of engine OFF → engine run
4. Initial cooling control is executed when the Auto switch is
"ON" in the manual status (A/C "OFF" and manual control
of air flow) in 5 seconds after engine run.
5. Initial cooling control should be before max cooling.
6. Release condition (OR condition)
(1) A/C "OFF"
(2) Air flow: Manual control
(3) Release is possible with the "OFF" switch but not
allowed within 12 seconds (after Start "ON") while the
system is off using the "OFF" switch and during the time of
initial cooling control.

9-1-114
1. Start condition (AND condition)
(1) When wind direction mode is one of the following modes
in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
(2) The Water temperature sensor is stable and the water
temperature < 73°C
(3) Air flow: Auto mode
(4) Set temperature > Internal air temperature + 3°C
* Air flow falls gradually up to 12 seconds when operation
released.
Water temperature sensor 2. One time control in the cycle of engine OFF → engine run
Starting Internal air temperature 3. Initial heating control should be before max heating.
control of sensor
4. Air flow is controlled only when the wind direction is in the
heating (1) Auto mode manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
Set Temperature 5. Control through the water temperature sensor for start.
6. Starting control of heating (2) starts in case of fault of the
water temperature sensor during controlling.
7. Operation release (OR condition)
(1) Only air flow is released if it is selected manually.
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) When Max Cooling (17°C) is selected.
(4) Water temperature sensor > 73°C.

9-1-115
Starting Water temperature sensor 1. Entry condition (AND condition)
control of
Ambient air temperature (1) Auto Mode
heating (2)
sensor
(2) Ambient air temperature < 5°C and difference between
Internal air temperature ambient and internal air temperature ≤ 5°C
sensor
(3) Failure of water temperature sensor
Auto mode
2. Only one time of engine OFF → engine run
3. Starting control of heating is before max heating.
4. Operation release (OR condition)
(1) Air flow: Manual selection
(2) When handling the wind direction mode switch, only
wind direction is released but the air flow control is
performed only for the remaining period of the starting
control of heater.
(3) Difference between internal and ambient air
temperature>15°C
(4) When Max Cooling (17°C) is selected.
5. Exceptional case
Starting control of heating is performed only once during
the remaining period if the entry condition is satisfied within
the starting control period that is the accumulation of initial
start times.
(Inclusive of Auto mode "ON" case within the period of
starting control of heater.)
* Air flow should be reduced slowly for up to 12 seconds in
case of exceptional entry case.
Duct sensor 1. Function: Magnetic clutch of compressor is turned "ON/
OFF" depending on temperature of the duct sensor to
prevent the freezing of the evaporator with A/C being "ON."
2. Control pattern.
2.0 0.5 C 3.5 0.5 C

Compressor
control External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern.
*Only for Auto mode.

9-1-116
Self Diagnosis
How to start self diagnosis
FG001367
Figure 167

9-1-117
Error codes
Code Description
E0 Normal
E1 Internal Air Temp Sensor Short
E2 Internal Air Temp Sensor Open
E3 Ambient Air Temp Sensor Short
E4 Ambient Air Temp Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E9 Water Temp Sensor Short
E10 Water Temp Sensor Open
E11 D.P.S OPEN
Position Error of Wind Direction
E12
Actuator.
Position Error of Temp Control
E13
Actuator.
NOTE: Position error means that it fails to move to

designated place in 40 seconds.
Sun sensor displays E8 in case of no sunlight. E1 E1 E2 E2 E3
2 and more fails: Codes concerned blinks twice at a

time.
0.5 0.5
FG001067
Figure 168
Ambient Temp Display

Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temp in the set temp display
department.
- Range of temp display: -40 - +60°C
NOTE: Display of ambient temp may be released in the
same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temp display mode.

9-1-118
Compressor
Categories Specifications Relief Valve
155.3 cc/rev
Output
(9.48 in3)
150 cc (ND-OIL8)
Oil Level
(9.1 in3 (ND-OIL8))
Refrigerant R134a
Rated Voltage 24V
Open: 34.3 ~ 41.3 bar
(35 ~ 42.2 kg/cm2, 500 ~ 600 psi)
Relief Valve FG001365
Close: over 28 bar Figure 169
(28.1 kg/cm2, 400 psi)
Compressor sucks in refrigerant which evaporates completely in

the evaporator and discharges it to the condenser.
Refrigerant undergoes repeated status change in the order of
liquid, gas, and liquid in the freezing cycle, and the compressor
makes evaporated refrigerant a high temperatures and high-
pressured gas to freeze it in the condenser.
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
• Weight of refrigerant: 800 ±20 grams FG001366
Figure 170
MAX. 0.25 kg/cm2

32 2 kg/cm2
2.0 0.2 kg/cm2 6 2 kg/cm2
FG001462
Figure 171

9-1-119
TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 -
2,000 rpm.
LO HI
Figure 172
4. Check high/low-pressure of refrigerant.
High-pressure: 8.0 - 10.0 bar (114 - 142 psi)

1
Low-pressure: Approximately 1.0 bar (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct tightening
Yes
1 Check for traces of refrigerant oil. torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.
High-pressure: Over 23 bar (327 psi)

2
Low-pressure: Approximately 2.5 - 3.0 bar (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.
High-pressure: Approximately 20 - 25 bar (285 - 356 psi)

3
Low-pressure: Approximately 2.5 - 3.5 bar (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long time, replace the receiver dryer.

9-1-120
High-pressure: Over 6 bar (85 psi)
4
Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace receiver
Yes
dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1
minutes.
Contaminated system, replace
5. Recheck high/low-pressure readings. expansion valve.
No
High-pressure: 13.0 - 19.0 bar (185 - 270 psi) (Replace evaporator core assembly.)
Low-pressure: 1.5 - 3.3 bar (21.3 - 46.9 psi)
High-pressure: Over 6 - 18 bar (85 - 256 psi)

5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful readings
must be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long time, replace the receiver dryer.
High-pressure: Over 22.0 - 23 bar (313 - 327 psi)

6
Low-pressure: 2.5 bar (36 psi)
Possible Cause: Refrigerant pressure problem because of defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7.0 - 11.0 bar (100 - 156 psi)

7
Low-pressure: 4.0 - 6.0 bar (57 - 85 psi)
Possible Cause: Low refrigerant pressure because of poor compressor compression.
Inspect and replace compressor if necessary.

9-1-121
REFRIGERANT SYSTEM REPAIRS
WARNING
Always wear safety goggles and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and must
be stored below 40°C (104°F). Be careful not to drop the
container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 173
The following procedures must be observed for safe handling of

refrigerant during vacuum and charging process.
1. Use an approved recovery/charging device which can
safely perform vacuum and charge work simultaneously.
2. The new refrigerant has improved cooling characteristics
than the old type and care must be used not to overcharge
the system.

9-1-122
3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. DO NOT attempt to use equipment
use in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering the system.
6. When joining unions which use O-ring seals, lightly coat
O-rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
Repair and Replacement Procedure

1. Work Procedure
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition
A. Run engine at maximum engine speed.
B. Select 'HI' blower fan speed and select A/C switch to
'ON'.
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

9-1-123
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 174

9-1-124
Refrigerant Recovery
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the refrigerant recovery 5

unit to the refrigerant lines as shown. HDA6067L
Figure 175
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 bar (50 psi),
slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
manifold gauge dials indicates 0 bar (0 psi).
Vacuuming Refrigerant System

2 3
Reference 1 4
Description
Number
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure Figure 176
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

9-1-125
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
HDA6069L
A. Turn on the vacuum pump and slowly open both
Figure 177
valves.
B. Allow vacuum pump to run for additional 20 minutes
until low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 178
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. Now, do
not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.

9-1-126
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
2. Charge system until low side gauge dial indicates a
pressure of 1 bar (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage. 1
Reference
Description
Number
1 Refrigerant Leak Detection Device
4. If a leak is detected, check for O-ring damage or correct

tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging
process.
HDA6071L
Figure 179
WARNING
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply Container
2. Charge the system by opening the manifold gauge low

5
side valve. HDA6072L
Figure 180
Initial charge amount: 100 g (3.5 ounces).

9-1-127
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
• Temperature control switch setting: Maximum
Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 ~ 1,500 rpm
WARNING
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in the
upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge

system to standard capacity.
Gauge Dial Standard Reading

13 ~ 20 bar
High Side Gauge
(185 ~ 285 psi)
1.5 ~ 3.5 bar
Low Side Gauge
(22 ~ 50 psi)
NOTE: These standards are for outside temperatures

between 30° ~ 35°C (86° ~ 95°F). The gauge
readings may vary for extreme temperature
conditions.
IMPORTANT
• When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40°C (104°F). Do not allow water to
come in contact with the charging adapter valve
handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
machine.

9-1-128
Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
2
starting from the high-pressure side.
1
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the
low-pressure will start to increase until they are
equalized. Starting the inspection from the high side 3
will result in an accurate test.
Reference 4
Description HDA6073L
Number Figure 181
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet → condenser inlet → receiver dryer
inlet → air conditioner unit inlet.
2. Low-pressure side
Compressor inlet → air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the
air-conditioning unit, perform the inspection in a
well ventilated area.

9-1-129
9-1-130
1Options
One Way
Edition 1
DX210WA One Way

10-1-1
MEMO
One Way DX210WA

10-1-2
Table of Contents
One Way
General ...........................................................9-1-5
Caution for Installation............................................... 9-1-7
Installation Procedure .....................................9-1-8
Main Piping - One Way ............................................. 9-1-8
Pilot Piping - One Way ............................................ 9-1-10
Pilot Piping - EPPR Valve (One or Two-way).......... 9-1-12
Boom Piping - One or Two-way .............................. 9-1-14
Arm Piping - One or Two-way ................................. 9-1-16
After Installation Precautions................................... 9-1-17
Air Bleeding ............................................................. 9-1-17
Completing Work ..........................................9-1-18
DX210WA One Way

10-1-3
One Way DX210WA
10-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
The following description is of the installation of a pipe to
operate an attachment such as a breaker.
This description explains how to install a new pipe in equipment
in which a breaker operating pipe is not installed.
Figure 1 EX1301482
Theory of Operation
When a breaker (hammer) switch located at a right side joystick
lever is operated, an OPT spool will move to the maximum
extent possible through a hammer-operated solenoid valve.
Oil ejected from the front (P1) pump is connected to a
high-pressure line from the breaker through the OPT spool, and
the pressure thereof is controlled by a PPR valve connected to
the high-pressure line (the variable pressure being controlled
according to a current value).
FG000036
The low-pressure oil of a breaker return line is returned to the
Figure 2
tank through a return filter and an oil cooler.
The flow rate through the front (P1) pump is controlled by an
instrument panel.
DX210WA One Way

10-1-5
Hydraulic Circuit
6 P2 Pg
A B
R.H XBo
5
L.H Bo Option
A T XAo
Ao
A3 A2 T P
(Front) HO
X1
C1 T P1
(Breaker)
P2
PAR
C6 (Forward)
C5
X3
P3
PBR (Ram
(Ram Lock)
Lock)
C5 (Backward) CH C1
Fl
(Rear) X1
(Inching)
PL
A1 IC C2
C2 (PressUp)
(Press Up) GTS
C4
1 A
P PB
Fr C7 (Cruise) (Safety Cut-off)
T C3
TS PS
7
4 3
P1
EX1400586
Figure 3
Reference Reference
Number Number
1 Main Pump 5 Pressure Proportional Relief V/V
2 Control Valve 6 Stop Valve
3 Solenoid Valve (3 Functions) 7 EPPR Valve
One Way DX210WA

10-1-6
Caution for Installation
• When you install piping, make sure there is no foreign
substance inside piping sub-parts such as hoses, pipes,
valves and fittings.
• Prior to installing piping:
A. Park on firm and level ground.
B. Lower front attachment (bucket) to ground.
C. Stop engine.
D. Move safety lever to "RELEASED" (UNLOCKED)
position.
E. Turn starter switch to "I" (ON) position.
F. Fully stroke work levers (joysticks) in all directions to
G. Move safety lever to "LOCK" position.
H. Turn key to "O" (OFF) position and remove from
starter switch.
I. Attach a maintenance warning tag on controls.
CAUTION
AVOID INJURY
Release any pressure in the hydraulic oil tank before work.
IMPORTANT
Contact your DOOSAN distributor about proper size of
hydraulic pipes for installation.
DX210WA One Way

10-1-7
INSTALLATION PROCEDURE
Install the parts as below pictures and needed parts refer to parts book.
Main Piping - One Way
BOOM ONE&TWO WAY

PIPING
32
31
BOOM ONE&TWO WAY

PIPING
32
53
17 A
54
31 7
16
2
14 17
11
16
17
5 8
17 10 A 15 3
12
9 14
16 1
52
16 6
51
15
17
54 9 Ao
4 13
17
CONTROL VALVE
63
61
62
OIL COOLER PIPING
MAIN FRAME
Figure 4 WE1400549
One Way DX210WA

10-1-8
Reference Reference
Number Number
1 Valve; Relief 14 Washer; Spring
2 Block 15 O-ring
3 Pipe 16 O-ring
4 Hose 17 O-ring
5 Hose 31 Hose
6 Flange; Split 32 O-ring
7 Adapter 51 Hose
8 Elbow 52 Bracket
9 Tee 53 Bracket
10 Bolt 54 Bolt; Set
11 Bolt 61 Elbow
12 Bolt; Socket M10 x 1.5 x 30 62 O-ring
13 Socket-head Bolt 63 O-ring
DX210WA One Way

10-1-9
Pilot Piping - One Way
FR
ON
T
###
P BLOCK
55
52
8
6
52 54
### 55
T BLOCK
53 7
5
54
55
51 4
53
8
XAo
OIL TANK
1
CONTROL VALVE XBo 2
8
4
3 HO
7
SOLENOID VALVE
WE1400761
Figure 5
One Way DX210WA

10-1-10
Reference Reference
Number Number
1 Hose 8 O-ring
2 Hose 51 Adapter
3 Adapter 52 Elbow
4 Adapter 53 Bolt M10 x 1.5 x 55
5 Elbow 54 Washer, Spring
6 Plug 55 O-ring
7 O-ring
DX210WA One Way

10-1-11
Pilot Piping - EPPR Valve (One or Two-way)
FR
ON
T
OIL TANK
14
13 10
Fr 1
Pg
2 3
CONTROL VALVE
8 X1
13 1
7 A
T 5
13
P
1
1-1
12 13
11 6
16
15
MAIN PUMP
WE1400550
Figure 6
One Way DX210WA

10-1-12
Reference Reference
Number Number
1 Valve, EPPR 9 Tee
1-1 Valve; E.P.P.R 10 Tee
2 Hose 11 Bolt
3 Hose 12 Washer, Spring
4 Hose 13 O-ring
5 Hose 14 O-ring
6 Adapter; Filter 15 Bracket, EPPR Valve
7 Elbow 16 Bolt; Set
8 Tee; Shuttle
DX210WA One Way

10-1-13
Boom Piping - One or Two-way
A
3
5
3
4
A
5
4 2
BOOM
A
6
A
7
4
9
6 4
10
9
B
8 10
Figure 7 WE1400552
One Way DX210WA

10-1-14
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 7 Rubber
2 Pipe Assembly, Hydraulic 8 Clamp; Pipe
3 Pipe Assembly, Hydraulic 9 Flange
4 O-ring 10 Socket-head Bolt
5 Bolt 11 O-ring
6 Clamp; Pipe 12 Plug
DX210WA One Way

10-1-15
Arm Piping - One or Two-way
NOTE: This is for STD Arm (2.75 m).
FR
ON
T
5
3
4
2
5 2
3
4
BOOM
3
4 5
3
6 4
6
6
11 12
12 11
6
13
4 13
41 10
41-7 14
41-1
4
14 42
10 41-2 41-6 42-6
41-3 ARM 42-1
41-5
41-4 42-2 42-7
42-3
42-5
42-4
WE1400570
Figure 8
One Way DX210WA

10-1-16
Reference Reference
Number Number
1 Pipe 41-3 Adapter
2 Hose PF1-1750L 41-4 Cap
3 Flange 41-5 O-ring
4 O-ring 41-6 Plug
5 Socket-head Bolt 41-7 O-ring
6 Clamp; Pipe 42 Valve Assembly, Stop (RH)
10 Bolt; Socket 42-1 Valve, Stop (RH)
11 Washer; Spring 42-2 O-ring
12 Bolt 42-3 Adapter
13 Bolt; Socket 42-4 Cap
41 Valve Assembly, Stop; (LH) 42-6 Plug
41-1 Valve, Stop (LH) 42-7 O-ring
41-2 O-ring
After Installation Precautions

• After finishing installation of piping, connect 'P' and 'T' line Bucket Cylinder
directly to each other without connecting the breaker and
do flushing process a few minutes to make hydraulic oil Stop Valve
clean before connecting the hoses to the attachments. Breaker Cap
• Connect hydraulic hoses as shown in Figure 9. Make it

sure that 'Pressure' and 'Tank' lines are not reversed each
other.
When connecting the hoses, make it sure that no foreign
substances get into the hoses.
Dirt and sand can cause serious trouble to the
EX1301485
attachments.
Figure 9
• Arrange the connecting hoses which are not to be twisted
or excessively bent.
Air Bleeding
1. Start the engine and run at low idle.
cylinder 4 ~ 5 times very slowly about 100 mm before the
end of stroke.
(The air breather of oil tank is actuated to bleed the air.)
DX210WA One Way

10-1-17
COMPLETING WORK
Breaker line overload relief valve can be changed from the
monitor (range 142 ~ 255 kg/cm2 (140 ~ 250 bar)).
Set to 255 kg/cm2 (250 bar). Check the pressure at maximum
flow. (If maximum control pressure is out of tolerance, check
EPPR current)
One Way DX210WA

10-1-18
Two-way
Edition 1
DX210WA Two-way
9-2-1
MEMO
Two-way DX210WA
9-2-2
Table of Contents
Two-way
General ...........................................................9-2-6
Structure.................................................................... 9-2-7
Installation Procedure ...................................9-2-10
Main Piping - Two-way ............................................ 9-2-10
Pilot Piping - EPPR Valve (One or Two-way).......... 9-2-12
Pilot Piping - Two-way............................................. 9-2-14
Pilot Piping - Two-way............................................. 9-2-16
Floor Mat - Two-way................................................ 9-2-18
Boom Piping - One or Two-way .............................. 9-2-20
Arm Piping - One or Two-way ................................. 9-2-22
Air Bleeding ............................................................. 9-2-23
Completing Work ..........................................9-2-24
DX210WA Two-way
9-2-3
Two-way DX210WA
9-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX210WA Two-way
9-2-5
GENERAL
General Description
The following description is of the installation of a pipe for use as
an attachment such as a crusher or shear in which hydraulic
pressure operates in both directions.
The description explains how to install a new pipe in equipment
in which a corresponding attachment-operating pipe is not
installed.
EX1301486
Figure 1
Theory of Operation
When a push button located at a right side joystick lever is
pushed, an output signal (1.0 ~ 4.0 V) of the switch supplies a
current value to a two-way EPPR valve through an EPOS
controller to variably control (move) an OPT spool of a main
control valve.
A shear operation pressure is controlled by a selector valve
connected to a line. (the variable pressure is controlled
according to a current value)
The two-way selector valve is used in the shear (two-way). EX1402066
Figure 2
Two-way DX210WA
9-2-6
Structure
Main Control Valve (OPT Spool)

XBo XAo
RH High LH High
(Close) (Open)
A B
Current
EPOS Controller
Voltage
Joystick
(Right-hand)
WE1400571
Figure 3
DX210WA Two-way
9-2-7
Hydraulic Circuit
2
8
5 P2 Pg
L
A B
R.H C XBo
X Bo Option
XAo
XAo
L Ao
L.H A
T
X
5 Option Pedal (Two-way)
9 LH High
10 2
A LH HIGH RH HIGH
XAo XBo
11
T A B 1
T RH High
1 T P 2
4.6 BAR 7
W
P A1 B1
S1
6
P
A2 B2
from Select Switch from Joystick (R) Switch
Operating at Hammer Select
A3 A2
(Front) X1
X3 T P
HO T P1
X1 C1 (Breaker)
(Rear)
A1 P2
PAR
C6 (Forward)
C5
1 P3
A PBR (Ram Lock)
P
C5 (Backward) CH C1
Fr
T
(Inching)
PL
12 (Press Up) IC C2
C2 GTS
C4
PB
C7 (Cruise) (Safety Cut-off)
C3
TS PS
P1 4 3
WE1400587
Figure 4
Two-way DX210WA
9-2-8
Reference Reference
Number Number
1 Main Pump 7 Shuttle Valve
2 Control Valve 8 Select Valve (RH)
3 Solenoid Valve (3 Functions) 9 Select Valve (LH)
4 Solenoid Valve (5 Functions) 10 Pedal Valve
5 Stop Valve 11 Breaker Select Valve
6 Solenoid Valve (Two-way) 12 EPPR Valve

C. Stop engine.
position.
starter switch.
CAUTION
AVOID INJURY
DX210WA Two-way
9-2-9
Main Piping - Two-way
BOOM ONE&TWO WAY

PIPING
52
51
BOOM ONE&TWO WAY
PIPING
52
73
51 A
21
10 20
20
18 74 9
20
13 21
21
21
2 11 6
7
21 4
18 A 19
14 15
12
20
72 1 16
20
8
71 19 17
21 Ao 8
74 Bo 19
12
5
21 3
19
CONTROL VALVE
83
81
82
OIL COOLER PIPING
MAIN FRAME
WE1400574
Figure 5
Two-way DX210WA
9-2-10
Reference Reference
Number Number
1 Valve; Select 16 Socket-head Bolt
2 Valve; Select 17 Bolt; Socket
3 Block; Spacer 18 Washer; Spring
4 Pipe 19 O-ring
5 Hose 20 O-ring
6 Hose 21 O-ring
7 Hose 51 Hose
8 Flange; Split 52 O-ring
9 Adapter 71 Hose
10 Adapter 72 Plate
11 Elbow 73 Plate
12 Tee 74 Bolt; Set
13 Bolt 81 Elbow
14 Bolt 82 O-ring
DX210WA Two-way
9-2-11
Pilot Piping - EPPR Valve (One or Two-way)
FR
ON
T
OIL TANK
14
13 10
Fr 1
Pg
2 3
CONTROL VALVE
8 X1
13 1
7 A
T 5
13
P
1
1-1
12 13
11 6
16
15
MAIN PUMP
WE1400550
Figure 6
Two-way DX210WA
9-2-12
Reference Reference
Number Number
1 Valve, EPPR 9 Tee
1-1 Valve; E.P.P.R 10 Tee
2 Hose 11 Bolt
3 Hose 12 Washer, Spring
4 Hose 13 O-ring
5 Hose 14 O-ring
6 Adapter; Filter 15 Bracket, EPPR Valve
7 Elbow 16 Bolt; Set
8 Tee; Shuttle
DX210WA Two-way
9-2-13
Pilot Piping - Two-way
7
16
3 FR
ON
T
7
16
SELECTOR 16
VALVE
12 SELECTOR
VALVE
1
2
16
7
17
11
OIL TANK
14
15
8
6 13 17
4
XAo
5 4
FRAME
10 CONTROL VALVE XBo

16 17
9
HO
SOLENOID VALVE
Figure 7 WE1400572
Two-way DX210WA
9-2-14
Reference Reference
Number Number
1 Hose 10 Tee; Shuttle
2 Hose PF1/4-1120L 11 Tee
3 Hose 12 Tee
4 Bracket 13 Bolt
5 Bracket 14 Screw
6 Harness; Joint 15 Washer; Spring
7 Elbow 16 O-ring
8 Elbow 17 O-ring
9 Elbow PFO3/8-PF1/4
DX210WA Two-way
9-2-15
Pilot Piping - Two-way
4 3
FR
3B ON
4B
T
3A SELECTOR
4A VALVE
50
PS
5 39 PILOT SUPPLY
VALVE OIL TANK
9 49
BLOCK P
FLOOR PLATE 47 53
34 29 20
30
34 28
33 16 52 32
51 21
10 7 33
15 A
P 27 24
26 51
51
15
33 31 T 4
19
34 3 T
1 6 51 37
32 B 18
51 41 A
T 15 23 38
19 P 35
P
51 51
51 42
15 16 15
(47)
48 40 XAo
(44)
45 21
(46)
52 36
BLOCK T 53 (38)
20
43
2
52 XBo
51 14 CONTROL VALVE
46
(50)
17 8 22
52
32 (35)
13 12 44
25 11 HO
SOLENOID VALVE
WE1400573
Figure 8
Two-way DX210WA
9-2-16
Reference Reference
Number Number
1 Pedal Valve 26 Bolt; Socket M8 x 1.25 x 25
2 Valve; Shuttle 27 Bolt
3 Valve; Solenoid 28 Bolt; Socket M8 x 1.25 x 65
3A Spool; Solenoid 29 Bolt; Socket
3B Coil 24 V 30 Bolt; Socket
4 Valve; Solenoid 31 Bolt; Socket M10 x 1.5 x 30
4A Spool; Solenoid 32 Washer, Spring
4B Coil 24 V 33 Washer; Spring
5 Rubber; Pedal 34 Washer; Spring
6 Bracket 35 Hose
7 Bracket 36 Hose
8 Bracket 37 Hose
9 Plate 38 Hose PF1/4-590L
10 Plate 39 Hose
11 Switch; Pressure 40 Hose PF1/4-420L
12 Harness 41 Hose
13 Reducer 42 Hose PF1/4-2750L
14 Adapter 43 Hose PF1/4-2400L
16 Elbow 45 Hose PF1/4-410L
17 Elbow 46 Hose
18 Tee; Shuttle 47 Hose
19 Tee 48 Hose
20 Tee 49 Hose
21 Tee 50 Hose
22 Nut 51 O-ring
23 Bolt 52 O-ring
24 Bolt M10 x 1.5 x 55 53 O-ring
25 Bolt
DX210WA Two-way
9-2-17
Floor Mat - Two-way
ONT
1
FR
FLOOR PLATE
WE1400575
Figure 9
Reference
Description
Number
1 Mat, Floor
Two-way DX210WA
9-2-18
DX210WA Two-way
9-2-19
Boom Piping - One or Two-way
A
3
5
3
4
A
5
4 2
BOOM
A
6
A
7
4
9
6 4
10
9
B
8 10
Figure 10 WE1400552
Two-way DX210WA
9-2-20
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 7 Rubber
2 Pipe Assembly, Hydraulic 8 Clamp; Pipe
3 Pipe Assembly, Hydraulic 9 Flange
4 O-ring 10 Socket-head Bolt
5 Bolt 11 O-ring
6 Clamp; Pipe 12 Plug
DX210WA Two-way
9-2-21
Arm Piping - One or Two-way
FR
ON
T
5
3
4
2
5 2
3
4
BOOM
3
4 5
3
6 4
6
6
11 12
12 11
6
13
4 13
41 10
41-7 14
41-1
4
14 42
10 41-2 41-6 42-6
41-3 ARM 42-1
41-5
41-4 42-2 42-7
42-3
42-5
42-4
WE1400570
Figure 11
Two-way DX210WA
9-2-22
Reference Reference
Number Number
1 Pipe 41-3 Adapter
2 Hose PF1-1750L 41-4 Cap
3 Flange 41-5 O-ring
4 O-ring 41-6 Plug
5 Socket-head Bolt 41-7 O-ring
6 Clamp; Pipe 42 Valve Assembly, Stop (RH)
10 Bolt; Socket 42-1 Valve, Stop (RH)
12 Bolt 42-3 Adapter
13 Bolt; Socket 42-4 Cap
41 Valve Assembly, Stop; (LH) 42-6 Plug
41-1 Valve, Stop (LH) 42-7 O-ring
41-2 O-ring

• After finishing installation of piping, connect 'P' and 'T' line
directly to each other without connecting the attachments
and do flushing process a few minutes to make hydraulic
oil clean before connecting the hoses to the attachments.
• When connecting hydraulic hoses, make it sure that
'Pressure' and 'Tank' lines are not reversed each other.
attachments.
Air Bleeding
cylinder 4 -~ 5 times very slowly about 100 mm before the
end of stroke.
DX210WA Two-way
9-2-23
COMPLETING WORK
• Pilot pressure: 9.8 bar (10 kg/cm2, 142 psi)
• Overload relief pressure setting: 216 bar (220 kg/cm2, 3,129 psi)
Two-way DX210WA
9-2-24
1Rotating
Edition 1
DX210WA Rotating
9-3-1
MEMO
Rotating DX210WA
9-3-2
Table of Contents
Rotating
General ...........................................................9-3-6
Structure.................................................................... 9-3-7
Main Piping - Rotating ............................................. 9-3-10
Pilot Piping - Rotating (1) ........................................ 9-3-12
Pilot Piping - Rotating (2) ........................................ 9-3-14
Floor Mat - Rotating + Two-way .............................. 9-3-16
Boom Piping - Rotating ........................................... 9-3-18
Arm Piping - Rotating .............................................. 9-3-20
Air Bleeding ............................................................. 9-3-21
Completing Work ..........................................9-3-21
DX210WA Rotating
9-3-3
Rotating DX210WA
9-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX210WA Rotating
9-3-5
GENERAL
General Description
When an attachment such as a crusher or a shear is used, an
optional rotating mechanism is provided according to the task
needed to be performed with the attachment.
EX1301491
Figure 1
Theory of Operation
When a push button located on the left joystick lever is pushed,
the switch output signal (1.0 ~ 4.0 V) supplies a current to the
rotating EPPR valve through the EPOS controller and a control
valve for rotating is controlled.
Push right side button is for clockwise rotation and push left side
button is for counterclockwise rotation.
Thumbwheel switch voltage output → rotating EPPR valve
current supply → control valve spool variable supply.
EX1402068
Figure 2
Rotating DX210WA
9-3-6
Structure
Main Control Valve (OPT Spool)

pb pa
RH High LH High
(Close) (Open)
A B
Current
EPOS Controller
Voltage
Joystick
(Left-hand)
WE1400576
Figure 3
DX210WA Rotating
9-3-7
Hydraulic Circuit
Option Pedal (Rotating)

6 LH High
2
1
LH RH RH High
1 T P 2
Pa A B
RH High LH High
P A B
T
78 bar
98 bar 5
T
P
pb
from Joystick (L) Switch
T P1
1 7
A3 A2 3 P2
(Front) C5
X1 P3
Engine (Ram Lock)
(Ram Lock)
DB58 CH C1
(Inching)
(Inching)
2 IC C2
X3 GTS
C4
PB
X1 (Safety Cut-off)
(Rear)
PS
A1
WE1400588
Figure 4
Rotating DX210WA
9-3-8
Reference Reference
Number Number
1 Engine 5 Solenoid Valve (Rotating)
2 Gear Pump (Rotating) 6 Pedal Valve
3 Solenoid Valve (3 Functions) 7 Gear Pump (Pilot)
4 Control Valve (One Spool)

C. Stop engine.
position.
starter switch.
CAUTION
AVOID INJURY
DX210WA Rotating
9-3-9
Main Piping - Rotating
BOOM ROTATING
PIPING
28
25 12
12 25 14
28 A
B 29
10
2 T
P 26
19
ENGINE
23
( 5)
8
21
22
18 OIL
16
11 29 29 COOLER
26
PIPING
27 15 30
13
26 20
1 24 17 6
4 9
5
OIL COOLER
PIPING
9
17
MAIN FRAME
WE1400578
Figure 5
Rotating DX210WA
9-3-10
Reference Reference
Number Number
1 Pump, Gear 16 Elbow
2 Valve; One Spool 17 Bolt
3 Bracket 18 Bolt
4 Gasket 19 Bolt; Socket M8 x 1.25 x 25
5 Hose 20 Bolt; Socket M10 x 1.5 x 30
6 Hose 21 Washer; Plain
7 Hose 22 Washer; Spring
8 Hose 23 Washer; Spring
9 Clip 24 Washer, Hard; M10
10 Adapter 25 O-ring
13 Elbow 28 O-ring
14 Elbow 29 O-ring
15 Elbow 30 O-ring
DX210WA Rotating
9-3-11
Pilot Piping - Rotating (1)
16
15
3
ONE SPOOL 13
VALVE
Pa
OIL TANK
12
13 6
3 7
Pb
2
13
3
13 8-2
11 8-4
B 8-3
2 A T 10
13 8-2
P 8-4
8-3
1
13 8-1
3
8-6 1
9 8-7
1-2
1-1
P 4
13
SOLENOID VALVE
WE1400579
Figure 6
Rotating DX210WA
9-3-12
Reference Reference
Number Number
1 Valve; Solenoid 8-4 Washer; Spring
1-1 Spool; Solenoid 8-6 Bolt
1-2 Coil 24 V 8-7 Bracket
2 Tee; Shuttle 9 Hose
3 Adapter 10 Hose
4 Tee 11 Hose
6 Bolt; Socket 12 Hose
7 Washer; Spring 13 O-ring
8-1 Harness, Solenoid Valve 15 Tee
8-2 Bracket 16 O-ring
8-3 Screw
DX210WA Rotating
9-3-13
Pilot Piping - Rotating (2)
15
12 11
15
4
2
10 13
14
15
1
23
7 P BLOCK
T 17
P 22
2 9
23 1
23
23 7 21
7
8
18
20
16
19
9
T BLOCK 22
21
22
6
20
B
A
SOLENOID VALVE
(PERO)
WE1400580
Figure 7
Rotating DX210WA
9-3-14
Reference Reference
Number Number
1 Pedal Valve 13 Bolt; Socket M10 x 1.5 x 30
2 Bracket 14 Washer; Spring
3 Plate 15 Washer; Spring
4 Plate 16 Hose
5 Rubber; Pedal 17 Hose
8 Elbow 20 Bolt M10 x 1.5 x 55
9 Tee 21 Washer, Spring
11 Bolt; Socket 23 O-ring
12 Bolt; Socket
DX210WA Rotating
9-3-15
Floor Mat - Rotating + Two-way
1 ONT
FR
FLOOR PLATE
WE1400577
Figure 8
Reference
Description
Number
1 Mat, Floor
Rotating DX210WA
9-3-16
DX210WA Rotating
9-3-17
Boom Piping - Rotating
FR
ON
T
a
4
b
b
8 9
3
4
8
9 3
D#
BOOM
e
8
9
8 2
e
7
6 c
13
11
13
6
7
a b c
7 5
13 6 6
17 15
5 7 16
6 6 10
17
13 13 5
6 12
4
5 6
6 12
7 13
4 1 2
6 14
6 7
5
WE1400581
Figure 9
Rotating DX210WA
9-3-18
Reference Reference
Number Number
1 Pipe 10 Clamp; Pipe
2 Pipe 11 O-ring
3 Pipe 12 Plate
4 Pipe 13 Clamp; Pipe
5 Bolt 14 Plate
6 Washer; Spring 15 Bolt M10 x 1.5 x 45
7 Bolt 16 Washer, Spring
8 O-ring 17 Plate
9 Bolt; Socket M8 x 1.25 x 45
DX210WA Rotating
9-3-19
Arm Piping - Rotating
ONT
FR
Ḻ#
3 BOOM
3
9
8
1
2
5 3
6 1 9
8
4
6 ◾#
5 ARM
5
6
4 4
6
16
5
15 16
13
12
15
11
31 12
11
32
14
31
34 32
33
34
33
Figure 10 WE1400582
Rotating DX210WA
9-3-20
Reference Reference
Number Number
1 Pipe 12 Washer, Spring
2 Hose ORS1/2-1250L 13 Valve; Switch (RH)
3 O-ring 14 Valve; Switch (LH)
4 Clamp; Pipe 15 O-ring
5 Bolt 16 Bolt; Socket
6 Washer; Spring 31 O-ring
8 O-ring 32 Elbow
9 Adapter 33 Cap
11 Bolt 34 O-ring

attachments.
Air Bleeding
end of stroke.
COMPLETING WORK
• Control valve (rotating) pressure check (main relief):
81.6 kg/cm2 (80 bar)
• Left joystick pilot pressure check: 31.6 kg/cm2 (31 bar)
DX210WA Rotating
9-3-21
Rotating DX210WA
9-3-22
Quick Coupler
Edition 1
DX210WA Quick Coupler

9-4-1
MEMO
Quick Coupler DX210WA

9-4-2
Table of Contents
Quick Coupler
General ...........................................................9-4-6
Quick Coupler Operation ................................9-4-9
Securing Work Tool................................................... 9-4-9
Attaching Quick Coupler to Excavator....................... 9-4-9
Releasing the Work Tool ......................................... 9-4-11
Main Piping - Quick Coupler.................................... 9-4-12
Electric Parts - Quick Coupler ................................. 9-4-13
Boom Piping - Quick Coupler .................................. 9-4-14
Arm Piping - Quick Coupler..................................... 9-4-16
Air Bleeding ............................................................. 9-4-17
Completing Work ..........................................9-4-17

9-4-3
9-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

9-4-5
GENERAL
General Description
Quick Couplers are attachments installed at the outer end of the
work equipment of various types of construction and earth-
moving machines. They facilitate the shorter time exchange of
working tools, buckets and etc.
Figure 1
Theory of Operation
O
1. LOCK I
When the quick coupler switch on the right control stand is
operated, a flow path will form according to the movement
of the spool on the quick coupler solenoid valve, and
pressure from the pump will be applied to the cylinder of
the quick coupler, moving the quick coupler in a locking
direction.
2. UNLOCK
When the quick coupler switch of the right control stand is FG001342
operated, a flow path will form because of the movement of Figure 2
the spool of the quick coupler solenoid valve, and pressure
from the pump will be applied to the cylinder of the quick
coupler, moving the quick coupler in an unlocking direction.

9-4-6
Hydraulic Circuit
Keyway
A B
B1
3 2
3
P T
A3 A2 P2 P3
(Front)
X1
XBt
X3 2
1 Bt Travel
XAt
X1 At
(Rear)
A1
WE1400589
Figure 3
Reference Reference
Number Number
1 Main Pump 4 Switch (Quick Coupler)
2 Control Valve 5 Quick Coupler
3 Quick Coupler Solenoid Valve

9-4-7
CAUTION
AVOID INJURY

C. Stop engine.
position.
starter switch.

9-4-8
QUICK COUPLER OPERATION
Securing Work Tool
WARNING
The following safety instructions are for your safety, the
safety of bystanders, and to prevent property damage. Read
the descriptions before using the machine and make sure
you are familiar with all safety notices.
Hydraulic quick couplers must be installed, operated,
inspected, serviced, maintained and repaired by qualified,
appropriately trained and experienced people only.
Ensure that work tool or bucket is not carrying a load. If
work tool or bucket is on unstable position or carrying a
load, it can cause serious accident.
The buzzer will sound unless the coupler is not locked.
Perform physical test by dragging the attachment on the
ground to confirm the coupler pins are engaged.
• Do not operate the machine if there are other workers
or people in the work area. Also, never allow people to
stand or pass under the bucket or attachment for any
reason.
• Do not start or perform any work unless you are
property trained. You should understand how to use
the device according to the instructions.
• Make sure that device is correctly and securely
engaged every time you change working tools or
attachments.
• Perform the recommend daily check for safe
operation.
Attaching Quick Coupler to Excavator

1. Place the excavator and quick coupler on firm and level
ground.
2. Retract the bucket cylinder. Align the quick coupler
between the hinges of the work tool.
EX1300731
Figure 4

9-4-9
3. Move the arm (1, Figure 5) forward and raise it until hook
(2, Figure 5) engages the hinges of work tool.
1
2
EX1300732
Figure 5
4. Set quick coupler switch to "I" (UNLOCK) position.

NOTE: To remove holding pin, maintain hydraulic relief
condition for 2 - 3 seconds in bucket crowd
position with the switch turned on.
NOTE: Whenever the hitch part is extended, a warning <UNLOCK>
alarm will sound. When setting switch to "O" I
O
(LOCK) position, the warning alarm will stop.
5. Extend the bucket cylinder to move hitch part of quick
coupler to bucket pin side.
EX1300733
Figure 6
6. Set quick coupler switch to "O" (LOCK) position.

7. Retract the bucket cylinder to attach the hitch completely.
8. Check that hitch is engaged and the work tool is properly
locked before operating.
<LOCK>
NOTE: Insert safety pin (Figure 8) after completion.
O I
EX1300734
Figure 7
Push Type
Pull Type
EX1300735
Figure 8

9-4-10
Releasing the Work Tool
1. Place the excavator and quick coupler on the level ground.
2. Set quick coupler switch to "I" (UNLOCK) position.
NOTE: To remove holding pin, maintain hydraulic relief <UNLOCK>
condition for 2 ~ 3 seconds in bucket crowd O I
position, with the switch turned on.
NOTE: Whenever the hitch part is extended, a warning
alarm will sound. When setting switch to "O"
(LOCK) position, the warning alarm will stop. EX1300736
Figure 9
3. Retract the bucket cylinder to move the quick coupler

toward the machine.
EX1300737
Figure 10
4. Set quick coupler switch to "O" (LOCK) position. Lower

and move the arm away from the work tool and toward the
machine.
<LOCK>
O I
EX1300738
Figure 11

9-4-11
Main Piping - Quick Coupler
FR
ON
T 1-3
1-1
1-2
OIL TANK
13
6
2 15
13
P3 3
2
10 7
11 CONTROL VALVE 4
12
8
12
12
1 14
5
9
MAIN FRAME
Figure 12 WE1400583

9-4-12
Reference Reference
Number Number
1 Valve; Quick-fit 7 Elbow
1-1 Valve; Solenoid 8 Elbow
1-2 Valve; Reducing 9 Bolt
1-3 Coil 10 Bolt
2 Hose Assembly, Hydraulic 11 Washer, Spring
3 Hose Assembly, Hydraulic 12 O-ring
4 Hose Assembly, Hydraulic 13 O-ring
5 Clip 14 Adapter, Filter
6 Adapter 15 Adapter
Electric Parts - Quick Coupler

3
1
NT
FRO
2
CONTROL
STAND(R.H)
EX1402055
Figure 13
Reference Reference
Number Number
1 Switch; Lockout Toggle 3 Plate; Name
2 Harness; Joint

9-4-13
Boom Piping - Quick Coupler
FR
ON
5 T
12
13
9
2
7
A
1
BOOM
A
10
11
A
1 A
1
3
5
7 6
4
13
Figure 14 WE1400584

9-4-14
Reference Reference
Number Number
1 Hose 7 Plate
2 Hose 9 Bracket
3 Adapter 10 Bolt
4 Bracket 11 Clip
5 Bolt 12 Adapter
6 Washer; Spring 13 Nut

9-4-15
Arm Piping - Quick Coupler
BOOM
5,6 ,7
5,6 ,7
#
ARM
7
6
5
1
2
5,6 ,7
4 5,6 ,7
Figure 15 WE1400585

9-4-16
Reference Reference
Number Number
1 Pipe 5 Bolt
2 Pipe 6 Washer, Spring
3 Hose 7 Clamp; Pipe
4 Plug

attachments.
Air Bleeding
end of stroke.
COMPLETING WORK
• The quick coupler switch and the installation state of the
pipes can be verified with the eye.
• High-pressure can be checked using the push/pull type
quick coupler.

9-4-17
9-4-18
1Schematic
1Hydraulic Schematic
/ Electrical Schematic
Edition 1
DX210WA Hydraulic Schematic / Electrical Schematic

11-1-1
MEMO
Hydraulic Schematic / Electrical Schematic DX210WA

11-1-2
64 59 71 16 14 15
HIGH
LH
OPT. PEDAL
(RO)
OPT. PEDAL
(TWOWAY)LH
HIGH
OPT. PEDAL
(ARTI. BOOM)
DOWN
DOZER ARM/SWING BOOM/BUCKET
A3
DX210WA
Hydraulic Schematic
2 2 2 1 2 2
4.6 bar 1 3 1 3
1 1 1 2 4 4 1.2 bar 3.5 bar
RH RH UP 1 P T 2 1 P 3 2 T 4 1 P 3 2 T 4
10
HIGH 1 T P 2 1 T P 2 HIGH 1 T P 2
XAd XBd
2 1.7 bar
(DN) (UP)
A1 B1
R3
S1 R1
SOCKLESS
A2 B2 VALVE
41
7 26 bar
A2 A1
VALVE M2 PRESSURE
T P
4.6 bar SWING ARM BOOM BUCKET WARNING
B2 S1 B1 A2
17 1 2 3 4 5 6 P2 P2
W
M
C1 HO Pa1
(UP)
Pb1
(DN)
C5 11
(Front) EPPR
XAt Ø0.7 7 13 8 14 9 15 10 16 11 17 12 18 PUMP Vgmax X1 A 5
C6
PAR XBs XAs ENGINE Vgmin
3 CH C1 M
(R) (L) XAa2 XBa2 XBb2 XAk XBk DB58 1. MAIN PUMP
XBt
XAa1 XBa1 XBb1 XAb1
C1
12 2. PILOT FILTER
Xak2 C2
C5 PBR (CR) (DU) (UP) (DN) (CR) (DU) 63 IC
C4 GTS
2x0.7 L
30 bar 3. ACCUMULATOR(for PILOT)
M3
C6 C3 4. SOLENOID VALVE(for LOWER)
PBP 0.75 L PB B(HIGH) PSA
PZ 43 X3 10 bar 103 bar 5. SOLENOID VALVE(for TM)
PL Vgmax P 125 bar 6. SOLENOID VALVE(for UPPER)
C2 Vgmin C3 K(LOW)
PS C4 ACC A 7. STEERING & BRAKE PUMP
Fl 160 bar 8. STEERING UNIT
C7 6 X1 C2 C5 ACC B
9. PRIORITY VALVE
TS (Rear) 10. BRAKE FILTER
4 T BRAKE
T BLOCK P BLOCK 1 M SUPPLY PSD 11. BRAKE SUPPLY VALVE
P1 P1 12. ACCUMULATOR(for BRAKE)
A1 VALVE
M1 13. BRAKE PEDAL
R2 S G1 AC AB 65 bar 14. JOYSTICK VALVE(L)
Front Rear LOW
Axle Axle PRESSURE 15. JOYSTICK VALVE(R)
T A
WARNING 16. JOYSTICK VALVE(DOZER)
P 42 17. JOINT PLATE
19 bar
W
ACCEL PEDAL VALVE AUTO IDLE 18. CONTROL VALVE
19. SWING DEVICE
20. BOOM CYLINDER
STANDARD
0.5 bar 21. ARM CYLINDER
LH HIGH
Hammer Select XAo
RH HIGH
XBo 19 27
22. BUCKET CYLINDER
24 23. OIL COOLER
A A B SWING MOTOR SH 23 26 13 24. RESTRICTION VALVE
A2 ARTI V/V P A1
W
T T 19 bar PG BR1 P1 25. RESTRICTION VALVE

PL 1.5 bar 26. FULL FLOW FILTER
R TRAVEL MODE P2 Py Pg Px P3 P4 P1 Pz Rs DB 4.6 bar
w W T1 27. AIR BREATHER
TANK BL1 28. HYDRAULIC TANK
CRUISE
60 MRV 265 bar265 bar
2.5 bar A2 A1 RELEASE 29. CENTER JOINT
P2
28 BR2 30. TRAVEL MOTOR
P P 56 XBt
C
PB 25 2.0 bar
B2 S1 B1 4.6 bar
T2 31. TRANSMISSION
323 bar@90L/min PA
from JOYSTICK(R) SWITCH 343 bar@90L/min CRUISE BL2 32. FRONT AXLE
from SELECT SWITCH Bt 65±4 bar
XAt TRAVEL to ONE SPOOL VALVE RELEASE 33. REAR AXLE
Hammer Select operating AUTO RAM BRAKE VALVE 34. CHOCKING CYLINDER
T2 OPERATE 80 bar
58 At 35. DOZER BLADE(FRONT)
A(LH) B(RH)
T1 P DOZER/STAB. 36. STABILIZER(REAR)
XBo 353 bar@20L 37. 1-SOLENOID VALVE(for FR-DZ.)
L Rear Front 38. 2-SOLENOID VALVE(for RE-OR.)
57 BUCKET
T2 73 Bo OPTION ROD Bd Axle Axle L STEERING VALVE R 39. CHOCKING VALVE
A B
22 T1
P XAo
Ao
XBd 225 +20
0 bar 40. SHOCKLESS VALVE for BOOM DOWN
HEAD Ad
R.H Ck2 41. SHOCKLESS VALVE for ARM DUMP
C
EPPR VALVE XBk 353 bar@20L
353 bar@20L
Ø0.9 8 42. ACCELERATOR PEDAL VALVE
40 XAs 43. AUTO IDLE CYLINDER
55 P A
Fr Bk1 ROD BUCKET
Bs
X
T
XAk 353 bar@20L
SWING Ø0.9
XBs CENTER 3 3 1 1 1 1 3 3 1 1 3 3 1 3 1 29 51. LOCK VALVE for BOOM
XAb1 Ak1 HEAD As JOINT 8 8 2 2 8 8 4 4 8 8 2 4 4
52. LOCK VALVE for ARM
X1 SOCKLESS 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
L 53. PROPORTIONAL VALVE (for FLOW CONTROL)
57 53 (Front) VALVE
XBb1 34 54. SELECT VALVE WITH RELIEF
BOOM2
Xop 55. SELECT VALVE
L.H A Bb1 HEAD BOOM1 op 56. 2-SOL VALVE for PE3C
215 bar
Ab1 ROD 57. STOP VALVE
T Dr1 B(HIGH) 58. BREAKER FILTER
ARM1 GP 175 +10
0 bar
353 bar@20L
K(LOW) 59. OPT PEDAL VALVE for PE3C
BP 353 bar@20L
X XBa1 31 60. 1-SOL VALVE for PE3C
54 XBa2 ARM2
OPTION
RH HIGH ROD Ba1 CHOCK 61. ROTATING VALVE
XAa1 62. 2-SOL VALVE for PERO
XAa2 Aa1
LH HIGH BOOM
HEAD P T LS 63. ROTATING PUMP
X1(IC) 64. OPT PEDAL VALVE for PERO
353 bar@20L G 3 bar
Pa A B ARM Dr4 MB GEXT B 65. QUICK COUPLER VALVE
61 20 BC U T1
66. QUICK COUPLER
18 HOLDING GP
GP
J (FWD) Pi BL
M 67. ARTI. BOOM CYLINDER
ROTATING PA PA 68. LOCK VALVE for ARTI. BOOM
PUMP Fr PBP Dr3 Fl XAk2 Par Ck1 Pal qmax STEER
STEER DOZER CF EF
E E S CYLINDER 69. SLOW RETURN V/V for ARTI. BOOM
P
EPPR VALVE qmin
A Y BR 70. CONTROL VALVE for ARTI. BOOM
78 bar A (REV) LS 71. OPT PEDAL VALVE for ARTI. BOOM
X1
CHOCK P 72. RELIEF VALVE for BREAKER
OIL COOLER MA
(RETURN ROOM) Pi1 Pi1 T2 73. SWITCH VALVE(for CLAMSHELL)
T T
M3
M2 30 39 9
98 bar X2
T PC PC GP
Pb 51 (TU) TRAVEL MOTOR
REAR AXLE
LOCK VALVE FRONT AXLE
BRAKE
36 BRAKE
LH HIGH XAa1 T
QUICK COUPLER VALVE T
PC T Pil E V2 V2 V1
RH HIGH A B C1 C2
35
ø1.0
V3
A 67 33 V1 V1 A
T
P3
P PA ARTICULATED BOOM V3 V3
V2
32
A
SLOW C
RETURN
T 69 VALVE
62 B 52 LOCK VALVE 38 37
P
21 ARM A B
65 66 P.B A1 B1 T2 70 AO ONE WAY
72
57
PC T Pil E L.H
Pb1 275 bar 275 bar Pa1
68
PA
(DN) (UP) ARTI. SHUTTLE
T A Serial Number 5001 and Up
ARTI. VALVE B2
SHUTTLE
VALVE B1 B A EX1400888
LOCK VALVE P T1 R.H
C/V P4 OIL COOLER

11-1-3
DX210WA
TELESCOPIC BEACON
0.85Or 33C
Electrical Schematic
0.85B
0.5Gr 0.5Gr 0.5Gr
STARTER SWITCH CONNECTION 0.5BrB
ROTATING BEACON SWITCH
0.85WL 1
0 ROTATING BEACON
PST TML B BR R1 R2 C ACC 0.85BR 88B 2
PILOT CUT-OFF SW 2 PILOT CUT OFF SW 1 3 33A 0.85Or 33B
OFF 0.5BrB
0.85YG 41A 3 4 122B 0.85Y 122A NC
I
FUEL HEATER (OPT)
0.5BrB
CONSOLE ASS'Y 0.5WR 54K 8 7 0.5B 0.85B
0.5Y 2 COM 0.85RW
PREHEAT 1 N0 40E 87a
ON TURN SIGNAL (R) 2 185F CN17-2 0.5GR 0.5GR T/M & PILOT VALVE 0.5WR WORK/TRAVEL SWITCH 0.5WR 62B
L2 2RG 30
DOZER STAB 250D 0.85WL 246A 87 2.5R
START TURN SIGNAL (L)
L1
1 184F CN17-1 0.5GL 0.5GL
250E 5
0.85WL 0.85BrW
39A
0.85BrW ROTATING BEACON (OPT) 0.85BR 2
0 1
246B
(C1) DA6-4 PARKING BRAKE SWITCH I 3 0.5RY 86 245 85
DA2-1 RAM LOCK SW 209F 0.85YG 210E 39B CN17-8 1 (T) 0 202H 2 88D
5 0.85B 1 5 1 0.5B
209A 3 CN17-10 0.85OrR 202A 3 0 0.5WR 8 7 0.5B
DIODE ARRAY (OPT) 0.85B I 210B 2 224A 40F CN17-9 3 (W) I 2 0.85Or
7
DA6-4 7 3
CN17 AMP SEAL 12P 211D 0.85Y 0.85Y 0.85Y 211B 1 DA9-3 209B 1 (P) I 54K
3
0 40A 7 54AA 8 CN17-11 201B FUEL HEATER
0.85VC
213B 213C 0.85W 213A 1 RAM LOCK 226D 87a 226A FUEL HEATER
5 6 7 8 3 4
4 0
2 212B 0.85YR (C2) 211E 6
DA2-2 0.5WR 54L 7 8 224E 30 224D
DA9-4
225A 0.5VB CN17-12 0.5WR
0.5B 7 8 FUEL PUMP (OPT) SWITCH RELAY 2.5B
5 DA5-1 250A 3 I 2 210A 87 4 8
54H
0.5B FUEL HEATER
1 0.85B 8 54S 0.5WR 0.85B 86 FUEL PUMP SW FUEL PUMP
0.5B 7 0.5B 0.5Br 170C
4 INDEPENDENT OUTRIGGER (OPT)

FRONT L 87a
1 2 3 4 1 2 DIODE 38 PILOT CUT OFF 41B 0.85YG 0.85YG INCHING RELAY 0.85VW
124C 30
170B 225B
(C4) 41C 7 87a 221A 1.25WR 130J 64A 1.25WL 64B + - 1.25B
ANTENNA
OUTRIGGER(FL) DA2-3 RAM LOCK PRESS SW 30 202B P
0.85YR
3 RAM LOCK RELAY
0.5WR
0.5BrB
0.85OrW 203A 87
0.5GR
DA1 ~ DA7 DA8 ~ DA12
0.5GL
0.85OrW
0.5Gr
0.85OrR 85 124D 86
0.5Y
0.85B
203B LOW SPEED RELAY 192B 86 85 CAR STEREO MODULE
INCHING 203C 0.85OrW 87a
0.5B 220A
OUTRIGGER(FR)
6-LAMP ASS'Y (OPT) 214B 214C 0.85WG 5 0.85WG 1 0
(C3) 203D 8
DA2-4 7
3
DA7-3
0.85OrB 204A 87
30 202C 0.85OrR 0.5G
PILOT RELAY 0.85WR 5
4 0.5Gr
2 212C 0.85YR 204B 130H
129B 0.85RG 6 DA5-2 214A 3 0.85B 85 86 193B SPEAKER
1.25RG 0.85RG 129C I 0.85OrB HI SPEED RELAY 0.5B
0.5GrR 0.85VW 0.85OrR (LH) (RH)
2 0.85B 87a 0.5WR 3
(RR) 7 8 54T 0.5WR 204C 205B 204D 30 202D 0.5GrR 221B 54T
0.85B 0.85B FRONT R DIODE 39 0.85W 0.85W
87 205A 0.85OrR CN15-7 0.85BR 4 88E
205C 5 6 0.85OrR (+)
0.85RG 129D
(REAR) DA7-1 DA7-2 + - + -
REAR WORKING LAMP 87a
215B 215C 0.85RY
1 2 85 86 194B 0.5GrL 0.5GrL CN15-4 192A I 117B 118B 119B 120B
30 125E 1.25RL 6 0.85RY 215A 1 0 LOW HI 0.85B 0.5B 7 0.5GrR
129A 87 (RL) 2 212D 0.85YR
87a CN15-5 193A 0.5WR 54D 1 117A
1.25RG 0.85B 7 DA5-3 0.85B 30 195B 0.85LY II 17 0.5BY
3 I 0.85BY 196A 87 118A
0.5B 85 86 128B 0.5RW 1.25B 3 0.85B FORWARD
196C 0.85BY 0.85BY CN15-6 194A III 0.85BR 88B 1 2 132A 0.85R 2 121B 0.5WG 121A 15
127B 0.85RG CABIN LAMP 7 8 54U 0.5WR DC/DC Vcc(+5V) 2 0.5GrL
REAR R (C6) 196D 5 85 86 206B 0.5YB CN15-2 206A
0.5YB 132B 3 123B 0.5W 123A 16 119A
DIODE 40 DA3-1 REVERSE RELAY 199B F CONVERTER 2 10 0.5BW
(FR) 1
87a 0.5B 0.85B 3 + 120A
0.5WB CN15-3 207A
1.25WR
0.85B
0.85RY
0.85BR
4 169A 0.5BL 169B 13
0.85Or
12V POWER
0.5WR
0.85B 30 0.85RG R CN13 MOLEX 4P MICOM 11 0.5B
OUTRIGGER(RR) SOCKET
CABIN LAMP RELAY 2 200B 0.85RY 0.85RY 200A 87 FORWARD RELAY 0.5BrY CN15-8 191A KD - 0.85B
127C 0.85RG REVERSE 0.85B AUDIO CONTROL PANEL
216B 216C 0.85YB 7 0.85YB 216A 1 0
200C 6
0.5B 85 86 0.5WB CN15-1 190B 0.5RG 22F 1 99XS 14 Vcc(+5V) 99
(FMR) (C5) DA3-2 (+) 0.85B
0.85B CABIN LAMP SWITCH 2 212E 0.85YR 2 0.85RL
8 DA5-4 3 I 0.85B 207B CRUISE RELAY(2) 1 2 3 CRUI ENG TIME DELAY
2B 8 87a 0.5Br F N R STEP STEP STEP SE 0.5LR 13D 3
0 4 0.85B 197C 0.85YB 0.85YB 0.85YB 197B
87a 0.5WR 126A 3 2 125B 7 8 54V 0.5WR CRUISE 30 198B 1 5 0.5BrY
(FRONT) 30 125D 2RL I 0.5RL REAR L
DIODE 41 0.5B 197D 7 CRUISE RELAY(1) 87 COMBINATION SWITCH (RH) 0.5RG 261A 4 2 99ET 0.85B
0.85BY
127D 0.85RG 2RG 127A 87 II (C7) DA3-3 87a 198A 191B
ELEC. 0.85B 3
197A 85 86 DA1-1 COBO C9 (K1002657)
0 OUTRIGGER SW (RL) 30 170A 206C 207C
0.5WR
(FML) 0.85B 0.5B 85 86 126B CENTER JOINT RELIEF 0.85B 87 0.85OrR
I 5 125C 0.5RL (549-00101/ 188E 0.5GW ROOM LAMP
PRESS UP 22B 0.85RG 196B
0.85Or
0.5RW 128A 6 II 0.5B
DA1-2
DA1-4
6 3 4
86
DA1-3
(C2) 22C 8 0.5P 85 0.5BrY 0.85RY 1.25B 10W OFF
127E 0.85RG 7 8 54W 0.5WR DA3-4 2 7 8 STARTER CONTROLLER STARTER RELAY
0.5B 0.5WR 4 104B 191C 0.5WR 83B B+ DR E 0.5B
CABIN LAMP RELAY 1 23A 23B 0.85GrW 0.85BR S 14C 0.85BW 14A D PP AVX 3Y
(FL) 0.85B 208C 208A 208B
0.5RG 0.5RG ON
BREAKER 61C 0.85YG +
14B 5A
2B 2RL 0.5OrR 1.25L 34L CIGAR LIGHTER
CABIN LAMP 61B
(C1) 3
DA8-1 12C C B 3W
0.85YR
0.5BrB
0.5BrW 208E N
0.5GR
DIODE 3
0.5BrW
0.5GL
1 0.5BrW 0.5BrW 0.5BrW
0.5Gr
0.5Y
0.85B 4C
ALARM RELAY 1 0.85LR/0.5WR 0.85LR/0.5WR
87a ALARM RELAY 2 0.85RL 0.5GW E B P
30 20B 0.5WL 20A 87a 0.85BL
LCD GAUGE PANEL 0.5LR 0.5LR 0.85L 0.85L 219B A 18B 12B
REAR VIEW CAMERA 0.5B 87 30 19B
0.5WB 29A 0.85B
(301102-00021) 87 0.5BrB 0.85RG 0.85G 0.85G ENG STOP RELAY 0.85LY 217A P1
86 54Z 0.5WR STARTER RELAY 2 0.85BL
0.5BW
254A 85 219A 87 217B 13B
V+ 9V CN7-7 0.5Y 254A 86 13E 0.85LR 83C B
0.85RY
0.85RG
1.25WR
0.85BR
0.85LY
0.85RL
85
0.85Or
255A
0.85Lg 1.25YR 63B 0.85G 30 87a 12A
1.25WG
V- CN7-17 0.5YB 255A 0.5B A 0.85BY 30
B 87a 218B 0.85LW 218A P2
0.5LR
Sig 256A CN7-10 0.5YL 256A 1.25RL 1.25RL 1.25RL 87
190A 195A 199A 201A 124A 88A 83A 6A 85 0.5B 0.85B E 11B
0.85RG
E 0.85B
1.25YR
2RY 2RY 86
1.25RL
257A 0.5LR 2RY BLINKER UNIT
0.85G
Sig Gnd CN7-20 0.5YW 257A 0.5LR 86 85 0.5GB
1 2 3 4 5 6 7 8
CN7-2 13F 0.5LR ACC 0.5LR 2RL 2RL 2RL 261B
10A 10A 10A 10A 10A 10A 10A 10A 13C 89A
1.25YR 125A 50A 21A 212A 22A 63A 2B 2WR ENG STOP MOTOR
L
0.85YG 182A 0.85GY 15 16 0.5LR
9 10 11 12 13 14 5W 4D FUSE BOX 1
WORKING LAMP RELAY FUSIBLE LINK
CN7-3 99 0.5B 0.5BW 87a 0.5LR 0.5LR 30A 20A 20A 15A 15A 15A 5W 4E 1.25WR 0.5GB
2D 1.25WR 0.5G
CN7-4 99 0.5B 19A 50B 30 2RY 0.85GrW 0.85GrW 17 18 2C 1.25WR 2WR 2WR 2R 2R
0.85RG 51C 51A 87 17 18
- 2RG
0.5GW FUSE BOX 2
4G 5W 2A 1B
PILOT
PILOTBUZZER
BUZZER 30A 20A 20A 15A 15A 15A 3W
0.85B 0.5RG 55B 86 85 4F 5W 2RG
CN6-1 29B 0.5WB (2516-1116
(2516-1116) ) 0.5B 0.5BrW 0.5BrW 0.85BY 0.85BY 3Y
+ 0.5Y 0.85RY 15 16 54N 0.85WR 52A 9 10 11 12 13 14
0.5LR 5B
CN7-5 130C 0.5RW 0.85RG 8W 11A 0.5GB C
130E 42A 62A 143A 34A 130A
CN7-6 130D 0.5RW 0.85B 0.5OrR 0.5OrR 10A 10A 10A 10A 10A 10A 10A 10A 2LR 1.25WR 13A C STARTER SWITCH
1.25L
1.25RB
0.5RG 1 98A B
2RG
0 50C 2 15R 15R
0.5RW 0.5RY 0.5P 0.5P 1 2 3 4 5 6 7 8 0.85L 1.25L ACC
CN7-16 28B 0.5R KEY-ON/BR 55A 3 I 6B 1.25WG
WORKING LAMP 0.85R 0.85R 28A 93A 131A 66A 133A 56A 186A 187A 2RG 1.25WR
7 54F 8 0.5WR B
0.5B 0.85RL 0.85RL 1.25WR 1.25WR R2 BR 0.85Br
CN6-4 54B 0.5WR HOUR METER
0.85RB 0.85RB 1.25RB 0.5WR 6C 1 10A 7A A
OVER LOAD WARNING (OPT) WORKING LAMP SWITCH
0.85GR 0.85GR 0.5RW 0.5RW 9D 3 HOUR 2 0.5B R1
0.85WR
0.85BW
0.85WL
1.25RB
0.85BG
0.85LB
0.85R 0.85BrR 0.85BrR 0.85RG 1.25RG 0.5RG 15A 60R STARTER 60B
0.85L
OVER LOAD WARNING SWITCH
0.5RW 0.5GB 0.5GB 0.5GB 0.5GB 24V 4.5KW
1 0 0.5BG 0.5BG 0.5BG
2 140B 0.5BrY CN5-4
CN2-6
0.5B 3 I 0.5RW 8W 8W 8W
BATTERY RELAY
7 8 54Q 0.5WR 55D 0.5BW 0.5BW 0.5BW 7B 0.85Br CIRCUIT BREAKER 2R
3W
0.5B CN2-14 0.5RW ALT 'I' 0.5RW 0.5RW 0.5RW
9C 0.85BW B A
8W
0.85BG
28D 0.85R 8W
AMP MIC 21P
DIODE 2
+ 89B CN1-15 0.5 START RELAY 0.85WR 0.85WR 15B
PRESSURE SENSOR 139B 0.85BrW CN3-5 139A 4B 3B 3A
SIG 178B CN1-16 0.5LB AFTER HEAT 0.5LB 0.5LB 0.5LB 8A 0.85BrW
(OWD) 2
DA6-2
145A 0.85W CN3-6 145B 1.25BrW 8C BR
- 39C CN2-3 0.5BrB TRAVEL 1.25RB 0.85WY 0.85WY 0.85G 4
140A E
28E 0.85R 211C CN2-7 0.5Y RAM LOCK 0.85GY 87a 10C 8B 0.85BrW
+ 30 52B 1.25B
CN1
PRESSURE SENSOR(A) 74B 0.85GR 74A 202E CN5-1 0.5OrR PARKING ARM POSITION LAMP(L) FRONT FRONT ARM POSITION LAMP(R) 0.5WR 0 0.85BG
SIG CN3-1 HEAD LAMP(L) HEAD LAMP(R) HAZARD SWITCH 180A 87 54A 3 2
(FRONT PUMP) (OPT) T/S LAMP(L) T/S LAMP(R) (OPT) 0.85RG I 60R
75A 0.85W CN3-2 75B 10B CN2-1 0.5BG KEY SW 'START' 3W 75/70W 75/70W 3W COBO AA1 DIODE 1 60B 60R
- 186D 0.85WL 21W 21W
0.85WR 187D 1 2 182B 0.5B 85 86 179B 0.85WR II 63C
AVX 1.25WG
53C CN2-4 0.85R HIGH BEAM
+ 28F 0.85R 0.5GrW 0
183A 3
0.85WR
0.85WY
0.85RG
0.85GY
0.85LY 9B 1.25RW
0.85LB
PRESSURE SENSOR(B) CN17-7
0.5RW
PRESS UP 5
AVX 8W
23C CN1-11 0.85GrW I
0.85L
76B 0.85GY CN3-3 76A 0.5B
2LR
(REAR PUMP) SIG 179A 6 II 63D 0.5RW AVX 2RW - + - +
208D CN2-12 0.85BrW F/R 184C 185C 54AA 4 5 HEAD LAMP RELAY
77A 0.85WL CN3-4 77B 12V 150AH 12V 150AH
- SIDE T/S LAMP (RH) 183B 183C COMBINATION SWITCH (LH) COBO N5 0.5WR 8 7 0.5B
0.85BrR
0.85WR
15R
0.85GR
0.85RW
0.85RW
0.85YG
0.85WR
0.85RB
1.25RB
0.85RY
0.85GL
SIDE T/S LAMP (LH)
0.85WL
0.85GR
0.85RL
PREHEAT
0.85GL
0.5GW
15C CN2-13 0.85BW CN17-6 6

0.5GR
0.85R
0.85R
0.85R
0.85B
0.85B
0.85B
0.85B
0.85B
0.85B
28K 0.85R BATTERY
0.5P
184D 0.85GL 54G

21B CN1-1 0.85RL 1.25RL 0.85GR 185D 1 2
DA9-1
252A 0.85YB CN3-19 252C
0.5B 7 8
DA9-2
3 4 LAMP SWITCH 9A I 18A R 4A B+
21C CN1-2 0.85RL 0.85B 0.85B SW TURN SIGNAL HEAD LAMP
(turn sig)
253A 0.85BY CN3-20 253C
(turn sig)
0.85GR
(clearanc)
(clearanc)
0.85GL
220B PILOT RELAY 181C 53C 181B 53D 181C 181C 184A 185A TML N 0.5 uF
CN1-12 0.5Gr
0.85WR 0.85GY 182C CN16-7
(high)
(high)
WIF SENSOR B+
49a
(low)
(low)
99 CN1-8 0.85B
CN6-12 80A 4 0.5Y 80B CN4-4 0.5GR 0.85GR 0.85GR 185B CN16-3 R AFTER HEAT RELAY
99 CN1-9 0.85B ALTERNATOR
AUXI MODE RESISTOR 0.85GL 0.85GL 0.85GL 184B CN16-1 87a I(L)
CN6-13 81A 5 0.5YB 81B CN4-5 L 30
0.5RG
CN6-14 82A 6 SHIELD WIRE 82B CN4-6 0.85BrB 94A 93B 0.85RL 0.85WL 0.85WY 180B CN16-4 52C 87 10D 0.5BG
56 REG.
0.85RW 181A CN16-5 85 178A TRIO DIODE
120 CN4-8 120 0.85RW
56b 0.5RG 86
CAN 101A CN1-10 0.85Or 101B 1 5 0.85LgR 0.5LB
CN4-12 CAN P/V-(A) 0.85R 0.85R 0.85R 0.85R 53A CN16-6 52D FIELD
94B 2 56a F+
135B 0.5GL CN4-1 135A TxD 95A 95B 0.85WR 0.85WR 0.5WR 0.85RG 52E CN16-8
1 30 F-
102B CN1-21 0.85OrB 102A 3 6 0.85LgW 0.85B 0 CN16-9
2
136B 0.5GW CN4-2 136A RxD 0.85GW 0.85GW 15
E
0.85B 4 96B 96A
DIAGNOSTIC
137B 0.5RG CN4-3 137A GND PUMP 0.85RY 0.85RY 0.85B 0 CN16-12
15/1
(clearanc)
3
(turn sig)
RS-232 AUXILIARY MODE SW PROPORTIONAL V/V 0.85OrL 162B CN16-11 99 GRD
0.85GW
0.85WR
0.85RY
0.85B 0.85B
(back up)
200D
0.85GR
80C
(stop)
(clearanc)
0.5Y
0.85RY
(turn sig)
0.85GL
0.85WL
(stop)
0.85GW
0.5P
CONN
53c
(back up)
4 0.85WR 8B
DA10-1
1
81C 0.5YB CN4-7 258A 104A 0.85G 58C CN16-2
5 DIAGNOSTIC CONN 14 CN2-15 0.85P 3
H
82C DA7-4 184E 188C 186C 200E 54BB 200F 187C 188D 185E 0.85LR 159B CN16-10
6 SHIELD WIRE 189A J 15R PREHEAT RELAY
93E 78B 0.85Lg CN1-19 78A C A B D F E E F D B A C AIR HEATER
P/V-(C) 189B 0.85RW 0.85LG 161B CN15-10 PREHEAT FUSE 100A 100B
4
8
FUSE BOX 2-2 12 TRAVEL ALARM SWITCH Py 251B 53b 98C

CN7 CN6 FLOW CONTROL + 189C 98B 200A 98B' H 15L (1)
13 0.85B 104C 0.85LY 160B CN15-9 B -
+
0.85P 5W 53
0.85WR
AMP 040 12P+16P 258B

0.85BrR
0.85GW
-
0.85YG
0.85GR
PROPORTIONAL V/V
0.85RB
1.25RB
79A 0.85LgB CN1-20 79B 0 1 19bar

EPOS CN4-7 14 (OPTION) 2 196E 4
21W LICENCE LAMP 21W 21W
DA10-2
Px AUTO IDLE (1) BACK BUZZER 21W 31b 0.85BG 0.85B

e-EPOS I 3 251A 2
REAR COMBI LAMP
CN14 0.85B 103B 0.85V CN2-16 103A / TRAVEL SW REAR COMBI LAMP TML I 0 JI J II OFF ON OFF ON
AUTO IDLE (2) SW 0.5B 7 8 10E C D (2)
Arti.Boom
19bar CONTROLLER
54H 0.85B
SW WIPER WASHER HORN AIRCON UNIT -
(543-00110A) 162A 11 (WASHER) 0.85OrL 2LR
+
TERMINAL NO AUTO IDLE (3) SW 0.85B 103F 0.5V
84D CN2-11
SEAT AIR SUSPENSION(OPT) - 155B 2 0.85LW 3 155A
159A 5 (CONT) 1.25LR CN11-2 42C
15B
+
4.7bar M 0.85LR
SEAT AIR SUSPENSION 42B CN9-5 1.25LR 0.5LR CN10-8 42D
INDICATOR 0.85B 67B 0.85BW CN2-17 67A 156A 4 0.85LB 4 156B 161A 10 (INT-2) 0.85LG
0.5WR
MOLEX 4P 1.25RB 143C 1.25B
(Fix) 1 P 160A 8 (INT-1) 0.85LY CN10-18 46B TERMINAL NO
2 133J LED 1~12 RECEIVER DRIER
68B 0.85BG CN2-18 68A POWER MODE SW (Release) WIPER CUT SW
PILOT FILTER SWITCH 0.85B 0.5Br 0.85Br 3 CN9-11 54E 42E 46A
1 2 3 4 0 0.85BrR AMP MIC 13P AMP 070 18P AMP MIC 21P
258B CN5-2 258A 2
3 99 0.5B 84C 84A SEAT HEATER (OPT) 157B 1 0.85WL 7 157A
138A 9 0.85Lg 138B 0.85B 0.5WR
0.5BW
BLOWER
0.85L
(CN13) RETURN FILTER SWITCH 0.85B 69B 0.85RB CN5-3 69A 0.5YB I 84B QUICK CLAMP SW 1 ILL 1 2 3 4 5 6 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0 168B CN8-10 0.5LG CN10-16 168A
DIODE 6
(OPTION) 1.25RB 143B 2 RELAY

1.0bar 99 7 8 54P 158B 5 0.85WB 6 158A 34B 1 0.85L
0.5B I 3 144A 1.25R 144B 1.25B
DIAGNOSTIC CONN. 14P 0.7bar 0.5WR 130F 6 0.5RW 13 130B 105B CN9-8 0.5LB CN10-5 105A 7 8 9 10 11 12 13 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
WINDOW WASHER
ENG OIL PRESS SWITCH 59B 0.85BY CN5-5 59A 0.85B SOL-VALVE 0.5WR 54R 8 7 0.5B A/C (CN12) WIPER CONT. (CN2)
- + 0.85L (CN1)
0.85LB
35C 12 0.85RB
0.5RW
0.5WR
SEAT HEATER 1.25B 2 99 106B CN8-11 0.5LY CN10-6 106A
RELAY
0.5G
P FET
WIPER MOTOR 35A 34C
7
3
6
2
5
1
4
BRAKE OIL PRESS SW 141B 0.85YL CN5-6 141A
60B CN2-2 0.5BrW (POWER MAX) QUICK CLAMP(OPT) 0.5BrW
SEAT HEATER SWITCH
WIPER CONTROLLER 0.5RB 0.5L
1.25B CN11-1 - M
+ AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
65bar 223F
223F CN2-10 0.85GY (FLOW CONTROL) 3 1 61D 35B 34D 107B CN8-12 CN10-1 107A
11 10 9 8
0.85B 70B 0.85GB CN5-7 70A 0.5LW BLOWER 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
PEDAL BRAEKER PRESS. SW BREAKER SHEAR SELECT SW 0.5RW DIODE 5 CN9-6 130C
14 13 12 150E CN2-8 0.5RL (1-WAY) DA6-1 0.5RL 108A CN9-13 0.5GrG CN10-2 108B FRE (P1)
(OPT) 0.5RW INTAKE
12 11 10 9 8 7 16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11
0.5RY 0.5B 16 15 14 13 12 11 10 9
24B 0.85GrL CN5-15 24A 151C CN2-9 0.5RY (2-WAY) PST SHEAR PRESS BREAKER 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
ENG SPEED SENSOR UP L 0.85LR 0.85LR 0.85LR M (CN7) (CN6) (CN5) (CN4) (CN3)
30B 0.85GrR CN5-16 30A 1 0 2
A/C CONTROL PANEL

(CN14) TML 38B 37B 1 110A CN9-15 0.5OrR CN10-12 110B DEF (P1)
(1) STOP LAMP SWITCH 99 0.85G 0 AMP 040-III 20P
9 2 38A 111A CN9-14 0.5OrW CN10-13 111B VENT (P2) KET D/L 4P AMP 070 18P AMP 070 12P
31B CN5-13 31A 0.85RB 131B
+
0.85YL 9 B 0.85L 0.85L 34F 3
W/TEMP SENSOR 0.85GR 66B 188A 0.85GW 0.5WR 54J
10
STOP RUN I M MODE 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
32B 0.85BL CN5-14 32A II 163A 0.5RW 163B 15 8 54X 0.5WR 43A CN9-18 0.5YB CN10-11 43B Vref MODE
CN1-3 0.85RY 151A ACTUATOR 9 8 7 6 5 4 3 2 1
AMP MIC 17P
M 34H 0.5B 7
0.85GR 66C 188B 3 44A CN9-17 0.5YW CN10-10 44B MODE F/BACK 20 19 18 17 16 15 14 13 12 11 10
A/I 164A CN1-4 0.5WG 164B 10 0.85YG 0.85BrR 133G 4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(2) 0.85GW LOWER WIPER SW
14 37A S 0.85G
-
72B 0.85YR CN3-7 72A CN1-5 165B 14
W/M 165A 0.5YL 0.85BrR 133H (CN11) (CN10) (CN9) (CN8)
FUEL SENSOR 13 E 0.85B 112A CN9-1 0.5LgW CN10-19 112B WARM (P1)
73B 0.85BR CN3-8 73A O/H 166A CN1-6 0.5LG 166B 17 BREAKER 150D 150C 0.85RL 2 0.85RL 150A
SELECT 11 113A CN9-18 0.5LgB CN10-3 113B COOL (P2) AMP SEAL 10P AMP SEAL 12P(R) AMP SEAL 12P
I 300A 0.5RY 300B 16 34E 0.85L M
CN3-18 8
114A CN9-3 CN10-7 114B Vref MIX
26B DA4-4 6 0.5YR MIX AMP MIC 17P
0.85LgR CN3-9 26A 4 LOWER WIPER MOTOR
OIL TEMP SENSOR 3 0.85B 0.85BrW 60A 115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR 8 7 6 5 4 3 2 1
27B 0.85LgW CN3-10 27A 16
ENG CONTROL MOTOR 0.85B 12 1 2 3 4 5 6 6 5 4 3 2 1
CN18
0.85BrL 134B 5 4 3 2 1
167C CN9-2 1.25BL CN10-4 167A GND
AMP MIC 17P
15 7 8 9 10 11 12 12 11 10 9 8 7
(523-00006) 0.5G 10 9 8 7 6
LOWER WIPER (OPT)
17 16 15 14 13 12 11 10 9
90D P4 153B 0.85GW 153A 4 0.85YG 61A
0.85GR 12 HORN RELAY (CN18)
PARKING BRAKE
+ (+) 0.85BrR
87a 116A CN8-2 0.5OrW CN10-15 116B DUCT
174B CN3-11 174A
CN15 AMP 070 12P
0.85YG 0.85YG 30 0.85LB CN9-10 1.25B (CN15) (CN16) (CN17)

SIG SENSOR
SENSOR
-
175A 0.85BL 0.85BL CN3-12 175B
M
P5 154A 0.85Y 154B 5 (-)
0.85GY DA12-3
223C JOYSTICK LEVER SWITCH R.H JOYSTICK LEVER SWITCH L.H ROTATING S/V (OPT) 57A 87 56B
223B 7 86 0.5LB 45A CN8-1 0.5LgR CN10-14 45B COMPRESSOR
1 90C 0.5GR 0.5GR CN3-15 90A RETRACT P3 85B 0.85L 85A 8 0.5G 85 WATER
LOW CW (+) 148B 3 148G 1 148F 0.85BrL 134A 6 3 133D 0.85BrR 0.5G 58B 3 6 99 0.5B 146B 146C
(CLOSE) 148C 1 CCW 58A 56C SENSOR MAGNET
TPS(E/G THROTTLE LEVER) 2 176B 0.85LY 0.85LY CN3-13 176A P2 86B (BREAKER/POWER MAX) (HORN) 0.85LW
CN9
0.85Or 7 86A CN11-4 47C CLUTCH

AMP 18P + 12P
3
3 (C) (C) DA11-1 (A) 0.85RY
3 177A 0.85WB 0.85WB CN3-14 177B DA12-1 48A CN8-5 0.5LY CN10-17 48B 1
P1 0.85Gr 6 87B 1 223A 0.85OrY 148A 4 1 133E 0.85BrR 0.85BrR 133B 1 4 146A 0.85OrB 1 INCAR 47A 47B
HIGH 0.85RY 57B SUN SENSOR 2 SENSOR
87A (-) (SHEAR - CLOSE) (ROTATE-CCW) HORN 1
DIODE 4
8
86C CN5-11 0.85Or DA12-4 (L) (L) H.F
0.85B 142A CN8-3 0.5Lg 2 - + 1
Serial Number 5001 and Up

THROTTLE CONTROLLER
1 222C 0.5GR 90A +(5V) 149C 149B 4

149G 2 149F 0.85OrG 149A 5 2 133F 0.85BrR 0.85BrR 133C 2 5 147A 0.85OrR 147B 147C
CN8
LOW CW 87C CN5-12 0.85Gr (OPEN) 2 CW CN10 AMP 20P CN11 KET 4P
142B 0.5YR
ENG CONTROL DIAL 2 91B 0.5G 0.5G CN3-16 91A SIG 4 (SHEAR - OPEN) (R) (R) (ROTATE-CW) 4 0.85B 0.85B
DA12-2 DA11-2 (B) 57C 114C 0.5BL 167B 2
GND 0.85RY
3 92A 0.5GB 0.5GB CN3-17 92B 2 3 0.85B 0.85B 3 2 HORN 2 49A CN8-4
HIGH PEDAL SWITCH (OPT) 0.85B L.F 0.5YG 0.5YG 49B 1 AMBIENT SENSOR
0.5G 0.5G 91C 2 0.85BrL 134C 133J 0.85BrR
0.5GB
0.5GR
0.5GB 92C 3
0.5GR 222A 1
1WAY-2WAY S/V (OPT) EX1400889

11-1-5

Dx210wa (950106-01517e) 1412 SM en (#5001 - 2014) PDF

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Dx210wa (950106-01517e) 1412 SM en (#5001 - 2014) PDF

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Shop Manual

Serial Number 5001 and Up

DOOSAN and the DOOSAN logo are registered

Copyright DOOSAN 2014 Original Instructions

11/07/2014 1st Edition

3 General Maintenance 1 General Maintenance Instructions

5 Upper Structure 1 Cabin (Non-Rops)

7 Front 1 Boom and Arm

8 Hydraulic System 1 Hydraulic System

9 Electrical System 1 Electrical System

10 Options 1 One Way

11 Schematic 1 Hydraulic Schematic/Electrical Schematic

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

Wheel Excavator Maintenance Safety

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

DX210WA Wheel Excavator Maintenance Safety

Safe Operation is Operator's Responsibility

Know Your Machine

Wheel Excavator Maintenance Safety DX210WA

DX210WA Wheel Excavator Maintenance Safety

Flying or Falling Objects

Wheel Excavator Maintenance Safety DX210WA

Correction of Machine Problems

Crushing and Cutting

DX210WA Wheel Excavator Maintenance Safety

Hot Coolant and Oils - Burn Prevention

Wheel Excavator Maintenance Safety DX210WA

• Add fuel, oil, antifreeze and hydraulic fluid to machine only

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

Never Use Ether Starting Aids

Welding and Grinding

DX210WA Wheel Excavator Maintenance Safety

Fire Extinguisher and First-Aid Kit

Wheel Excavator Maintenance Safety DX210WA

Rollover Protective Structure (ROPS)

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

When working in mines, quarries or other work sites where there

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

Obey State and Local Over-the-Road

Loading and Unloading

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

Before Engine Starting

Make sure that the machine is equipped with a lighting system

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

Securely latch door. If you grip handrail inside door when

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

DX210WA Wheel Excavator Maintenance Safety

Your machine may be equipped with visual aids such as mirrors

Work Site Rules

Wheel Excavator Maintenance Safety DX210WA

Boost Starting or Charging Engine

DX210WA Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210WA

DX210WA Wheel Excavator Maintenance Safety

Do not operate attachments while traveling.