Doosan DX210W 5 Excavator Shop Manual 950106 01052 E 1

950106-01052 E
May 2015
EXCAVATOR
Shop
Manual
DX210W-5
Serial Number 1001 and Up
Shop Manual
DX210W-5 EXCAVATOR
DOOSAN and the DOOSAN logo are registered

trademarks of DOOSAN Corporation in the United
States and various other countries around the 950106-01052 E
world.
May 2015
Copyright
OperationDOOSAN 2015
and Maintenance Manual Copyright Doosan 2011
Pub.No. 950106-01052 E
DX210W-5
Product Label
Instructions
Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine
Pub. No. 950106-01052 E

1NOTICE
Date Contents Section No. Page
09/05/2015 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 1 Engine
5 Upper Structure 1 Cabin

2 Counterweight
3 Hydraulic Oil Tank
4 Fuel Tank
5 Main Pump
6 Drive Coupling (Main Pump)
7 Main Control Valve
8 Swing Device
9 Joystick Valve (Work Lever)
10 Gear Pump (Brake and Steering)
11 Brake System
12 Brake Filter
13 Brake Supply Valve
14 Brake Pedal Valve
15 Accelerator Pedal Valve
16 Accumulator (Brake and Pilot)
17 Steering System
18 Steering Valve
19 Priority Valve
20 Dozer Joystick Valve
21 Solenoid Valve (4 Functions)
22 Solenoid Valve (4 Functions)
23 Gear Pump (Rotating)
24 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
5 Two Pump
11 Schematic 1 Hydraulic Schematic/Electrical Schematic
Table of Contents
Page II
1Safety
Wheel Excavator
Maintenance
Safety
Edition 1
DX210W-5 Wheel Excavator Maintenance Safety

1-1-1
MEMO
Wheel Excavator Maintenance Safety DX210W-5

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..................1-1-54

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 Operation &
Maintenance Manual, 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 1
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.
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.
FG020947
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
immediately.
NOTE: The preceding instructions assume that conditions
are for standard operations, but it may be necessary FG018595
to add additional guards depending on operating Figure 18
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 Operation & Maintenance Manual, 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 Operation & Maintenance Manual, 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
HAOA190L
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.
Figure 32
This will disable all pilot control functions.
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
Operation & Maintenance Manual, to determine amount of protection cooling
system requires. Add coolant as required.
Hydraulic System Once a month, start engine and follow procedures in Operation & Maintenance
Manual, 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 Operation & Maintenance Manual, 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
IMPORTANT
When disconnecting or connecting connectors between
ECU and engine, or connector between ECU and the
machine, always disconnect the battery to prevent damage
to ECU.
If you do not follow this procedure, the ECU will be
damaged and/or the engine will not operate properly.
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.
• Disconnect the connector between ECU and machine, and
the connector between ECU and engine.
• 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.

1-1-47
Preparation for Electrical Welding On Body Structure
To prevent damage to ECU by electrical welding, observe the
following procedures: OFF ON
1. Turn battery disconnect switch to "OFF" position. OFF OFF
ON
ON
2. Disconnect the connector between ECU and machine, and
the connector between ECU and engine.
3. Proceed with welding.
4. After welding, connect the connector between ECU and
machine, and the connector between ECU and engine. EX1500481
5. Clean battery compartment. Figure 40

6. Turn battery disconnect switch to "ON" position.
7. Close battery compartment door.
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 41 WE1400011

1-1-48
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 42
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.

1-1-49
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 Operation &
Maintenance Manual.
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 43
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 44

1-1-50
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 Operation & Maintenance
Manual. 
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 45
– 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 Operation & Maintenance Manual, 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.

1-1-51
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 46
• 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.

1-1-52
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.

1-1-53
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 47
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 48
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.

1-1-54
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.

1-1-55
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 49
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.

1-1-56
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 50
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 51
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.

1-1-57
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 Operation & Maintenance Manual,
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
filter upon regular basis. To prevent fuel from being

1-1-58
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 Operation &

Maintenance Manual, 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.

1-1-59
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" and

"Check for Leaks in Fuel System", of Operation &
Maintenance Manual. Check for water content before filling
fuel tank. High temperatures and cooling off cause
condensation in storage drums.
4. Lubricate as specified in Operation & Maintenance
Manual, 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.

1-1-60
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 Operation & Maintenance
Manual. 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", in Operation &
Maintenance 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.

1-1-61
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 52
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.

1-1-62
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.

1-1-63
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 53
• 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.

1-1-64
Vibration Information
NOTE: The level of vibration is influenced by many different
parameters such as operator training, job site
organization, weather, material, environment,
machine type, machine and seat suspension system,
attachments, and condition of the machine.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standards:
ISO 2631/1, ISO 5349, and SAE J1166.
Vibration levels were given consideration in accordance with
uncertainty (K) determined to manufacturer.
Hand/Arm Vibration Level

The vibration total value to which the hand-arm system is
subjected, is less than 2.5 m/s2.
Whole Body Vibration Level

The highest root mean square value of weighted acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Guidelines for Use and Working Conditions of Earth-moving 

Machinery to Reduce Vibration Levels (ISO/TR 25398 Annex E)
Properly adjusting and maintaining machines, operating
machines smoothly, and maintaining the terrain conditions can
reduce whole-body vibrations. The following can help the users
of earth-moving machinery reduce whole-body vibration levels.
1. Use the right type and size of machine, equipment, and
attachments.
2. Maintain machines according to the manufacturer's
recommendations:
• Tire pressure;
• Brake and steering systems;
• Controls, hydraulic system and linkages.
3. Keep the terrain where the machine is working and
travelling in good condition:
• Remove any large rocks or obstacles;
• Fill any ditches and holes;
• Provide machines and schedule time to maintain
terrain conditions.
4. Use a seat in conformance with ISO 7096 and keep the
seat maintained and adjusted:
• Adjust the seat and suspension for the weight and
size of the operator;
• Inspect and maintain the seat suspension and
adjustment mechanisms.

1-1-65
5. Steer, brake, accelerate, shift gears, and move the
attachments smoothly.
6. Adjust the machine speed and travel path to minimize the
vibration level:
• Drive around obstacles and rough terrain conditions;
• Slow down when it is necessary to go over rough
terrain.
7. Minimize vibrations for long work cycle or long distance
travelling:
• Use machines equipped with suspension systems;
• Use lift arm suspensions on wheel loaders;
• If no suspension system is available, reduce speed to
prevent bouncing;
• Haul machines long distances between worksites.
8. Back pain associated with whole-body vibrations can be
caused by other risk factors. To minimize the risk of back
pain:
• Adjust the seat and controls to achieve good posture;
• Adjust the mirrors to minimize twisted posture;
• Provide breaks to reduce long periods of sitting;
• Avoid jumping down from the cab or access system;
• Minimize repeated handling and lifting of loads;
• Minimize any shocks and jolts during sports and
leisure activities.

1-1-66
1Specifications
Specifications
Edition 1
DX210W-5 Specifications
2-1-1
MEMO
Specifications DX210W-5
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..2-1-18
Performance Tests .......................................2-1-20
Purpose of Performance Tests................................ 2-1-20
Kinds of Tests.......................................................... 2-1-20
Performance Standards .......................................... 2-1-20
Precautions for Evaluation of Test Data.................. 2-1-20
Definition of "Performance Standard"...................... 2-1-20
Preparation for Performance Tests ..............2-1-21
The Machine............................................................ 2-1-21
Test Area................................................................. 2-1-21
Precautions ............................................................. 2-1-21
Make Precise Measurement.................................... 2-1-21
Operational Performance Standard Table ....2-1-22
Operational Performance Test .....................2-1-25
Hydraulic Cylinder Cycle Time ................................ 2-1-25
Driveshaft Revolution Speed................................... 2-1-27
Swing Speed ........................................................... 2-1-28
Swing Function Drift Check ..................................... 2-1-29
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 5
16 6
13
14
9 8 7
12
WE1401578
Figure 1
Reference Reference
Description Description
Number Number
1 Cabin 12 Rim
2 Boom Cylinder 13 Wheel
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
2
FR
ON
1 T
4
7
View A A WE1500001
Figure 2
Reference Reference
Number Number
1 Engine 6 SCR Catalyst
2 Radiator 7 SCR Muffler
3 Precleaner 8 Urea Tank
4 Air Cleaner 9 DEF (AdBlue) Filter
5 Main Pump
2-1-7
FR
ON
T
13
11
10 12 5
7
2
Figure 3 1
WE1500002
Reference Reference
Number Number
1 Battery 8 Engine Oil Filter
2 Fuel Tank 9 Pilot Filter
3 Fuel Cap 10 Fuel Filter
4 Hydraulic Oil Tank 11 Gear Pump (Rotating)
5 Air Breather 12 Gear Pump (Brake and Steering)
6 Return Filter Water Separator & Pre Fuel
13
7 Suction Filter Filter (Fuel Prefilter)
2-1-8
FR
ON
T
Engine
6
2
5
4
3
Figure 4 WE1400003
Reference Reference
Number Number
1 Main Control Valve Solenoid Valve
5 (Ram Lock, Inching,
2 Swing Device Pilot Cut-off, Breaker)
3 Swing Bearing Solenoid Valve
6 (Forward, Backward,
4 Center Joint Power Boost, Cruise)
2-1-9
OVERALL DIMENSIONS
One - Piece Boom
I A
E
M
D
H
G
F
L J K
B
WE1400337
Figure 5
5.6 m (18' 4") Boom

Dimension
2.75 m (9' 0") Arm 3.0 m (9' 10") Arm 2.4 m (7' 10") Arm
A Shipping Length 9,450 mm (31' 0") 9,455 mm (31' 0") 9,475 mm (31' 1")
B Shipping Width 2,530 mm (8' 4")
C Shipping Height (Boom) 3,075 mm (10' 1") 3,355 mm (11' 0") 3,140 mm (10' 4")
D Height Over Cabin 3,140 mm (10' 4")
E Counterweight Swing Clearance 2,755 mm (9' 0")
F Ground Clearance 335 mm (1' 1")
G Counterweight Clearance 1,255 mm (4' 1")
H Upper Structure Height 2,300 mm (7' 6")
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")
M Overall Height to the Guardrail 3,332 mm (10' 11")
2-1-10
Two - Piece Boom
I A
E
C
M
D
H
G
F
L J K
B
WE1400338
Figure 6
5.4 m (17' 9") Boom

Dimension
2.4 m (7' 10") Arm
A Shipping Length 9,225 mm (30' 3")
B Shipping Width 2,530 mm (8' 4")
C Shipping Height (Boom) 3,140 mm (10' 4")
D Height Over Cabin 3,140 mm (10' 4")
E Counterweight Swing Clearance 2,755 mm (9' 0")
F Ground Clearance 335 mm (1' 1")
G Counterweight Clearance 1,255 mm (4' 1")
H Upper Structure Height 2,300 mm (7' 6")
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")
M Overall Height to the Guardrail 3,332 mm (10' 11")
2-1-11
WORKING RANGE
One - Piece Boom
F
G
D
E
d
G.L
L
H J C
K 2,500 mm
A
WE1400340
Figure 7
2-1-12
Boom Type 5.6 m (18' 4")
DIM. Arm Type 2.75 m (9' 0") 3.0 m (9' 10") 2.4 m (7' 10")
Bucket Type (PCSA) 0.86 m3 (1.12 yd3) 0.86 m3 (1.12 yd3) 0.86 m3 (1.12 yd3)
A Max. Digging Reach 9,705 mm (31' 10") 9,980 mm (32' 9") 9,410 mm (30' 10")
B Max. Digging Reach (Ground) 9,505 mm (31' 2") 9,785 mm (32' 1") 9,200 mm (30' 2")
C Max. Digging Depth 5,905 mm (19' 4") 6,160 mm (20' 3") 5,555 mm (18' 3")
D Max. Loading Height 7,115 mm (23' 4") 7,350 mm (24' 1") 6,985 mm (22' 11")
E Min. Loading Height 2,840 mm (9' 4") 2,630 mm (8' 8") 3,230 mm (10' 7")
F Max. Digging Height 9,870 mm (32' 5") 10,140 mm (33' 3") 9,770 mm (32' 1")
G Max. Bucket Pin Height 8,570 mm (28' 1") 8,805 mm (28 11") 8,440 mm (27' 8")
H Max. Vertical Wall Depth 5,280 mm (17' 4") 5,715 mm (18' 9") 5,120 mm (16' 10")
I Max. Radius Vertical 6,365 mm (20' 11") 6,260 mm (20' 6") 6,090 mm (20' 0")
J Max. Depth to 2.5 m Line 5,715 mm (18' 9") 5,980 mm (19' 7") 5,345 mm (17' 6")
K Min Radius 2.5 m Line 3,180 mm (10' 5") 3,180 mm (10' 5") 3,180 mm (10' 5")
L Min. Digging Reach 850 mm (2' 9") 1,040 mm (3' 5") 1,690 mm (5' 7")
M Min Swing Radius 3,300 mm (10' 10") 3,445 mm (11' 4") 3,340 mm (10' 11")
d Bucket Angle 178° 177° 177°
2-1-13
Two - Piece Boom
F
G
E
d
G.L
H J C
K 2,500 mm
A
WE1400341
Figure 8
2-1-14
Boom Type 5.4 m (17' 9")
DIM. Arm Type 2.4 m (7' 10")
Bucket Type (PCSA) 0.86 m3 (1.12 yd3)
A Max. Digging Reach 9,385 mm (30' 9'')
B Max. Digging Reach (Ground) 9,175 mm (30' 1'')
C Max. Digging Depth 5,605 mm (18' 5'')
D Max. Loading Height 7,530 mm (24' 8')
E Min. Loading Height 3,310 mm (10' 10')
F Max. Digging Height 10,435 mm (34' 3'')
G Max. Bucket Pin Height 8,985 mm (29' 6'')
H Max. Vertical Wall Depth 4,830 mm (15' 10'')
I Max. Radius Vertical 5,060 mm (16' 7'')
J Max. Depth to 2.5 m Line 5,460 mm (17' 11'')
K Min. Radius 2.5 m Line 1,062 mm (3' 6'')
M Min Swing Radius 3,285 mm (10' 9'')
d Bucket Angle 177°
2-1-15
GENERAL SPECIFICATIONS
Shipping Weight 21,476 kg (47,346 lb)
Includes 10% fuel, 5,400 mm (17' 9"), 2,400 mm (7' 10") arm, 0.86 m3
(1.12 yd3) bucket and front & rear outrigger
Counterweight 4,000 kg (8,818 lb)
Upper Turntable 6,030 kg (13,294 lb)
Lower Turntable 
7,360 kg (16,226 lb)
(Include Swing Bearing)
Operating Weight 21,730 kg (47,906 lb) with full fuel tank and operator
Major Component Weights One-Piece Boom 5,600 mm (18' 4") 1,334 kg (2,941 lb)
Two-Piece Boom (Lower) 1,920 mm (6' 4") 500 kg (1,102 lb)
Two-Piece Boom (Upper) 3,840 mm (12' 7") 1,010 kg (2,227 lb)
Boom Cylinder 164 kg (362 lb) each
Standard Arm 3,000 mm (9' 10") 671 kg (1,479 lb)
2,750 mm (9' 0") 619 kg (1,365 lb)
Short Arm
2,400 mm (7' 10") 568 kg (1,252 lb)
Arm Cylinder 233 kg (514 lb)
Bucket 0.86 m3 696 kg (1,534 lb)
Bucket Cylinder 145 kg (320 lb)
Dozer 389 kg (858 lb)
Dozer Cylinder 52 kg (115 lb) each
Outrigger 1,224 kg (2,698 lb)
Outrigger Cylinder 113 kg (249 lb) each
Digging Forces (At Power Boost, ISO)
Bucket Cylinder 157.3 kN or 16,036 kg (35,353 lb) with 2,400 mm & 3,000 mm Arm
(One-Piece Boom)
157.1 kN or 16,022 kg (35,322 lb) with 2,750 mm Arm 
(One-Piece Boom)
157.3 kN or 16,036 kg (35,353 lb) with Two-Piece Boom
Arm Cylinder 110.1 kN or 11,228 kg (24,754 lb) with 2,750 mm (9' 0") Short Arm
105.5 kN or 10,758 kg (23,717 lb) with 3,000 mm (9' 10") Standard Arm
123.8 kN or 12,619 kg (27,820 lb) with 3,400 mm (7' 10") Short Arm
Fuel Tank Capacity 292 L (77.1 U.S. gal.)
Hydraulic System Capacity 290 L (76.6 U.S. gal.)
Hydraulic Reservoir Capacity 207 L (54.7 U.S. gal.)
Bucket Heaped Capacity Range SAE 0.51 ~ 1.28 m3 (0.67 ~ 1.67 yd3)
NOTE: Refer to the Load Weight, Bucket and Arm Length Compatibility
Table for information on which bucket sizes are approved for which arm
length and workload material weights.
2-1-16
Undercarriage
Ground Clearance 335 mm (1' 1")
Wheel Base 2,850 mm (9' 4")
Overall Width 2,530 mm (8' 4")
Dozer Blade Width 2,530 mm (8' 4")
Tire Size (Std. Double) 8 x 10.00 - 20 -14PR
Shipping Dimensions
Overall Shipping Length 9,225 mm (30' 3")
Overall Shipping Width 2,530 mm (8' 4")
Overall Shipping Height 3,140 mm (10' 4")
Transport Loading Ramp
15° angle
Allowable Slope 
When Transporting NOTE: Refer to Operation and Maintenance Manual for Recommended
Transportation Instructions.
2-1-17
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)
2-1-18
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)
2-1-19
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.
2-1-20
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 9
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.
2-1-21
OPERATIONAL PERFORMANCE STANDARD TABLE
Performance
Item Model Unit Measuring Conditions
Standard
Power Plus Mode rpm - 2,000 ±25
Travel Mode
Standard Mode rpm - 1,700 ±25
rpm SPC Off 1,700 ±25
Power Plus Mode
rpm SPC On 1,600 ±25
Power Mode
Standard Mode
Economy Mode
Lifting Mode rpm - 1,500 ±25
No Load Auto Warm Up On
Condition
Low Idle • Coolant Temperature 800 ±20
(Auto Warm Up Off) Below 15°C
Auto Warm Up Off
Condition
rpm
• Coolant Temperature
Low Idle
Engine  Above 30°C
(Auto Warm Up On)
Speed • 10 minutes Spent After
• It may occur for a little 1,200 ±20
Startup
while after the engine
• The Dial on the rpm
starts up in winter.
Gauge Moved
Load 1 Pump Relief rpm above 1,680
(P+ SPC Off) 2 Pump Relief rpm above 1,680
Power Plus Mode rpm above 1,680
Power Mode rpm above 1,580
Dial Max. SPC On
Revolution at  Standard Mode rpm above 1,480
Boom Up  Economy Mode rpm above 1,380
or Arm Dump Lifting Mode rpm Adjust Dial, SPC On above 1,280
Should Not
Low rpm Dial Min.
Stop Engine
Above Ambient Temp.
rpm 800 ±20
10°C (50°F)
Auto Idle
Below Ambient Temp.
rpm 1,100 ±20
10°C (50°F)
Fan Revolution
High Idle rpm *Standard 1,800 ±50
Speed
2-1-22
Performance
Standard
Power Mode mA Hill Up- Main Pump 230 ±30
Travel
Standard Mode mA Above 290 bar 230 ±30
Power+ Mode mA 250 ±30
EPOS Power Mode mA SPC Off 275 ±30
(Pump Minimum Value at Arm
Standard Mode mA Crowd 275 ±30
Proportional
Current) Work Economy Mode mA 300 ±30
Lifting Mode mA 230 ±30
Auto Idle mA Idle 650 ±30
Low Idle mA 700 ±30
Relief bar 350 +10
Front
Relief Power Up bar 370 +10
Relief (at Motor) bar 270 +10
Swing Motor
Relief (at Pump) bar 285 +10
Pressure 
Travel Motor At Motor bar 370 +10
Set
Max. Flow lpm 400 ±10
Relief (in Front of Valve) bar 350 ±25
Option
Relief (at Pump) bar 352 ±25
Proportional Current mA 140 +30
Up sec 3 ±0.3
Boom
Down sec 2.9 ±0.3
Crowd sec 3.3 ±0.3
Arm
Dump sec 2.7 ±0.3
Crowd sec 3.5 ±0.4
Bucket
Front Dump sec 2.5 ±0.3
Speed Up sec 5.5 ±0.6
Art Boom
Down sec 3.8 ±0.4
Up sec 1.5 ±0.2
Dozer
Down sec 1.5 ±0.2
Up sec 4.0 ±0.4
Outrigger
Down sec 3.9 ±0.4
Swing Single 3 *Standard, Swing Single
Swing sec 18.4 ±1.8
Revolution 3 Revolution
Swing Speed After 360° Swing, Empty
Swing 610 (50°)
After 360° Swing mm Bucket,
Coasting ±20%
Bearing Outer Race
Inching rpm 302 ±30
Jack-up 1st Speed rpm 755 ±30
Travel Speed
Speed 2nd Speed rpm 2,950 ±70
3rd (20 km/hr) rpm 1,650 ±50
2-1-23
Performance
Standard
Weight Standard ton 1.3
Max. Reach 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 Lock 20
Cylinder V/V is applied
Front Load Travel Posture,
Bucket Crowd Posture,
Arm Dump mm/5min Weight Bucket 20
(1.5 times bucket
capacity)
Dozer mm/5min below 5
Outrigger mm/5min below 5
• Standard Condition: P Plus Mode, SPC On, Engine Dial Max. A/I Off, Digging Mode, Oil 50 ±10°C, Coolant
80 +10°C
2-1-24
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 10
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.
2-1-25
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.
2-1-26
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 13.
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 13
3. Prepare a tachometer to measure driveshaft revolution.

(Figure 14)
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 14
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 15
2-1-27
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 16
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 -22.
2-1-28
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 17
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 18
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 19
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 -22.
2-1-29
2-1-30
1General Maintenance
General
Maintenance
Instructions
Edition 1
DX210W-5 General Maintenance Instructions

3-1-1
MEMO
General Maintenance Instructions DX210W-5

3-1-2
Table of Contents
General Maintenance Instructions

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
DX210W-5 Standard Torques

3-2-1
MEMO
Standard Torques DX210W-5

3-2-2
Table of Contents
Standard Torques
Torque Values for Standard Metric Fasteners...3-2-6
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
Engine
Edition 1
Engine DX210W-5
4-1-1
MEMO
Engine DX210W-5
4-1-2
Table of Contents
Engine
Overview.........................................................4-1-6
General Information ........................................4-1-7
General Description................................................... 4-1-7
Engine Maintenance................................................ 4-1-11
Inspection and Repair of the Engine ....................... 4-1-14
Engine Identification .....................................4-1-16
Engine Data Plate ................................................... 4-1-16
Engine Specification .....................................4-1-18
Engine Performance Curves ........................4-1-19
Special Tools ................................................4-1-20
Tightening Torques.......................................4-1-24
Major Parts Tightening Torque................................ 4-1-24
Tightening Torque for General Bolts ....................... 4-1-26
Tightening Torque of Plug Screw ............................ 4-1-27
Hollow Screw (4-Hole) Tightening Torque .............. 4-1-27
Engine Disassembly .....................................4-1-28
Engine Disassembly................................................ 4-1-28
Engine Assembly ..........................................4-1-44
Engine Assembly..................................................... 4-1-44
Cylinder ........................................................4-1-67
General Information................................................. 4-1-67
Cylinder Head.......................................................... 4-1-67
Cylinder Block ......................................................... 4-1-72
Valve Mechanism .................................................... 4-1-74
Actuating System..........................................4-1-86
Camshaft ................................................................. 4-1-86
Piston ...................................................................... 4-1-88
Connecting Rod....................................................... 4-1-92
Crankshaft ............................................................... 4-1-94
Timing Gear............................................................. 4-1-99
DX210W-5 Engine
4-1-3
Lubrication system......................................4-1-100
General Information............................................... 4-1-100
Oil Pan................................................................... 4-1-104
Oil Pump................................................................ 4-1-106
Oil Filter ................................................................. 4-1-108
Exhaust System..........................................4-1-111
Turbocharger......................................................... 4-1-111
EGR (Exhaust Gas Recirculation) System ............ 4-1-123
DNOx System........................................................ 4-1-130
Cooling System ..........................................4-1-141
General information............................................... 4-1-141
Thermostat ............................................................ 4-1-142
Cooling fan ............................................................ 4-1-145
Fuel System................................................4-1-147
General Information............................................... 4-1-147
Fuel High-pressure System Components ............. 4-1-148
Injector................................................................... 4-1-149
Common Rail......................................................... 4-1-153
Fuel Injection Pump............................................... 4-1-158
Electrical System ........................................4-1-161
Electrical Parts ...................................................... 4-1-161
Switches and Sensors........................................... 4-1-162
ECU (Electronic Control Unit)................................ 4-1-166
Starter.................................................................... 4-1-168
Exhaust Gas Reduction......................................... 4-1-170
Circuit Diagram...................................................... 4-1-174
Engine DX210W-5
4-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX210W-5 Engine
4-1-5
OVERVIEW
ONT
FR
EX1403491
Figure 1
Engine DX210W-5
4-1-6
GENERAL INFORMATION
General Description
This manual provides the most efficient methods for engine
maintenance as well as quick, efficient methods to determine
the cause of engine faults to ensure that any actions taken by
professionally certified maintenance technicians are done in the
most efficient and efficient way possible. If maintenance is
performed by unskilled technicians, or maintenance without the
specified tools and facilities, serious bodily injury or critical faults
in engine performance may occur. Regular inspection and
maintenance are required to maintain long-term optimal engine
conditions and best performance. In the event that a part must
be replaced, only genuine parts as defined by the parts the list
(Parts Book) should be used. Doosan shall not be held liable for
any critical damage or faults which may be caused by the use of
unauthorized or remanufactured parts. The maintenance
methods stated in this Operation and Maintenance Manual are
the most efficient and safest work procedures. Some work
procedures require special tools.
For questions about genuine parts and special tools, please
contact us.
This manual includes 'Danger', 'Warning', and 'Caution' in order
to reduce possible injuries and engine faults which may occur
while performing maintenance. If workers do not follow the
instructions, critical faults in engine performance and operation
or serious bodily injury may occurred. 'Danger', 'Warning', and
'Caution' instructions must be followed. However, we inform you
that it is not possible to describe all possible and unexpected
dangers which may arise while performing engine maintenance.
Cautions for Starting the Engine

1. Before starting the engine, please read this manual
carefully and fully understand 'Danger', 'Warning', and
'Caution'. If you cannot fully understand it or have any
question, please contact us.
2. For safety reasons, attach "Warning" signs around engines
in operation to keep people other than workers from
accessing the engines. Let engine operators know that
they are responsible for the safety of the engine room.
3. Only authorized people may start and operate engines.
Unauthorized people should not be allowed to handle
engines.
4. Do not access running or rotating parts while the engine is
in operation.
5. Be careful not to touch or contact the engine during
operation since it becomes hot during operation.
6. Exhaust gas is poisonous. Fully ventilate before starting
engine. If the space is airtight, ensure that it is well ventilated.
DX210W-5 Engine
4-1-7
Cautions for Inspection and Repair
1. Inspection and repair of engine should be performed only
when the engine is stopped. Otherwise, burns or safety
accidents may occur, so do not perform inspection or
repair while the engine is running.
2. If it is absolutely necessary to perform inspection or repair
on the operating engine, do not get close to the rotating
parts.
DANGER
AVOID DEATH
When accessories such as necklaces, rings, watches,
or gloves become stuck in rotating parts while the
engine is running, serious bodily injury may occur.
WARNING
Do not exchange or disassemble a pipe or horse (from
the engine fuel circuit, engine oil circuit, coolant
circuit, or compressed air circuit) while the engine is
running. The leaked liquid may cause bodily injuries.
3. Use an engine oil drain container that is large enough to

prevent the overflow of engine oil while draining engine oil.
4. Open the engine coolant cap after fully cooling the engine
to exchange or replenish coolant.
WARNING
If the coolant cap is opened while the engine is still hot,
hot water will spurt out and may cause burns. Open the
engine coolant cap after fully cooling the engine.
5. Fuel is highly flammable. Smoking or use of fire around an

engine may cause fire.
WARNING
Only refuel when the engine is stopped.
Engine DX210W-5
4-1-8
6. Mark and separately manage the containers for storing
coolant from beverage containers for avoiding confusion.
See a doctor immediately in case of drinking coolant.
7. Follow the instructions provided by the battery
manufacturer when checking or handling batteries.
WARNING
Battery fluid is corrosive and dangerous because of its
explosiveness and toxicity. Therefore, it should only
be handled by a skilled technician who specializes in
battery fluid.
8. Only certified professional technicians should repair and

maintain engines.
9. Only appropriate tools should be used. If the jaws of a
wrench are worn out, the wrench might slip during use,
causing safety accidents.
10. Do not allow other persons to stay or pass under an engine
when lifting the engine with a crane. Before lifting the
engine, ensure that there is no one around the engine and
reserve enough safety space.
11. Before inspecting or replacing the electrical apparatus,
disconnect the battery ground wire first. Connect the
battery ground wire after completing all required work for
checking or replacing the electrical apparatus in order to
prevent a short circuit.
12. Before performing electric welding works, turn off engine,
block the power supply to the engine, and remove the wire
harness connector connected to the engine control unit
(ECU).
13. Do not give any electric or mechanical shocks or perform
welding works on the electrical apparatus or the ECU.
General Repair
1. Wait until the engine is properly cooled down before starting
work, since you may get burned by the heated engine.
Before performing fuel line work, check the common rail
pressure and engine temperature by using the failure
diagnosis device.
2. Disconnect the battery ground wire from to prevent
damage of wires and sensors caused by a short circuit.
3. Engine oil and coolant may damage paint and should be
stored in a separate container and marked for safe
management.
4. Store the disassembled parts in a specified space to avoid
damage or pollution.
DX210W-5 Engine
4-1-9
5. Use specified and special tools for efficient and safe repair.
6. If parts need to be replaced, use only genuine parts for
replacement. Using unauthorized or remanufactured parts
may cause critical damage and faults in engine
performance.
7. Replace parts such as cotter pins, gaskets, O-rings, seal
rings, oil seals, and washers with new ones during repairs.
Reuse of parts may be the cause of engine faults and
engine may not operate properly.
8. Group and store disassembled parts in disassembling
order. The strength, shape, and screw torque of bolts and
nuts are different according to their assembly position.
Please divide and store them accordingly to these
characteristics.
9. Clean disassembled parts to remove foreign substances
before inspecting or reassembling parts. Use compressed
air to clean the oil holes or holes.
10. Thinly spread oil or grease on rotating parts or parts
requiring lubrication, before assembling them.
11. If required, use a specified adhesive to assemble gaskets
to prevent water or oil from leaking.
12. Assemble bolts and nuts with the specified tightening
torque.
13. After completing repairs, conduct a final inspection and
perform a test operation to check if all works have been
successfully completed.
Other Safety Instructions and Environmental Pollution

Observe the following instructions to protect workers from
danger and to prevent the environmental pollution while
performing engine repairs.
1. Good ventilation and low humidity should be maintained in
the work space.
2. The workspace should be clean, in good order, and no
flammables are allowed in the workshop.
3. Smoking is strictly forbidden in the workshop.
4. Workers should wear working clothes, protective goggles,
and safety shoes.
5. Workers are not allowed to wear accessories such as
necklaces, rings, watches, and earrings.
6. Start the engine in a well-ventilated space and fully
ventilate the space before starting engine to prevent
carbon monoxide poisoning.
7. Wait until the engine is properly cooled down before
starting work, since you may get burned by the heated
engine.
Engine DX210W-5
4-1-10
8. Do Not work on rotating or running parts once the engine
has been started.
9. Discard oil according to the regulations set forth by the
relevant authorities.
10. If engine oil or fuel leaks on the floor or is improperly
discharged, serious environmental pollution of sea, river or
underground water may occur.
11. Discard the undiluted anticorrosive agent, antifreeze, filter
elements, and cartridges as special wastes.
12. Discard coolant and special waste according to the
regulations of the appropriate authorities.
WARNING
Failure to observe the regulations of the relevant
authorities violates environmental pollution
regulations and may be subject to legal penalties.
Use of Genuine Parts

An engine consists of many parts which are mechanically
harmonized. To prevent engine faults in advance and use
engines with best performance for a long period, maintenance
and replacement of expendable parts should be conducted
regularly.
Use of genuine parts is recommended. Using unauthorized or
remanufactured parts may cause critical damage and faults to
engine for which Doosan shall not be held liable.
Engine Maintenance
Prevention of Damage and Abrasion

Using an engine for any purposes other than the designed
purpose may cause critical faults in engine performance for
which Doosan shall not be held liable. For details concerning the
usage and purpose of the engine, please direct questions to our
Sales Team. Do not adjust, convert, or change the ECU without
our authorization.
If a problem is found in an engine, figure out and solve the cause
to prevent the critical faults in advance.
Use of genuine parts is recommended. Using unauthorized or
remanufactured parts may cause critical damage and faults to
engine for which Doosan shall not be held liable.
Consider the following while managing engines.
1. Use clean, specified, and qualified fuel only. Use fuel
recommended in this Operation and Maintenance Manual.
DX210W-5 Engine
4-1-11
CAUTION
AVOID INJURY
Using inappropriate or unspecified fuel may cause
critical damage and faults in engine performance.
2. Do not operate an engine without lubrication oil or coolant.

Use only the products (engine oil, cooling water,
anticorrosive agent, and etc) recommended by Doosan.
3. Always keep surroundings of the engine clean.
4. Use fuel recommended in this Operation and Maintenance
manual.
5. Conduct inspections and exchanges regularly according to
the regular inspection table.
6. If the engine is overheated, do not stop it immediately, but
operate it at idle status for five minutes or more to lower the
engine temperature to the proper level.
WARNING
If the radiator cap is opened while the engine is still
hot, hot water will spurt out and may cause burns.
7. Check the engine oil level on a flat surface. Do not exceed

the maximum on the oil level gauge.
CAUTION
AVOID INJURY
Immediately replenish engine oil when the engine oil
level is below the lower limit of the engine oil gauge.
8. If there are gauges for battery, oil pressure and coolant

and temperature, check if they indicate a normal status.
9. Do not operate engine without coolant.
CAUTION
AVOID INJURY
Always use coolant mixed with antifreeze. If coolant
without antifreeze is used, the coolant may freeze
causing the coolant passage in the cylinder block to
freeze and damaging the engine.
Engine DX210W-5
4-1-12
Prevention of Pollution
Consider the following to manage engine without causing
environmental pollution.
1. Discharge oil and coolant using collection containers.
2. Discard oil and coolant according to the regulations of the
relevant authorities.
3. Be careful not to let discharged oil and cooling water flow
into the ground or the sewer. Otherwise, serious pollution
of the drinking water source may occur.
4. Classify the oil, filters, and filter cartridges as
environmental pollution wastes and discards them
according to regulations.
5. Classify the antifreeze, cooling water, and anticorrosive
agent as hazardous wastes and discards them according
to the regulations.
Handling of Engine Oil

Prolonged and repeated contact of skin with engine oil may
cause skin to dry out and contract, causing dermatitis. Engine oil
includes substances toxic to the human body. Handle engine oil
by observing the following safety rules:
1. Do not expose skin to new engine oil for a long time.
2. Always wear working clothes and gloves.
3. If skin comes in contact with engine oil, immediately wipe it
off with water, soap or hand cleaners.
4. Do not clean skin with gasoline, fuel, thinner, or solvent.
5. Apply a skin protective cream after cleaning from oil.
6. Do not put oil-stained gloves or cloth in ones pocket.
WARNING
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil
into the ground, sewers, drains, rivers, or the sea will
cause serious environmental pollution. Violation of
regulations regarding discard of engine oil without
observing the handling regulations, will be punished.
DX210W-5 Engine
4-1-13
Inspection and Repair of the Engine
Checking Engine Parts after Prolonged Operation

Wear, corrosion, or degradation of engine elements and
assemblies may occur, causing lowered performance of engine
parts. To maintain high engine performance, check the engine
after prolonged operation to enhance the durability of the engine.
Unexpected faults may occur in some weak engine parts after
normal operation of the engine, when operation time is
prolonged. In this case, it is difficult to maintain high engine
performance by simply repairing some parts. We recommend
the entire part be replaced or repaired in order to find out the
causes more accurately and maintain high engine performance.
To prevent engine failure in advance and use the engine safely for
a long period, perform periodic replacements and inspections.
It is recommended to perform engine adjustments and
preventive inspections during spring after the engine was
exposed to winter or cold weather. This allows economic, long-
term use of the engine without faults. As the following parts
affect the engine output and performance, these parts should be
regularly checked and inspected.
1. Parts affecting intake and exhaust
• Air filter
• Intercooler
• Turbocharger, muffler
• EGR cooler and valve
• Other parts
2. Parts affecting lubrication and cooling
• Air filter
• Oil filter
• Antifreeze
• Other parts
Inspection and Repair of Turbocharger

As performance of supercharger significantly affects the engine
performance, regular inspections and repairs should be
performed and inspection and maintenance regulations should
be observed.
Intake Unit
Be careful when handling the air filter in the intake unit. If oil
level of the wet air filter is below the specified level, filtering
performance is degraded. On the other hand, if the oil level is
higher, oil may flow into the case, and it may become polluted. In
regards to the dry air filter, intake resistance should be small to
ensure the smooth intake of air.
Engine DX210W-5
4-1-14
Exhaust Unit
If exhaust emission is leaked from the part connecting the
exhaust tube and the turbocharger, the supercharger efficiency
is lowered, causing degraded engine output and, if serious,
burning of related parts. As parts related to exhaust and
turbocharger are used at high temperature, be careful not to mix
the bolts and nuts with other parts when performing repair.
Lubrication System
Inspection and replacement of the lubrication system should be
performed according to the replacement schedule of oil and oil
filter. Overheated engine oil can affect not only the engine itself,
but also the engine performance.
DX210W-5 Engine
4-1-15
ENGINE IDENTIFICATION
Engine Data Plate
EX1403503
Figure 2
2 3 4
EX1403505
Figure 3
1. Engine Numbering
This decal indicates the model name and suffixes that ÿÿÿÿ ÿ ÿÿÿÿÿÿÿÿ
contain the engine’s information. (A) (B) (C) (D)
See Figure 2 for information on each set of numbers. A. Sales Model Name (4 ~ 7 digits)
B. Production Year (1digit)
C. Serial Number (5 digits)
D. Engine Suffix(2 digits)
ex) DL06P 418423E1
EX1403504
Figure 4
Engine DX210W-5
4-1-16
2. Quality Inspection Sticker
This decal displays a barcode for checking the engine’s
basic information and quality data. XXXX D
A
Reference B
Description
Number C
A Model
E
B Serial No.
C Option EX1403506
D Inspector Figure 5
E Barcode
3. Emission Label
This decal shows information on the region’s emission
regulations.
• NA
Reference
Description
Number
A Engine Displacement
B Engine Family
C Emission Control Device
EX1403507
D Useful Life Figure 6 NA
E Date of Manufacture
• EU
Reference
Description
Number
A Engine Displacement
B Engine Type
C Emission Control Device
D Useful Life
E Date of Manufacture
EX1403508
Figure 7 EU
4. Engine Oil
This decal specifies oil specification applicable to the
engine.
Figure 8 EX1403509
DX210W-5 Engine
4-1-17
ENGINE SPECIFICATION
Items Specification
4-Cycle Water Cooled, Waste Gate
Type Turbocharge, Air to Air Intercooled Direct
Injection
Engine Emission US EPA Tier 4 Final (EU Stage IV)
Model DL 06P
Injection System Extra High-pressure Fuel Injection System
Rated Net Power 189 HP (192 PS) @ 1,900 rpm (SAE J1995)
Intake Valve 0.3 mm
Valve Clearance
Exhaust valve 0.4 mm
Number of Cylinders and Configuration 6, Straight
Rotating Direction (from Flywheel) Counterclockwise
Max. Permitted 6 bar (6.1 kg/cm2, 87 psi)
Oil Pressure
Min. Permitted at Idling Speed 1.5 bar (1.5 kg/cm2, 21.7 psi)
Using Lubrication Oil API CJ-4 or Higher
Oil Filter Paper Filter
Interval Between Oil Changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 100 mm
Piston Stroke 125 mm
Displacement 5,890 cc
Compression Ratio 17.4:1
Low Idle Speed 800 ±25 rpm
Max. Full Load Speed 2,000 ±50 rpm
Weight, without Coolant and Oil 644 kg
Volume,
13,000 cc
Excluding Radiator
Coolant Temperature 90 ~ 95°C
Cooling System
Number of Thermostats 1
Thermostat,
83°C
Opening Temperature
Type 1-pin, 24 V, DC
Starter Motor
1-pin, 24 V, 6 kW
Electrical System (Standard Equipment)
Alternator
1-pin, 24 V, 80 A
(Standard Equipment)
Engine DX210W-5
4-1-18
ENGINE PERFORMANCE CURVES
80
70
Torque (kg.m)
60
50
180 40
160
Power Output (ps)
140
120
100
Fuel Consumption (g/ps.h)

170
160
150
800 1000 1200 1400 1600 1800 2000
Revolution (rpm)
Figure 9 WE1500435
Performance Standard KS R 1004

Power (Max. Rated) 189 HP (192 PS, 141 kW)/1,900 rpm
Max. Torque 804 N.m (82 kg.m, 593 ft lb)/1,400 rpm
Fuel Consumption (Max. Rated) 160 g/ps.hr
NOTE: DEF consumption is approximately 5% of fuel

consumption.
DX210W-5 Engine
4-1-19
SPECIAL TOOLS
Number Designation Picture Tool Board
Oil Seal Installation Jig

EF.121-299
(Front)
EX1403581
Oil Seal Installation Jig

EF.121-300
(Rear)
EX1403581
EF.123-065 Valve Spring Compressor
EX1403582
Cylinder Liner
EF.123-365A
Disassembly Tool
EX1403583
Piston Inserting Tool

EF.121-250
(Only for DL06 Engine)
EX1403584
Engine DX210W-5
4-1-20
Piston Inserting Tool

EF.120-208
(for all Engine Models)
EX1403585
Valve Stem Seal

EF.121-250 Inserting Tool
(for all Engine Models)
EX1403586
Camshaft Hole Cover

EF.121-181
Punch
EX1403587
Step Idle Gear Pin

EF.121-252
Installation Jig
EX1403588
60.99901-0027 Feeler Gauge
EX1403589
DX210W-5 Engine
4-1-21
EF.121-260 Wear Ring Punch (Rear)
EX1403590
65.98801-0001 Filter Wrench
EX1403591
T7610001E Snap Ring Pliers
EX1403592
Crankshaft Gear
EF.121-259
Inserting Jig
EX1403593
T7621010E Piston Ring Pliers
EX1403732
Engine DX210W-5
4-1-22
860104-01045 Diagnostic Device
EX1403595
UVIM (CAN Module)

860104-01046
(for Diagnostic Device)
EX1403597
14-pin Connector
860104-01047
EX1403596
USB
860104-01048
EX1403598
DX210W-5 Engine
4-1-23
TIGHTENING TORQUES
Major Parts Tightening Torque

The specifications in the tables below show the major parts
tightening torque for screws, nuts and unions. The values are to
be used unless other values are specified in the inspection
information. Always check whether there are special tightening
torques given in the descriptions for the respective areas in the
inspection information before using the general values for
normal and special tightening torques respectively.
The following conditions apply:
• A tolerance of ±15 % applies to all values unless otherwise
specified.
• All contact surfaces are to be clean and free of paint.
• Bolts and nuts are normally not lubricated regardless of
surface treatment. All exceptions are specified in the
inspection information.
Size Tightening Torques

Major Parts
(Diameter x Pitch) N.m kg.m ft lb
Cylinder Block Bearing Cap Bolt M16 x 2.0 294 ±20 30 ±2 217 ±14
Oil Spray Nozzle M10 x 1.25 20.6 + 4.9 2.1 + 0.5 15.2 + 3.6
Flywheel Housing Mounting Bolt M12 x 1.5 109.8 + 9.8 11.2 + 1.0 81 + 7.2
Crank Pulley Mounting Bolt M14 x 1.5 196 + 2 20 + 0.2 144.7 + 1.4
Shock Absorber M10 x 1.5 60.8 + 4.9 6.2 + 0.5 44.8 + 3.6
Flywheel Mounting Bolt M14 x 1.5 196 + 20 20 + 2.0 144.7 + 14
Connecting Rod Cap Bolt M12 x 1.5 95.6 + 2.45 9.75 + 0.25 70.5 + 1.8
49 + 90° + 5 + 90° + 36.2 + 90° +
Cylinder Head Bolt M13 x 1.5
90° + 90° 90° + 90° 90° + 90°
Cylinder Head Cover Bolt M8 21.6 + 4.9 2.2 + 0.5 15.9 + 3.6
Injector Cable Mounting Nut M4 1.47 + 0.1 0.15 + 0.01 1.08 + 0.07
Rocker Arm Bracket Mounting Bolt M8 x 1.25 36.3 + 4.9 3.7 + 0.5 26.8 + 3.6
Rocker Arm Adjusting Nut M10 x 1.0 49 + 4.9 5.0 + 0.5 36.2 + 3.6
Oil Pump Cover M8 21.6 + 4.9 2.2 + 0.5 15.9 + 3.6
Oil Pump Mounting Bolt M10 x 1.5 43 + 4.9 4.4 + 0.5 31.8 + 3.6
Oil Cooler Mounting Bolt M8 21.6 + 4.9 2.2 + 0.5 15.9 + 3.6
Oil Pan Mounting Bolt M8 21.6 + 4.9 2.2 + 0.5 15.9 + 3.6
Oil Drain Plug M30 x 1.5 98 + 9.8 10 + 1.0 72.3 + 7.2
Exhaust Manifold Mounting Bolt M8 49 + 4.9 5.0 + 0.5 36.2 + 3.6
Intake Manifold Mounting Bolt M10 x 1.5 43 + 4.9 4.4 + 0.5 31.8 + 3.6
Start Motor M12 x 1.5 78.5 + 9.8 8.0 + 1.0 57.6 + 7.2
Alternator Bracket Mounting Bolt M12 x 1.5 75.5 + 4.9 7.7 + 0.5 55.7 + 3.6
Engine DX210W-5
4-1-24
Size Tightening Torques
Major Parts
(Diameter x Pitch) N.m kg.m ft lb
21.6 2.2 15.9
Coolant Temperature Sensor M12 x 1.5
(Max. 24.5) (Max. 2.5) (Max. 18.1)
Engine Mounting Bracket M10 x 1.5 60.8 + 4.9 6.2 + 0.5 44.8 + 3.6
Fuel High-pressure Pump Gear Nut
M18 x 1.5 107.9 ±4.9 11 ±0.5 79.6 ±3.6
(CP Pump)
Fuel Injector Mounting Bracket Bolt M8 30.4 3.1 22.4
Fuel High-pressure Pump Mounting Bolt
M8 43.1 + 4.9 4.4 + 0.5 31.8 + 3.6
(Cylinder Block)
Fuel High-pressure Connector Nut M22 x 1.5 49 + 4.9 5 + 0.5 36.2 + 3.6
Common Rail Mounting Bolt M8 21.6 + 4.9 2.2 + 0.5 15.9 + 3.6
Fuel High-pressure Pipe - High-pressure
M14 x 1.5 27.5 + 4.9 2.8 + 0.5 20.3 + 3.6
Fuel Connector
Fuel High-pressure Pipe - Common Rail M14 x 1.5 24.5 + 4.9 2.5 + 0.5 18.1 + 3.6
Fuel High-pressure Pipe - Fuel High-
M14 x 1.5 20.6 + 4.9 2.1 + 0.5 15.2 + 3.6
pressure Pump
Fuel Filter Mounting Bolt M10 43.1 + 4.9 4.4 + 0.5 31.8 + 3.6
DX210W-5 Engine
4-1-25
Tightening Torque for General Bolts
Keep the following torque values for bolts not specified in the
Tightening Torque for Major Parts table.
Hardness
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Dia. x Pitch (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
(mm) Elastic Limit (kg/mm2)
20 24 32 30 40 36 46 54 64 90 106
Tightening Torque (kg.m)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5
(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
(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
(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
(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
(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
(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
(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 1.5
(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
(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
(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
(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
(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
(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
(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 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
NOTE: The standard torque values specified above are based on 70% of a bolt's elastic limit.
The tensile force is calculated by multiplying the tensile strength by the cross-sectional area of a
screw. A special screw should be tightened to about 85% of the standard torque. For example, a screw
coated with MoS2 should be tightened to about 60% of the standard torque.
Engine DX210W-5
4-1-26
Tightening Torque of Plug Screw
M10 M12 M14 M16 M18 M22 M24 M26 M30
5.0 5.0 8.0 8.0 10.0 10.0 12.0 12.0 15.0
Hollow Screw (4-Hole) Tightening Torque

M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
DX210W-5 Engine
4-1-27
ENGINE DISASSEMBLY
Engine Disassembly
CAUTION
AVOID INJURY
• Prepare the necessary tools and genuine parts before
engine disassembly.
• Prepare a shelf to keep removed parts.
• Keep the working area well lighted and clean.
• Keep your hands clean at all times during service.
• Keep parts removed from the engine in the removal
order.
• Make sure that removed parts are not mixed and do
not touch each other.
Disassemble the engine according to the following procedure:

1. Drain coolant.
A. Check that the engine and radiator is sufficiently
cooled down.
B. Place a container in front of the coolant drain plug.
C. Remove the radiator cap.
D. Open the drain valve on the bottom of the radiator to
drain coolant.
E. Remove the coolant drain plugs from the cylinder
block and oil cooler.
F. Drain coolant into the prepared container.
Figure 10 EX1404285
G. After draining coolant, install the drain plug.
DANGER
AVOID DEATH
• Never open the radiator cap while the engine is hot.
If opening the radiator cap while the engine is still
hot, hot coolant may spurt, resulting in a severe
burn. Open the radiator cap after confirming that
the engine is sufficiently cooled down.
• Put a label on the coolant container not to get EX1404306
mixed with other containers. If you swallow coolant, Figure 11
seek professional medical help immediately.
Engine DX210W-5
4-1-28
WARNING
Used coolant should be discarded according to the
local regulations. Never discard used engine oil to the
ground, ditch, sewer, river, sea, etc. Such action can
pollute the environment. Discarding used engine oil
improperly can result in punishment due to violation of
the corresponding regulation.
CAUTION
AVOID INJURY
When changing coolant, make sure that it is not left on
any belt or electric part.
2. Separate the dipstick.

A. Pull out the dipstick.
3. Drain engine oil.
A. Place a container under the engine to collect drained
engine oil.
B. Remove the drain plug from the oil pan and drain
engine oil into the prepared container.
C. Remove the oil filler cap.
D. Remove the engine oil filter.
E. After draining engine oil, install the engine oil filter
Drain Valve EX1403623
and drain plug.
Figure 12
WARNING
Used oil should be discarded according to the local
regulations. Never discard used engine oil to the
ground, ditch, sewer, river, sea, etc. Such action can
pollute the environment. Discarding used engine oil
improperly can result in punishment due to violation of
the corresponding regulation.
DX210W-5 Engine
4-1-29
4. Remove the intercooler.
A. Remove all the hoses and air pipes from the Hot Air by
Turbo Charger
intercooler.
Compressor
B. Unscrew the intercooler mounting bolts to remove the Cooled Air to
intercooler. Intake Stake
Air Flow by
Cooling Fan
EX1404312
Figure 13
5. Remove the cooling fan.

A. Remove the fan guide and bracket.
B. Unscrew the flange mounting bolt to remove the
flange and cooling fan.
Electronic
Clutch
Cooling Fan
EX1403625
Figure 14
6. Remove the belt.

A. Unscrew the tension adjusting bolts and mounting
bolts of the A/C compressor, air compressor and
alternator.
B. Remove the belt.
EX1403626
Figure 15
7. Remove the engine from the machine.

8. Disconnect the cables and harnesses of the engine from
each sensor.
9. Remove the alternator and A/C compressor.
Aircon Compressor
A. Unscrew the mounting bolt to remove the alternator.
Alternator
B. Unscrew the idle puller mounting bolt to remove the
A/C compressor.
EX1403627
Figure 16
Engine DX210W-5
4-1-30
10. Remove the breather.
A. Unscrew the mounting clamp screw to disconnect the
rubber hose.
B. Remove the breather valve assembly.
EX1403628
Figure 17
11. Disconnect the air pipe and remove the air heater.
A. Unscrew the mounting bolt to disconnect the air pipe
and remove the air heater.
CAUTION
AVOID INJURY
Never let foreign materials enter the turbocharger.
EX1403629
Figure 18
12. Remove the fuel filter.

A. Unscrew the hollow screw from the fuel filter and
disconnect the fuel hose.
B. Unscrew the fuel filter mounting bolt to remove the
fuel filter.
EX1403630
Figure 19
13. Disconnect the intake stake.

A. Unscrew the mounting bolt to disconnect the air
hose.
EX1403631
Figure 20
DX210W-5 Engine
4-1-31
14. Separate the intake manifold.
A. Unscrew the intake manifold mounting bolts to
remove the intake manifold from the cylinder block.
B. Remove the gasket and clean the gasket mounting
surface thoroughly with a scraper.
EX1403632
Figure 21
15. Remove the common rail and high-pressure pipe.

A. Disconnect the high-pressure pipe between the fuel
high-pressure connector and common rail.
B. Unscrew the common rail mounting bolts to remove
the common rail.
CAUTION
AVOID INJURY EX1403633
Figure 22
• Seal the common rail thoroughly after removing it
to prevent foreign materials from entering it.
• Once the fuel high-pressure pipe is
disconnected, it cannot be reused.
16. Remove the fuel high-pressure pump.

A. Unscrew the fuel high-pressure pump mounting bolts
to remove the fuel high-pressure pump.
EX1403634
Figure 23
Engine DX210W-5
4-1-32
17. Remove the EGR valve.
A. Unscrew the EGR valve mounting bolts to remove
the EGR valve and exhaust manifold.
B. Unscrew the mounting bolts to remove the exhaust
pipe from the EGR cooler.
C. Disconnect the coolant pipe from the EGR valve.
CAUTION EX1403635
Figure 24
AVOID INJURY
Seal the EGR valve and exhaust pipe thoroughly after
removing them to prevent foreign materials from
entering them.
EX1403636
Figure 25
18. Remove the EGR cooler.

A. Unscrew the EGR cooler and bracket connecting bolt
to separate the EGR cooler.
B. Disconnect the pipe and hose from the EGR cooler.
CAUTION
AVOID INJURY
EX1403637
Seal the EGR cooler thoroughly after removing it to Figure 26
prevent foreign materials from entering it.
19. Remove dosing module.

Unscrew the mounting bolt of the dosing module to remove
it from the UREA tank.
EX1404191
Figure 27
DX210W-5 Engine
4-1-33
20. Remove the turbocharger.
A. Disconnect the intake stake from the turbocharger.
B. Disconnect the coolant hose from the turbocharger.
C. Disconnect the oil feed pipe and oil drain pipe
between the cylinder block and turbocharger.
D. Unscrew the turbocharger mounting bolts to separate
the turbocharger from the exhaust manifold.
EX1404192
Figure 28
21. Remove the exhaust manifold.

A. Unscrew the exhaust manifold mounting bolts to
remove the exhaust manifold.
CAUTION
AVOID INJURY
Do not reuse the removed gasket.
EX1403642
Figure 29
22. Disconnect the coolant pipe and thermostat.

A. Unscrew the coolant pipe mounting bolt to disconnect
the coolant pipe from the thermostat housing.
B. Remove the coolant thermostat and O-ring.
C. Clean the gasket mounting surface of the coolant
pipe with a scraper thoroughly.
CAUTION EX1403643
Figure 30
AVOID INJURY
Make sure that the gasket residual does not enter the
coolant passage.
Engine DX210W-5
4-1-34
23. Remove the coolant pump.
A. Unscrew the bracket mounting bolts for the coolant
pump and oil cooler.
B. Unscrew the bolt (1 ea) for the oil cooler.
C. Unscrew the coolant pump mounting bolts to remove
the coolant pump.
D. Remove the O-ring for the coolant pump.
EX1403644
CAUTION Figure 31
AVOID INJURY
Do not reuse the O-ring.
EX1403645
Figure 32
24. Remove the start motor.

A. Unscrew the start motor mounting nut and remove
the start motor with care. Be careful not to damage its
gear.
EX1403646
Figure 33
25. Remove the oil filter.

A. Remove the oil filter cartridge using a special service
tool.
Oil Cooler
Oil Filter
EX1403647
Figure 34
DX210W-5 Engine
4-1-35
26. Remove the vibration damper.
A. Unscrew the mounting bolts of the vibration damper
and crank pulley in the reverse order to remove the
vibration damper assembly.
EX1403648
Figure 35
27. Remove the cylinder head cover.

A. Unscrew the cylinder head cover mounting bolts to
remove the cylinder head cover.
B. Unscrew the intermediate cover mounting bolts to
remove the intermediate cover.
EX1403649
Figure 36
28. Remove the rocker arm.

A. Unscrew the rocker arm bracket mounting bolts in the
reverse order to remove the rocker arm assembly.
EX1403650
Figure 37
29. Remove the push rod.

A. Remove the push rod.
EX1403651
Figure 38
Engine DX210W-5
4-1-36
30. Remove the fuel injector.
Injector Type Bolts
A. Unscrew the fuel high-pressure connector mounting
Fixing Bracket
bolts to disconnect the fuel high-pressure connector.
B. Remove the harness from the injector. O-ring
Seal Ring
C. Unscrew the injector mounting bracket bolts to
remove the injector.
CAUTION EX1403652
Figure 39
AVOID INJURY
Be careful not to damage the nozzle during removing
the injector.
D. Remove the seal ring from the nozzle hole from the
cylinder head.
CAUTION
AVOID INJURY
To remove the injector, unscrew the fuel high-pressure
connector mounting nut to disconnect the fuel high-
pressure connector completely. Then, unscrew the
caliper mounting bolt to remove the injector.
31. Remove the cylinder head.

Lifting Hook
A. Unscrew the cylinder head bolts in the reverse order
of tightening to remove the cylinder head. Head Bolt
– Step 1: Unscrew the bolt for 1 to 2 threads.
– Step 2: Unscrew the bolt completely to remove it.
B. Remove the cylinder head bolts in these two steps.
C. Keep the removed bolts in order with care, being
careful not to damage their threads.
EX1403741
Figure 40
CAUTION
AVOID INJURY
Make sure that the bolts are not hit by each other.
D. Remove the cylinder head gasket.

E. Remove foreign materials from the surface of the
cylinder head and block.
DX210W-5 Engine
4-1-37
CAUTION
AVOID INJURY
Be careful not to damage the mating surface.
F. Unscrew the mounting bolt of the lifting hook from the

cylinder head to remove the lifting hook.
32. Remove the valve and valve stem seal.
A. Press the valve spring and retainer with the valve
spring compressor to remove the valve cotter.
B. Remove the valve spring and retainer.
C. Remove the calipers.
D. Use a general service tool to remove the valve stem Valve Spring
seal. Copression Jig
EX1403742
Figure 41
CAUTION
AVOID INJURY
Do not reuse the valve stem seal.
E. Remove valve.
F. Unscrew the mounting bolt of the lifting hook from the
cylinder block to remove the lifting hook.
EX1403743
Figure 42
33. Remove the oil cooler.

A. Unscrew the oil cooler mounting bolts to remove the
oil cooler.
EX1403653
Figure 43
Engine DX210W-5
4-1-38
34. Remove the oil pan.
A. Unscrew the oil pan mounting bolts to remove the oil
pan.
B. Remove the oil pan gasket.
Oil Pan Fixing Bolt
EX1403654
Figure 44
35. Remove the front oil seal and cover.

A. Remove the oil seal using a oil seal removing tool.
B. Unscrew the gear case cover mounting bolt to
remove the oil seal cover.
EX1403655
Figure 45
36. Remove the oil pump and disconnect the pipe.

A. Unscrew the oil suction pipe mounting bolt to remove
the bracket.
B. Unscrew the oil pump pipe mounting bolts to
disconnect the suction pipe and feed pipe.
C. Unscrew the oil pump mounting bolts to remove the
oil pump.
EX1403656
Figure 46
37. Remove the flywheel.

A. Unscrew the flywheel mounting bolts and install the
guide bolt to remove the flywheel.
B. Unscrew the bolts in the reverse order of their
tightening to remove the flywheel.
EX1403657
Figure 47
DX210W-5 Engine
4-1-39
38. Flywheel housing
A. Unscrew the flywheel housing mounting bolts to
remove the flywheel housing.
B. Remove the flywheel housing oil seal.
EX1403658
Figure 48
39. Remove the cam gear and idle gear.

A. Unscrew the camshaft gear mounting bolts to remove
the camshaft gear.
B. Unscrew the idle gear mounting bolts to remove the
idle gear.
EX1403659
Figure 49
40. Remove the timing gear case.

A. Unscrew the timing gear case mounting bolts.
B. Tap the left and right sides on the back of the contact
surface of the timing gear case with a urethane
hammer gently to remove the timing gear case.
EX1403660
Figure 50
41. Remove the piston and connecting rod.

A. Unscrew the connecting rod cap bolts in the reverse
order of their tightening.
NOTE: Unscrew these bolts in two steps as the
cylinder head bolts.
B. Tap the top and bottom of the connecting rod cap
with a urethane hammer lightly to remove the bearing
cap and bearing.
C. Push the connecting rod from the oil pan side toward EX1403661
the cylinder head with a wooden stick to separate the Figure 51
piston assembly.
Engine DX210W-5
4-1-40
D. Keep the removed pistons in the corresponding
cylinder order and make sure that they are not hit by
each other.
E. Install the connecting rod caps to their corresponding
connecting rods loosely. Be careful not to mix them.
42. Remove the piston.
A. Remove the snap ring of the piston pin using pliers.
EX1403662
Figure 52
B. Tap the piston pin with a wooden stick gently to

remove the piston.
EX1403663
Figure 53
C. Remove the piston ring using piston ring pliers.

D. Remove carbon from the piston completely and clean it.
EX1403664
Figure 54
DX210W-5 Engine
4-1-41
43. Remove the bearing cap.
A. Unscrew the bearing cap mounting bolts in the
reverse order of their tightening to remove the
bearing cap.
NOTE: Unscrew these bolts with the same
method for the cylinder head bolts.
B. Keep the bearing caps in order.
EX1403665
Figure 55
44. Remove the crankshaft.

A. Fit the bolts to both sides of the crankshaft
temporarily.
B. Connect a rope to the bolts and lift the crankshaft
with a crane. Be careful not to damage the
crankshaft.
C. Store the removed crankshaft on a safe special shelf
so that it is not deformed or damaged.
D. Remove and store the main bearings in order. EX1403666
Figure 56
CAUTION
AVOID INJURY
• Make sure that the main bearing and bearing
caps are not mixed.
• Fit the main bearings to their bearing caps
temporarily to prevent mixing.
45. Remove the oil spray nozzle.

A. Unscrew the oil spray nozzle valve mounting screw to
remove the oil spray nozzle.
EX1403667
Figure 57
Engine DX210W-5
4-1-42
46. Remove the camshaft and tappet.
A. To prevent damage of the camshaft, pull it out while
turning it.
B. Store the removed camshaft on a safe special shelf
so that it is not deformed or damaged.
C. Remove the tappet.
CAUTION EX1403668
Figure 58
AVOID INJURY
Check for damage, scratch and wear. If any abnormal
condition is found, replace it.
47. Remove the cylinder liner.

A. Be careful not to damage the cylinder block when
removing the cylinder liner.
B. Remove the cylinder liner with its removing tool and
hands.
EX1403669
Figure 59
DX210W-5 Engine
4-1-43
ENGINE ASSEMBLY
Engine Assembly
CAUTION
AVOID INJURY
• Clean all the removed parts thoroughly. Especially,
clean the oil and coolant passages with compressed
air thoroughly to eliminate any restriction.
• Organize general tools and special service tools for
engine assembly.
• Prepare clean engine oil to apply onto moving parts.
• Prepare service parts, such as sealant and gasket.
• Replace any used gasket, seal ring and consumables
with new ones.
• Each bolt should to tightened to the specified torque
according to the tightening order. Never over-tighten it.
• After installing the engine components, check their
proper operation.
• After primary assembly, check if any bolt is loose.
• Keep your hands clean at all times during work.
Assemble the engine according to the following procedure:

1. Install the cylinder block.
A. Place a wooden block or thick paper on the ground of
the working area to prevent damage of the cylinder
head mounting surface. Then, set the head mounting
surface toward the ground.
2. Install the cylinder liner.
A. Stand the cylinder block with its flywheel side facing
the ground.
B. Clean the flange mounting surface and inside of the
liner with compressed air thoroughly.
C. After cleaning the cylinder liner, dry it completely and
insert it into the cylinder block with hands.
D. Apply engine oil to the inside of the cylinder liner.
EX1403670
Figure 60
Engine DX210W-5
4-1-44
3. Install the oil spray nozzle.
A. Align the oil spray nozzle with the groove of the
cylinder block using the oil spray nozzle installing jig.
B. Install the relief valve.
C. Tighten the mounting bolt to 20.6 N.m (2.1 kg.m,
1 ft lb).
EX1403667
Figure 61
4. Install the crankshaft.

A. Make sure to align the holes of the main bearing with
the machined oil holes (2 ea) on the cylinder block
during installation.
7 5 3 1 2 4 6
EX1403671
Figure 62
Key Groove
Oil Port and Passage
EX1403672
Figure 63
B. Apply clean engine oil to the bearing surface.

C. Heat the wear ring at 150°C for 10 minutes with a
heater and install this front wear ring using an
assembly jig.
EX1403673
Figure 64
DX210W-5 Engine
4-1-45
D. Fit the bolts to both sides of the crankshaft
temporarily. Then, place the crankshaft on the
cylinder block using the mounting bolts.
EX1403666
Figure 65
E. Apply engine oil to the pin and journal of the

crankshaft.
F. After oil application, install the thrust washer with its
oil groove facing the outside.
EX1403674
Figure 66
G. Install the bearing and thrust washer to the bearing

cap.
EX1403675
Figure 67
H. Apply oil to the bearing and thrust washer.

Tightening Order
I. Install the bearing caps correctly by matching their
numbers with the cylinder block numbers.
J. Tighten the bearing cap bolts to the specified
tightening torque in the specified order. 1 2 3 4 5 6 7
K. Tighten both bolts evenly to set the bearing cap tight.
L. Tighten the bolt according the following steps with a
torque wrench:
Bearing Cap
– Step 1: Tighten the bolt to 49 N.m (5 kg.m, EX1403676
36.2 ft lb) until it is tightly set against the Figure 68
surface.
– Step 2: Tighten it to 147.1 N.m (15 kg.m,
108.5 ft lb) with a torque wrench.
Engine DX210W-5
4-1-46
180.8 ft lb) with a torque wrench.
217 ft lb) with a torque wrench for the
final time.
M. Tighten the bearing caps in the following order:
4 - 3 - 5 - 2 - 6 - 1 - 7.
N. Rotate the installed crankshaft for 2 ~ 3 turns to
check its free motion.
EX1403677
Figure 69
5. Install the tappet and camshaft.

A. Cool a new bushing in dry ice for approximately 2
hours.
B. Press the new bushing into the cam bushing position
of the cylinder block using a bench press.
C. After pressing it in, measure the inside diameter of
the cam bushing to check for its deformation.
D. Apply engine oil to the face of the tappet and insert
the tappet into its hole of the cylinder block. EX1403678
E. Apply engine oil to the camshaft hole and camshaft Figure 70
journal sections of the cylinder block.
F. Insert the camshaft into its hole of the cylinder block.
6. Install the timing gear case.
A. Install the gasket to the cylinder block using a
reference pin.
B. Align the pin hole of the timing gear case with the
reference pin.
C. Install the timing gear case to the cylinder block.
D. Set it tightly against the cylinder block by tapping its
left and right with a urethane hammer.
E. Tighten the relief valve to 25.5 N.m (2.6 kg.m, EX1403660
18.8 ft lb). Figure 71
F. Tighten the timing gear case mounting bolts to

43.1 N.m (4.4 kg.m, 31.8 ft lb).
CAUTION
AVOID INJURY
When tightening the bolts, tighten the bolts on both
ends first and tighten the remaining bolts.
DX210W-5 Engine
4-1-47
7. Install the fuel high-pressure pump.
A. Install the gear of the fuel high-pressure pump using its jig.
B. Tighten the gear nut to 107.9 N.m (11 kg.m, 79.6 ft lb).
C. Tighten the mounting bolt to 43.1 N.m (4.4 kg.m, 31.8 ft lb).
D. Install the fuel high-pressure pump to the timing gear
case on the back of the flywheel housing.
E. Tighten the flow screw to 29.4 N.m (3 kg.m, 21.7 ft lb).
F. Tighten the nipple to 43.1 N.m (4.4 kg.m, 31.8 ft lb).
EX1403634
G. Tighten the mounting bolts to the specified torque in
Figure 72
the correct order.
8. Install the gear system.
A. Install the thrust washer to the camshaft.
B. Install the cam gear, aligning it with the pin hole of the
camshaft.
C. Tighten the camshaft thrust washer to 9.8 N.m
(1 kg.m, 7.2 ft lb).
D. Tighten the camshaft gear mounting bolt to 30.4 N.m
(3.1 kg.m, 22.4 ft lb).
EX1403679
Figure 73
CAUTION
AVOID INJURY
When installing the gears, install the camshaft gear,
idle gear, fuel high-pressure pump idle gear and fuel
high-pressure pump in this order.
E. Install the idle gear while aligning the marks on the

crankshaft gear, camshaft gear and idle gear. Fuel High Pressure
– Gear mark Pump Gear
Crankshaft Gear -
"0" and "0"
Idle Gear (A) Fuel High Pressure
Camshaft
Camshaft Gear - Pump Idle Gear
"1" and "1" Gear
Idle Gear (B) Idle Gear (A, B)
Crankshaft Oil Pump Gear
F. Tighten the step idle gear to 60.8 N.m (6.2 kg.m, 44.8 ft lb). Gear
G. Tighten the fuel high-pressure pump idle gear to EX1403680
60.8 N.m (6.2 kg.m, 44.8 ft lb). Figure 74
H. Use a feeler gauge to check the backlash and end

play of the gear.
– Backlash
Measuring Position Standard (mm)

Camshaft Gear and Idle Gear 0.074 ~ 0.163
Fuel High-pressure Pump
0.103 ~ 0.182
Gear and Idle Gear
Crankshaft Gear and Oil
0.073 ~ 0.239
Pump Drive Gear
Engine DX210W-5
4-1-48
– End play
Measuring Position Standard (mm)

Camshaft Gear 0.280 ~ 0.430
Step Idle Gear 0.107 ~ 0.183
Fuel High-pressure Pump
0.078 ~ 0.140
Idle Gear
9. Install the flywheel housing.

A. Install a guide bar to the cylinder block temporarily.
Fixing Bolt
B. Install the gasket to the cylinder block.
C. Use a dowel pin and guide bar to install the flywheel
housing.
Gasket
D. Tighten the mounting bolts to 109.8 N.m (11.2 kg.m, Oil Seal
81 ft lb) in the specified order.
E. Remove the guide bar.
EX1403681
F. Apply a thin film of engine oil to the outer surface of Figure 75
the oil seal and fit this seal into the flywheel housing.
10. Install the rear oil seal.
A. Align the oil seal with the crankshaft.
B. Install the oil seal using its jig.
Oil Seal Jig
EX1403682
Figure 76
11. Install the flywheel.

A. Heat the ring gear with a gas burner evenly to expand
it. Then, install it with a hammer.
CAUTION
AVOID INJURY
• Make sure that the temperature of the ring gear
does not exceed 200°C. EX1403683
Figure 77
• When installing the wear ring, heat it to 150°C
with a heater, and apply loctite #262 to it, and use
an assembly jig to install it.
DX210W-5 Engine
4-1-49
B. The front of the wear ring can be identified by the
mounting surface on the outer skirt.
C. Fit a guide bar into the crankshaft bolt hole.
D. Align the flywheel with the reference pin to install it
temporarily.
E. Apply adhesive (loctite #587) to the mounting bolt.
F. Fit the bolts that have no guide pin in their holes.
Then, remove the guide pin and fit the remaining bolt.
EX1403684
Figure 78
EX1403685
Figure 79
G. Tighten the bolts (M14 x 1.5) to 196.1 N.m (20 kg.m,

144.7 ft lb) in the specified order.
1
8 6
3 4
5 7
2
EX1403686
Figure 80
12. Install the piston and connecting rod.

A. Heat the piston to approximately 100°C with a heater Piston Heater
for 5 minutes.
EX1403687
Figure 81
Engine DX210W-5
4-1-50
B. When installing the piston and connecting rod, the
weight controlling section at the small end of the
connecting rod and the oil gallery inlet (big hole side)
of the piston should face the opposite direction.
C. Apply oil to the pin hole of the piston and align this
hole with the small end of the connecting rod. Then,
tap the piston pin with a rubber hammer gently to
install the connecting rod and piston.
EX1403663
Figure 82
D. The openings of the snap rings should be set in the

opposite direction (upwards and downwards).
CAUTION
AVOID INJURY
Direction of snap ring is assembling to be positioned
the opposite side.
EX1403688
E. Install the snap ring. Check its mounting condition. Figure 83
F. Use piston ring pliers to install the piston ring to the
piston.
G. Make sure to install the piston ring in the correct

direction. The mark "Y" or "TOP" on the ring
connection should face up.
Top Ring
2nd Ring
Oil Ring
EX1403689
Figure 84
"Y" or "TOP"
EX1403690
Figure 85
DX210W-5 Engine
4-1-51
H. Adjust each piston ring connection angle to 120° and
fit a piston inserting jig into the piston.
2nd Ring Oil Ring
CAUTION
AVOID INJURY
The connection of the piston ring should not be in the Piston
same direction with the pin.
Piston
Top Ring EX1403691
Figure 86
I. Install the connecting rod bearing while aligning it

with the key groove. Then, apply oil to the bearing View from Crankshaft Pulley
and piston.
J. Fit the piston so that the oil gallery inlet of the piston
is in the same direction with the spray nozzle.
K. Use a piston inserting tool to insert it into the cylinder
liner. Be careful not to damage the ring by the tip of
the liner.
Piston Oil Gallery
Spray Nozzle
EX1403692
CAUTION Figure 87
AVOID INJURY
Make sure that the cylinder liner and piston are not
damaged.
L. Fit the bearing to the connecting rod cap and apply oil
on it. Install the Opening part of
the Retaining ring on the Opposite
M. Check that the manufacturing serial numbers Side of Upper/Lower Side
stamped on the connecting rod cap and connecting
rod big end are the same.
Same number marking position

EX1403693
Figure 88
Engine DX210W-5
4-1-52
N. Install the connecting rod cap while aligning it with the
reference pin.
O. Apply oil to the mounting bolt and install the bolt
loosely.
P. Tighten the bolts to the specified tightening torque in
the specified order using a torque wrench.
– Step 1: When tightening the connecting rod
bolt, tighten it with a hand until its head
touches the bolt seat of the connecting
rod. EX1403694
Figure 89
– Step 2: Tighten it to 39.2 ~ 58.8 N.m
(4 ~ 6 kg.m, 28.9 ~ 43.4 ft lb) with a
torque wrench.
– Step 3: Tighten it to 95.6 N.m (9.75 kg.m,
70.5 ft lb) with a torque wrench for the
final time.
Q. Shake the bearing cap with a hand. If it does not
move, loosen and tighten it again.
13. Install the oil pump and oil pipe.
A. Install the reference pin to the bearing cap No. 7.
B. Tap the oil pump with a urethane hammer gently to
install it.
C. Fit the washer and tighten the mounting bolt (M8) to
21.6 N.m (2.2 kg.m, 15.9 ft lb). Tighten the bolt (M10)
to 43.1 N.m (4.4 kg.m, 31.8 ft lb).
D. Connect the oil feed pipe to the oil pump with the bolt.
EX1403656
Figure 90
14. Install the front oil seal.

A. Apply engine oil to the inside of the oil seal before
installing the oil seal to the cover.
Oil Seal Cover
B. Align a new oil seal with the center of the hole on the
oil seal cover.
Oil Seal
C. Use an installing jig to install the oil seal.
D. Tighten it to 21.6 N.m (2.2 kg.m, 15.9 ft lb).
EX1403695
Figure 91
DX210W-5 Engine
4-1-53
15. Install the oil pan.
A. Remove any protruded gasket on the timing gear
case, cover, cylinder block and flywheel housing
contact surface with a scraper thoroughly.
CAUTION
AVOID INJURY Oil Pan
Gasket
Make sure any gasket does not enter the engine during work. EX1403696
Figure 92
B. Apply silicon on the surfaces where the used gasket
was removed. Then, attach a new oil pan gasket.
C. Install the oil pan.
D. Tighten the bolts (4 ea) on both ends of the oil pan
first and tighten the remaining bolts.
E. Tighten the oil pan mounting bolt to 21.6 N.m
(2.2 kg.m, 15.9 ft lb).
CAUTION
AVOID INJURY
Align the bolt holes with the gasket holes before
tightening the bolts.
F. Tighten the drain plug to 98.1 N.m (10 kg.m, 72.3 ft lb).
16. Install the crankshaft pulley and vibration damper.
A. Install the vibration damper to the crankshaft pulley.
B. Tighten the bolts in the correct order.
C. Tighten the vibration damper to 60.8 N.m (6.2 kg.m,
44.8 ft lb).
D. Tighten the crankshaft pulley to 196.1 N.m (20 kg.m,
144.7 ft lb).
EX1403648
Figure 93
1
8 6
3 4
5 7
2
Bolt Tightening Order

Figure 94 EX1403697
Engine DX210W-5
4-1-54
17. Install the intake and exhaust valves.
A. Before installing the valve to the cylinder head, check
the marks "I" and "E" on the valve head surface.
Valve Marking Position
Intake Valve Exhaust Valve

EX1403698
Figure 95
B. Use a valve stem seal installing jig to install the valve

stem seal to the valve guide.
C. Install the valve cotter by pressing the retainer with a
valve spring compressing tool after installing the
valve spring and retainer.
D. Tap the valve stem with a rubber hammer gently to
check if the valve is corrected installed.
Valve spring compression jig
EX1403699
Figure 96
18. Install the cylinder head.

A. Blow compressed air through the bolt hole of the
cylinder head to remove any foreign materials.
B. Clean the gasket mating surface of the cylinder head
thoroughly.
Model Number Mark

CAUTION Manufactured Date

Figure 97
Ensure that no foreign material enters the combustion
chamber.
C. Align the new gasket bolt hole with the reference pin
on the cylinder block.
D. When installing the gasket, its mark on the right
should be upwards.
CAUTION
AVOID INJURY
Replace the gasket with a new one.
DX210W-5 Engine
4-1-55
E. Check if there is any foreign material in the
combustion chamber. Head Bolt
F. Install the cylinder head by aligning it with the
retaining pin. Torque Wrench
CAUTION
AVOID INJURY
• Be careful not to damage the gasket. EX1403701
Figure 98
• If the pin hole cannot be aligned, lift the head and
then try to seat it again.
G. Install the cylinder head bolt.

21 25
H. Tighten the cylinder head bolts to the specified 26
13 17
tightening torque in the specified order.
5 9 18 22
– Step 1: Tighten it for 1 to 2 threads with a 4 1 14
10
hand, and then tighten it to 39.2 N.m 6
12 8 2
(4 kg.m, 28.9 ft lb) temporarily. 16
20 7 3
– Step 2: Tighten it to 6 kg.m with a torque 24 15 11
wrench. 19
23
– Step 3: Tighten it for 90° with a torque wrench. EX1403702
– Step 4: Tighten it for 90° with a torque wrench. Figure 99
– Step 5: Tighten it for 90° with a torque wrench

for the final time.
CAUTION
AVOID INJURY
All the bolts should be tightened according to the
above steps.
19. Install the push rod.

A. Apply engine oil to the push rod.
B. Insert the push rod into the push rod hole of the
cylinder head.
EX1403651
Figure 100
Engine DX210W-5
4-1-56
20. Install the injector.
Injector Type Bolts
Fixing Bracket
CAUTION O-ring
Seal Ring
AVOID INJURY
• Clean all parts thoroughly and make sure that no
foreign material enters any part.
• Especially, the fuel line between the common rail
and injector is not equipped with a filtering EX1403652
function. Therefore, this section should be kept Figure 101
clean with care.
• Clean the drilling of the head for the fuel high-
pressure connector and the hole for the injector
thoroughly to remove any foreign materials from
them.
• If the injector is removed, the fuel high-pressure
connector should be replaced with a new one.
• If fuel collected in the fuel return line enters the
combustion chamber during injector
disassembly process, remove fuel by sucking it
out with a hand pump or by cranking the engine
with fuel flow blocked.
A. Install the injector correctly according to the following

steps.
B. Fit the O-ring to the injector and apply engine oil to 4 Injector
the outer circumference surface.
High Pressure Connector
1 , 2
3 5
CAUTION Coat the Engine
Oil on O-ring
(Be careful not to
AVOID INJURY allow the engine Lubricant Positions
oil to go into the hole - O-ring
Make sure that oil or foreign material is not on the fuel for high pressure - Hold Down Shoulder
high-pressure connector hole on the side of the connector) - Thread of Fixing Nut
injector. EX1403703
Figure 102
C. Align the seal ring with the injector hole on the
cylinder head. Then, insert the injector gently.
D. Align the injector mounting bolt with the thread of the
head. Then, tighten the bolt for 2 ~ 3 threads with a
hand.
E. Set the injectors to the mounting positions of the
injector mounting brackets (1 and 2) with the
mounting bolts. Then, tighten them temporarily.
EX1403592
Figure 103
DX210W-5 Engine
4-1-57
F. After tightening the injectors temporarily, unscrew the
bolts of the mounting brackets enough to move the Mount the High Pressure
injectors freely without load. Connector and Then
Assemble the Fixing Nut
G. Set the fuel high-pressure connector (3) with its balls
with Pre-tightening
set vertically.
3
2nd Step : Installing High Pressure Connector

and Temporarily Assembling
EX1403704
Figure 104
H. Ensure that it is aligned with the groove in the hole on

the side of the head on the intake manifold side. Final Tighten the Fixing Bolt of Injector
with Specified Torque
I. Align the fuel high-pressure connector through the
hole on the side of the head, and push in the fuel
high-pressure connector enough.
4
J. Tighten the mounting nut (M22 x 15) of the fuel high-
pressure connector for 2 ~ 3 threads with a hand.
K. Tighten the injector mounting bracket bolt to 2.9 N.m
(0.3 kg.m, 2.2 ft lb) with a torque wrench.
L. Tighten the injector mounting bracket bolt to
14.7 + 4.9 N.m (1.5 + 0.5 kg.m, 10.8 + 3.6 ft lb) using
Final Step : Final Assemble Injector with
a torque wrench.
Specified Torque EX1403705
M. Tighten the injector mounting bracket mounting bolt (4) Figure 105
to 30.4 ~ 34.3 N.m (3.1 ~ 3.5 kg.m, 22.4 ~ 25.3 ft lb)
N. Tighten the fuel high-pressure connector mounting nut
(5) to 49 ~ 53.9 N.m (5 ~ 5.5 kg.m, 36.2 ~ 39.8 ft lb). Final Tighten the Fixing Nut
of High Pressure Connector
with Specified Torque
Final Step : Final Assemble High Pressure

Connector with Specified Torque
EX1403706
Figure 106
Engine DX210W-5
4-1-58
21. Install the rocker arm.
A. For rocker arm assembly, install the spring, rocker
arm, bracket, rocker arm, spring, washer and snap
ring in order.
CAUTION
AVOID INJURY
Install the rocker arm and bracket in the same EX1403707
direction. Figure 107
B. Apply oil to the rocker arm bushing and shaft.

C. Use the mounting bolts to install the rocker arm and
bracket onto the cylinder head.
D. Tighten the bolts to 36.8 N.m (3.75 kg.m, 27.1 ft lb)
diagonally.
E. Install the valve clearance adjusting screw to the
rocker arm temporarily.
F. Adjust the valve clearance.
EX1403650
Figure 108
22. Install the intermediate cover.

A. Install a new gasket to the intermediate cover.
B. Tighten the mounting bolt to 30.4 N.m (3.1 kg.m,
22.4 ft lb).
EX1403708
Figure 109
23. Install the cylinder head cover.

A. Install a new rubber gasket to the cylinder head
cover.
B. Install the cylinder head cover to the cylinder head.
15.9 ft lb).
D. Install the oil filler cap to the cylinder head cover.
EX1403709
Figure 110
DX210W-5 Engine
4-1-59
24. Install the oil cooler.
A. Install the oil cooler and gasket to the cylinder block.
CAUTION
AVOID INJURY
Make sure to install the gasket in the correct direction.
B. Tighten the bolt to 21.6 N.m (2.2 kg.m, 15.9 ft lb). EX1403710
Figure 111
25. Install the oil filter.

A. Install the oil filter cartridge using a special service
tool.
Oil Cooler
CAUTION
Oil Filter
AVOID INJURY
The oil filter should be installed to the engine without
oil in it. Never fill the new oil filter with oil drained from EX1403647
the used oil filter. Figure 112
26. Install the coolant pump.

A. Install the coolant pump cover and coolant pump
gasket.
EX1403645
Figure 113
B. Install the coolant pump to the cylinder block.

15.9 ft lb).
D. Install the idle pulley bracket.
EX1403644
Figure 114
Engine DX210W-5
4-1-60
27. Install the start motor.
A. Install the start motor to the stud bolt of the flywheel
housing.
B. Tighten the mounting nut to 78.5 N.m (8 kg.m,
57.9 ft lb).
EX1403711
Figure 115
28. Install the common rail and high-pressure pipe.

A. Install the common rail to the cylinder block.
B. Connect the fuel feed pipe between the common rail
and fuel high-pressure connector.
C. Tighten the fuel high-pressure pipe on the common
rail side to 24.5 N.m (2.5 kg.m, 18.1 ft lb).
D. Tighten the fuel high-pressure pipe on the fuel high-
pressure connector side to 27.5 N.m (2.8 kg.m,
20.3 ft lb). EX1403633
Figure 116
E. Tighten the common rail fuel high-pressure pipe from
the fuel high-pressure pump to 20.6 N.m (2.1 kg.m,
15.2 ft lb).
F. Tighten the common rail mounting bolt to 21.6 N.m
(2.2 kg.m, 15.9 ft lb).
CAUTION
AVOID INJURY
• Never reuse the fuel high-pressure pipe.
• Tighten the fuel high-pressure pipe to the
specified torque for a cylinder by cylinder.
29. Install the intake manifold.

A. Install a new gasket between the cylinder head and
intake manifold.
31.8 ft lb).
EX1403632
Figure 117
DX210W-5 Engine
4-1-61
30. Install the exhaust manifold.
A. Install the exhaust manifold gasket to the stud bolt of
the cylinder head.
B. \Align the gas outlet of the cylinder head with the Projection Face
gasket hole.
C. Install the exhaust manifold.
D. Tighten the mounting bolt to 49 N.m (5 kg.m,
36.2 ft lb).
EX1403712
Figure 118
EX1403642
Figure 119
31. Install the turbocharger.

A. Install a new gasket to the stud bolt of the exhaust
manifold.
B. Install the turbocharger.
C. Connect the oil feed pipe and drain pipe.
D. Tighten the clamp for the rubber hose to connect the
air pipe and turbocharger.
E. Tighten the mounting bolt to 78.5 N.m (8 kg.m,
57.9 ft lb). EX1404192
Figure 120
32. Install the coolant pipe and thermostat.

A. Install the gasket to the cylinder head.
B. Install the housing to the thermostat.
C. Install the O-ring to the thermostat.
D. Connect the coolant pipe.
E. Tighten the bolt to 21.6 N.m (2.2 kg.m, 15.9 ft lb).
EX1403643
Figure 121
Engine DX210W-5
4-1-62
33. Install dosing module.
A. Install the dosing module to the UREA tank with the
mounting bolts.
B. Install the cover for the dosing module with the
mounting bolts.
C. Connect the dosing pipe.
EX1404191
Figure 122
34. Install the EGR cooler.

A. Install the EGR cooler mounting bracket to the
cylinder head with the mounting bolts.
B. Install the EGR cooler to the bracket with the
mounting bolts.
C. Connect the pipe and hose to the EGR cooler.
CAUTION EX1403637
Figure 123
AVOID INJURY
Do not reuse the gasket.
EX1403713
Figure 124
DX210W-5 Engine
4-1-63
35. Install the EGR valve.
A. Install the exhaust pipe to the EGR cooler with the
gasket and secure it with the mounting bolt.
B. Install the EGR valve to the exhaust pipe with the
gasket and secure it with the mounting bolt.
CAUTION
Figure 125
Do not reuse the gasket.
EX1403636
Figure 126
36. Install the ECU (Electrical Control Unit).

A. Fix the ECU mounting plate.
B. Install the ECU.
EX1403714
Figure 127
37. Install the crankshaft speed sensor and camshaft speed

sensor.
A. Measure the clearance between the mounting
section of the crankshaft speed sensor and flywheel.
Use shims to adjust this clearance to 1.0 mm.
B. Tighten the crankshaft speed sensor to 9.8 N.m
(1 kg.m, 7.2 ft lb).
C. Measure the clearance between the mounting
section of the camshaft speed sensor and timing
gear. Use shims to adjust this clearance to 1.0 mm. EX1403657
Figure 128
D. Tighten the camshaft speed sensor to 9.8 N.m
(1 kg.m, 7.2 ft lb).
Engine DX210W-5
4-1-64
38. Install the fuel filter.
A. Fuel needs to flow through the following components
in this order: fuel feed pump, fuel filter, fuel high-
pressure pump and common rail. Connect the fuel
feed pipe correctly according to the arrow direction
mark on the head of the fuel filter to ensure correct
fuel flow.
B. Tighten the fuel pipe to 29.4 N.m (3 kg.m, 21.7 ft lb).
C. Tighten the fuel temperature sensor to 21.6 N.m
(2.2 kg.m, 15.9 ft lb). EX1403715
Figure 129
D. Tighten the mounting bracket to 43.1 N.m (4.4 kg.m,
31.8 ft lb).
CAUTION
AVOID INJURY
A new fuel filter should be installed without fuel in it.
Never add fuel in the used fuel filter or fuel tank to a
new fuel filter.
39. Install the alternator and belt.

Alternator
A. Install the alternator and A/C bracket. Then, secure
them with the mounting bolts.
B. Install the alternator, A/C compressor and idle pulley. Air Conditioner
Compressor
C. Tighten the alternator mounting bolt to 75.5 N.m Idle Pulley
(7.7 kg.m, 55.7 ft lb).
Crankshaft Pulley
D. Tighten the alternator support mounting bolt to Cooling Water Pump
49 N.m (5 kg.m, 36.2 ft lb).
E. Install the belt and adjust its tension with its adjusting EX1403716
bolt. Figure 130
40. Connect the air pipe and install the air heater.
A. Install the air pipe, air heater and throttle valve.
15.9 ft lb).
CAUTION
AVOID INJURY
EX1403629
Never let foreign materials enter the turbocharger. Figure 131
DX210W-5 Engine
4-1-65
41. Install the cooling fan.
A. Install the fan flange to the coolant pump pulley.
B. Install the cooling fan.
C. Tighten the cooling fan bolt to 21.6 N.m (2.2 kg.m,
15.9 ft lb).
D. Tighten the fan drive to 43.1 N.m (4.4 kg.m,
31.8 ft lb).
EX1403717
Figure 132
42. Fit the dipstick.

A. Apply adhesive (loctite #262) to the guide tube.
B. Install the guide tube and dipstick to the oil pan.
EX1403718
Figure 133
43. Connect the cables and harnesses of the engine to each

sensor.
44. Mount the engine to the machine.
45. Add engine oil.
A. Open the oil filler cap on top of the cylinder head
cover and add engine oil to it.
CAUTION
AVOID INJURY
Make sure to use the recommended genuine oil.
46. Add coolant.

A. Open the radiator cap and add coolant.
CAUTION
AVOID INJURY
Make sure to use the recommended coolant.
Engine DX210W-5
4-1-66
CYLINDER
General Information
Doosan's diesel engine is an air-cooled electronic control diesel
engine that uses cooling fans, overhead valve, and
turbocharger.
The high-pressure fuel generated from the fuel high-pressure
pump is stored in the common rail. When a driver operates the
vehicle, fuel injection timing and optimum fuel amount are
decided based on the data set in the electronic control unit
(ECU) and the solenoid valve of the injector installed in each
engine cylinder is operated to inject fuel into the cylinder.
The cylinder block is made out of cast iron alloy and an anti-
vibration and anti-noise crank case is mounted. In addition, the
cylinder block and the timing gear case are designed as an
integral structure to reduce the engine length and improve
tightness. The cylinder head is an integral structure, too.
The forged crankshaft is an integral structure. The oil seals of
the crankshaft and the flywheel prevents oil from permeating
into the flywheel housing. The connecting rod is forged and its
big end part vertically separated. Like a piston, the connecting
rod can be disassembled through the upper side of the cylinder.
The alloy-type prefabricated bearing is used for the active part of
the crankshaft and the connecting rod.
Cylinder Head
General Description
The cylinder head is a cover mounted on top of the cylinder, and
it is bolted to the cylinder block with the head gasket in between,
forming the combustion chamber with other components,
including the pistons and cylinders. It has a oil passage for the
glow plug and lubrication and a coolant passage for reduction of
frictional heat. This cylinder head is integrated to each cylinder
and cannot be removed.
DX210W-5 Engine
4-1-67
Parts List
1-6
1-7
1 : 1-1 ~ 1-8
1-8
1-4
1-5
1-1
4
1-5
2
1-5
1-2
1-3
EX1403599
Figure 134
Reference Reference
Number Number
1 Head Assembly, Cylinder 1-7 Bush; INJ. Nozzle
1-1 Head, Cylinder 1-8 O-ring
1-2 Seat; Valve IN. 2 Pin
1-3 Seat; Valve EX. 3 Bolt; Head
1-4 Guide; Valve 4 Bolt; Stud
1-5 Core; Plug 5 Gasket; Cylinder Head
1-6 Plug; Core
Engine DX210W-5
4-1-68
Disassembly
1. After disassembling the cylinder head, keep it on a shelf in
an organized way for later assembly.
2. Be careful not to damage the contact surface of the
cylinder head gasket.
3. Remove the valve cotter, spring and spring seat using a
valve spring compression tool.
4. Pull out the intake and exhaust valves.
5. Keep the removed parts in order.
6. Remove the valve stem seal. EX1403719
Figure 135
Assembly
1. Clean the cylinder head thoroughly.
2. Replace the valve stem seal with a new one.
3. Use a special service tool to install the stem seal to the
valve guide of the cylinder head.
4. Apply engine oil to the valve stem and valve guide, and
install the valve.
CAUTION Valve Guide
AVOID INJURY
Be careful not to damage the valve stem seal.
5. Install the valve spring seat to the valve guide on the

cylinder head. Valve Seat
6. Install the inner and outer valve springs and place the EX1403720
spring seat on the top. Figure 136
7. While pressing the valve spring with the valve spring

compression tool, insert the valve cotter to install the valve. Painted portion
(Assemble Spring
8. After installing the valve, tap the valve gently with a to the Upper Side)
urethane hammer to check if it is firmly installed.
EX1403721
Figure 137
DX210W-5 Engine
4-1-69
Inspection
Cylinder Head Inspection

1. Remove carbon from the bottom of the cylinder head.
CAUTION
AVOID INJURY
Be careful not to scratch the valve seat surface.
2. Visually check if the cylinder head is damaged.

3. A minute scratch or damage that cannot be found with with
the naked eyes can be found through the hydraulic
pressure test or magnetic particle test.
Bottom Distortion
C
1. Use a straightedge and feeler gauge to measure the (t) B D
distortion of the cylinder head in 6 directions. E
F
2. If any measured value is over the allowable service limit,
correct it with a fine sandpaper or grinder.
3. If it is over the allowable limit, replace the cylinder head. A
• Distortion and height of cylinder head
Allowable
Standard EX1403747
Limit
Figure 138
Cylinder Head
0.08 mm or
Bottom 0.15 mm
below
Flatness
Head Height: t 104.9 - 105.1 mm 104.4 mm
Flatness
1. Use a straightedge and feeler gauge to measure the
flatness of the intake/exhaust manifold mounting surface of
the cylinder head.
Standard Allowable Limit

0.15 mm 0.3 mm
EX1403748
Figure 139
Engine DX210W-5
4-1-70
DX210W-5 Engine
4-1-71
Cylinder Block
General Description
This forms a base for the engine body, and component shapes, including the crankshaft's and head's, and bolt
holes are machined on it for their installation. It also has coolant and oil passage.
The cylinder block is cast in one piece, in compact graphite iron (CGI) and has all-in-one cylinder head. The
cylinder bores have wet liners.
Parts List
FRONT
1 : 1-1 ~ 1-11
2
1-1
3
REAR
1-7 1-8
4-1
4
4-2
1-10 REAR
1-5
1-6 CYL.6
CYL.5
CYL.4 1-8
1-9
CYL.3
CYL.2 1-11
CYL.1
FRONT
1-7
8
7
1-10
5 1-3B
6 1-3
1-3A
1-2B
1-2 NO.7
1-2A
NO.6
NO.5
1-4
NO.4
NO.3
NO.2
NO.1 EX1403600
Figure 140
Engine DX210W-5
4-1-72
Reference Reference
Number Number
1 Block Assembly, Cylinder 1-9 Plug; Core
1-1 Block, Cylinder 1-10 Plug; Core
1-2 Thrust Bearing Cap Assembly 1-11 Ball; Steel
1-2A Bearing Cap; Thrust 2 Plug Screw PT1/8
1-2B Ring; Stopper 3 Pin; Core
1-3 Bearing Cap Assembly 4 Relief Valve Assembly
1-3A Bearing Cap 4-1 O-ring
1-3B Ring; Stopper 4-2 Relief Valve
1-4 Bolt 5 Pin
1-5 Bush; Camshaft 6 Cover; Core Hole
1-6 Bush; Camshaft 7 Screw; Plug
1-7 Plug; Core 8 Seal; Ring
1-8 Plug; Core
Inspection
1. Cleanse the cylinder block and check if there is any
cracked or damaged part with naked eye.
2. Replace the cylinder block if it is seriously cracked or
damaged. Repair tiny cracks if existing.
3. Check if the oil path or coolant path is clogged or corroded.
4. Perform the hydrostatic test to check whether there is a
crank or an air leakage.
5. Block the discharging outlets of the cooling water path and
the oil path of the cylinder block and put pressure of 4 kg/cm2
(3.9 bar, 56.9 psi) on the inlet. Then sink the cylinder block in
the 70°C water for 1 minute and check if air leaks.
DX210W-5 Engine
4-1-73
Valve Mechanism
General Description
The valve mechanism consists of one or two camshafts, roller
tappets, pushrods, rocker arms and valve tappets.
Straight engines have one camshaft and V engines have two
camshafts, one for each cylinder line. In both cases the
camshaft is driven by the timing gears and rotates at half the
speed of the crankshaft.
The camshaft has two cams per cylinder, one for the intake
valves and one for the outlet valves.
One end of the push rod rests on the roller tappet, and the other
end acts on the rocker arm. At one end of the rocker arm there is EX1302148
an adjusting screw. The lower ball-shaped end of the screw Figure 141
rests in the pushrod, making the tappet adjust to the camshaft
movement.
The valve seat inserts are firmly pressed to a tight fit in the
cylinder head. The material in the seat inserts is very strong, so
the valve seats have a long service life. If required the valve seat
rings can be replaced.
With four valves per cylinder the valve area is greater, which
makes it easier to fill the cylinder with air. At the same time, less
energy is consumed in forcing out the exhaust fumes.
The effort required for gas flow is reduced and engine efficiency
is improved. This in turn leads to a reduction in fuel
consumption. EX1302149
Figure 142
WARNING
Wear protective goggles to prevent injury to eyes.
Engine DX210W-5
4-1-74
Parts List
Valve
13 12
4 4
5 5
3 3
11 11
10 10
2 1
EXHAUST INTAKE
EX1403601
Figure 143
Reference Reference
Number Number
1 Valve; Intake 10 Washer
2 Valve; Exhaust 11 Seal; Valve Stem
3 Spring; Valve 12 Caliper; Intake
4 Plate; Valve Spring 13 Caliper; Exhaust
5 Cotter; Valve
DX210W-5 Engine
4-1-75
Rocker Arm
1-6
REAR
1-1
1-8
1-2
1 : 1-1 ~ 1-16 1-5

1-1 1-7
1-8
1-2
1-4 1-9
1-13
1-1 1-7
1-3
1-13
1-7
1-16 1-2
1-11
1-10
1-12
1-6 1-8
1-14
1-12
FRONT
1-9 1-15
EX1403602
Figure 144
Reference Reference
Number Number
1 Rocker Arm Shaft Assembly 1-9 Ring; Snap
1-1 Rocker Arm; Intake 1-10 Bolt; Socket
1-2 Rocker Arm; Exhaust 1-11 Washer
1-3 Shaft; Rocker Arm 1-12 Screw; Adjust
1-4 Bracket; Rocker Arm 1-13 Nut
1-5 Bracket; Rocker Arm 1-14 Cap; Intake
1-6 Bracket; Rocker Arm 1-15 Cap; Exhaust
1-7 Spring; Compession 1-16 Bolt; Collared Hex.
1-8 Washer
Engine DX210W-5
4-1-76
Valve Tappet and Push Rod
ROCKER ARM
EX1403603
Figure 145
Reference Reference
Number Number
1 Tappet; Valve 2 Rod; Push
Valve Inspection
Wash the valve with clean engine oil and inspect it as follows:
Valve Stem O.D.

1. Measure the outside diameter of the valve stem at three
location (upper, middle and lower points).
2. If the wear amount is over the allowable limit, replace the
valve.
Allowable Valve Stem

Standard
Limit
Intake Valve ø6.963 ~
ø6.93 mm
Stem ø6.977 mm
Exhaust Valve ø6.950 ~
ø6.91 mm EX1403749
Stem ø6.964 mm
Figure 146
DX210W-5 Engine
4-1-77
Valve Seat Contact Surface
1. Check if the valve seat contact surface is scratched or
damaged.
2. If necessary, correct the surface with sandpaper. If
damage is severe, replace the seat.
Valve Head Thickness

1. Measure the thickness of the valve head.
2. If the measurement is below the allowable limit, replace the
valve.
Allowable
Standard
Limit
Intake Valve (A) 3.3 ~ 3.7 mm 2.8 mm or below A
Exhaust Valve (A) 3.3 ~ 3.7 mm 2.8 mm or below
EX1403750
Figure 147
Valve Guide Inspection

1. Install the valve to the cylinder head.
2. Measure the clearance between the valve guide and valve
with motion of the valve.
3. If the clearance is excessive, measure the size of the valve Measure
and replace either the valve or valve guide which is worn location
more.
• Valve stem play
EX1403751
Allowable
Standard Figure 148
Limit
Intake Valve 0.023 ~ 0.052 mm 0.1 mm
Exhaust Valve 0.036 ~ 0.065 mm 0.15 mm
Valve Seat Inspection
Contact area on contact surface.

1. To check the wear level of the valve seat, measure the
height of the contact surface from the intake/exhaust
valves.
2. If the measurement is over the allowable limit, replace the
seat.
3. Install the valve to the valve seat of the cylinder head. EX1403752
4. Use a dial gauge to measure the amount of insertion of the Figure 149
value from the bottom of the cylinder head.
Engine DX210W-5
4-1-78
– Valve step portion
Allowable
Standard Valve
Limit
Intake Valve (A) 0.35 ~ 0.65 mm 0.85 mm
Valve Seat
Exhaust Valve (A) 0.35 ~ 0.65 mm 0.85 mm
– Valve angle A
Intake valve (B) Exhaust valve (B) B

60° 45° EX1403753
Figure 150
A. If the amount of valve insertion is over the allowable
limit, replace the valve seat.
B. When removing the valve seat, arc weld two
positions of the valve seat and use a special service
tool to pull out the valve seat.
NOTE: When replacing the valve seat, it should
be bored.
C. When installing the valve seat, put it in dry ice for
approximately two hours to cool it down. Valve Sheet
D. Use a bench press to press the valve seat into the

cylinder head.
E. Apply abrasive to the valve head contact surface of
Cylinder Head
the valve seat.
F. Rotate the valve to grind the valve seat until the valve
is seated. Then, remove the abrasive thoroughly. Weld Bead
EX1403754
Figure 151
Valve Spring Inspection

1. Visually check the outside of the valve spring.
A. Visually check if the valve spring is damaged.
Replace it if necessary.
2. Check the free length of the valve spring.
A. Use vernier calipers to measure the free length of the
valve spring.
B. If the measurement is below the standard value,
replace the valve spring.
Free Length of Spring Standard

Intake Valve 53.5
Exhaust Valve 53.5
EX1403755
Figure 152
DX210W-5 Engine
4-1-79
3. Check the squareness of the valve spring.
B
Reference
Description
Number
A Free Length
B Squareness
A
C Straightedge
A. Use a surface plate and straightedge to measure the C

squareness of the valve spring.
EX1403756
B. If the measurement is over the allowable limit, Figure 153
Allowable
Specification
Limit
Valve Spring
1.4 mm or below 2.0 mm
Squareness
4. Check the tension of the valve spring.

A. Use a spring tester (A) to measure the tension of the
valve spring.
B. If the measurement is below the allowable limit,
Setting Spring Allowable

Item A
Length Tension Limit
Intake/ 39.4 mm 28.8 kg ±2 kg
Exhaust EX1403757
Valves 29.67 mm 50 kg ±2 kg Figure 154
Rocker Arm Removal

1. Use pliers to remove the snap rings from both ends of the
rocker arm shaft.
2. Remove the washer, rocker arm bracket, rocker arm spring
and rocker arm in order.
EX1403758
Figure 155
Engine DX210W-5
4-1-80
Rocker Arm Installation
1. Install the rocker arm in the reverse order of its removal.
CAUTION
AVOID INJURY
• Check if there is any foreign material in the oil
feed hole of the rocker arm shaft. Wash it cleanly.
• Make sure to install the rocker arm in the correct
position in the correct order.
Rocker Arm Inspection
Visual Inspection
1. Visually check the surface of the adjusting screw cap
assembly which moves in contact with the valve stem.
Check if the surface is scratched or has worn layers.
2. If the wear level is small, grind the surface with an oily
whetstone or fine sandpaper. If the surface has severely
worn layers, replace the rocker arm.
Rocker Arm Bushing I.D.
1. Use a micrometer or vernier calipers to measure the inside
diameter of the rocker arm bushing.
2. Compare the measurement with the outside diameter of
the rocker arm shaft. If the clearance is over the allowable
limit, replace either the bushing or shaft which is worn
more.

ø24.991 ~ ø25.012 mm ø25.04 mm EX1403759
Figure 156
Allowable
Standard
Limit
Clearance
between Rocker 0.031 ~ 0.073 mm 0.14 mm or below
Arm and Shaft
DX210W-5 Engine
4-1-81
Rocker Arm Shaft Inspection
Deflection of Rocker Arm Shaft

1. Place the rocker arm shaft on two V-blocks and use a dial
gauge to measure the deflection of the shaft.
2. If its deflection is minute, use a press to straighten it. If its
deflection is over the allowable limit, replace it.
Allowable Limit 0.1 mm
Rocker Arm Shaft O.D.

1. Use a O.D. micrometer to measure the outside diameter of
the rocker arm shaft at the location where the rocker arm EX1403760
was installed. Figure 157
rocker arm shaft.

ø24.939 ~ ø24.960 mm ø25.90 mm
Valve Tappet Inspection
Tappet Clearance
1. Measure the outside diameter of the tappet and the inside
diameter of the tappet hole of the cylinder block.
tappet.

0.028 ~ 0.069 mm 0.13 mm
Visual Inspection of Tappet

1. Visually check the surface of the tappet which moves in
contact with the camshaft. Check if the surface is cracked,
scratched or damaged.
Normal Abnormal Abnormal
2. If such damage is minute, grind the surface with an oily (Irregularity) (crack)
whetstone or fine sandpaper. If its surface has severely
damaged, replace it.
Abnormal Abnormal EX1403761

Figure 158
Engine DX210W-5
4-1-82
Tappet O.D.
1. Use a O.D. micrometer to measure the outside diameter of
the tappet.
tappet.
Standard ø27.962 ~ ø27.982 mm
EX1403762
Figure 159
Push Rod Deflection Inspection

1. Place the push rod on the surface plate.
2. Measure its deflection with a feeler gauge while rolling it.
3. If the measurement is over the allowable limit, replace it.
Allowable Limit 0.25 mm or below
Push Rod Length 344 mm

Feeler Gauge EX1403763
Figure 160
DX210W-5 Engine
4-1-83
Valve Clearance
Adjust the valve clearance under the following conditions:
• When disassembling the engine or cylinder head,
• When loud noise is heard from the valve connection,
• When the fuel injection system is intact but the engine
operates abnormally.
Valve Clearance Adjustment Procedure
Cooling Fan Exhaust Valve Intake Valve Cylinder No. Flywheel
1 2 3 4 5 6
Valve Clearance Adjusting Position
Figure 161 EX1403764
Valve Adjusting Bolt
Valve Rocker arm

Rocker Arm Adjusting
Calliper Adjusting Nut Valve Adjusting
Adjusting Screw
Screw
Screw
A Valve Adjusting
B
Push Rod Nut
Calliper Calliper Push Rod
Intake Valve Spring Exhaust Valve Spring
(Inside and Outside) (Inside and Outside)
Intake Valve Exhaust Valve
Valve Seat
Valve Seat
Intake Valve Adjusting Exhaust Valve Adjusting

EX1403765
Figure 162
Engine DX210W-5
4-1-84
Method 1
1. Turn the crankshaft to set the piston of the cylinder No. 1 to
the TDC on the compression stroke.
NOTE: The cylinder No. 1 can be identified by the
cooling fan.
NOTE: When the cylinder No. 1 is at the TDC on the
compression stroke, valve overlap is occurred
at the cylinder No. 6.
2. Unscrew the rocker arm mounting nut at the cylinder No. 1.
3. Adjust the cylinder clearance with its adjusting nut. Then,
tighten the mounting nut.
Intake Valve (mm) Exhaust Valve (mm)

0.3 0.4
4. Turn the crankshaft to adjust the valve clearance for each

cylinder at the TDC on the compression stroke.
5. According to the cylinder in the valve overlap period, adjust
the valve clearance for the corresponding cylinder at the
TDC on the compression stroke as follows:
Cylinder No. in Valve Overlap Period

1 5 3 6 2 4
6 2 4 1 5 3
Cylinder No. for Valve Adjustment
Method 2
1. Turn the crankshaft to set the valves of the cylinder No. 6
overlapped.
NOTE: The cylinder No. 1 can be identified by the
cooling fan.
2. Adjust the valve clearance marked with ' o ' in the table.
3. Rotate the engine for 1 turn (360°) in the engine rotating
direction to set the valves for the cylinder No. 1 overlapped.
4. Adjust the valve clearance marked with ' x ' in the table.
5. Check the valve clearance again, and adjust it as
necessary.
Cylinder No. 1 2 3 4 5 6
Valve E I E I E I E I E I E I
No. 1 TDC o o o o o o
Turn 360° x x x x x x
DX210W-5 Engine
4-1-85
ACTUATING SYSTEM
Camshaft
General Description
The task of the camshaft is to control the opening and closing of
the intake and exhaust valves. On engines equipped with the
injection system, the camshaft also provides the movement
required to build up pressure in the injectors.
Camshaft Design
The camshaft has two or three cams per cylinder. There is
always one for intake valves and one for exhaust valves. In
some cases, there is also one for the injectors.
A cam can be described with the following terms; see picture:
Reference
Description
Number
1 Cam Profile
2 Base Circle Diameter Figure 163
The Largest Lift of the Cam Profile,
3 Equivalent to the Maximum Movement of
the Roller Tappet.
Function
The camshaft rotates at half the speed of the crankshaft so each
group of cams can actuate the valves of their cylinder every
other engine revolution during the exhaust stroke and intake
stroke. Where applicable, the injectors are actuated in relation to
injection timing.
Valve transition occurs at the arrow. This is when the exhaust
valves are closing and the intake valves are starting to open.
The time point when both the exhaust valves and the intake
valves are open simultaneously is called valve overlap.
Figure 164
Camshaft Play
1. Move the camshaft gear to the opposite side of the cylinder
block.
2. Use a feeler gauge to measure the clearance between the
thrust plate and camshaft gear.
3. If the play is excessive, replace the thrust plate.

Feeler Gauge
0.280 ~ 0.430 mm 0.5 mm
EX1403766
Figure 165
Engine DX210W-5
4-1-86
Inspection
Measure the height of the cam lobe.

1. Use a micrometer to measure the cam lobe height and
journal diameter.
2. If the measurement is below the allowable limit, replace the
camshaft.
Allowable A
Standard
Limit C B B
Cam Lobe Intake 46.025 mm 45.73 mm
Height (C) D A EX1403767
Exhaust 47.782 mm 47.48 mm
Figure 166
Cam Journal Diameter ø55.92 ~
ø57.65 mm
(A and B) ø55.95 mm
Check the cam surface.

1. Check if the cam surface is scratched or damaged.
2. Minutely worn layers or small damage can be corrected
with an oily whetstone or fine oily sandpaper. If damage is
severe, replace it.
Clearance between camshaft and bearing.
1. Use an O.D. micrometer to measure the outside diameter
of the camshaft bearing section.
Camshaft Bearing
2. Use a cylinder I.D. gauge to measure the inside diameter
of the camshaft bearing, and compare the measurement
result with the outside diameter of the camshaft to
calculate the clearance.
camshaft bearing.
EX1403768
Standard Allowable Limit Figure 167
0.03 ~ 0.09 mm 0.18 mm
Camshaft deflection
1. Place the camshaft on two V-blocks.
2. Use a dial gauge to check the deflection of the camshaft.
Correct it as necessary.
3. If its deflection is excessive and cannot be corrected,
replace it.

0.05 mm 0.15 mm
EX1403769
Figure 168
DX210W-5 Engine
4-1-87
Piston
General Description
The piston moves in a reciprocating motion in the cylinder block
to receive high-pressure high-temperature gas in the
combustion stroke and produce rotating power for the crankshaft
through the connecting rod. Its head is designed to withstand hot
combustion gas and high pressure, and three to four piston rings
are fitting around its top to ensure its sealing and to prevent oil
entrance into the combustion chamber.
As it needs to move up and down in the cylinder at a high speed
repeatedly, it needs to be light and robust and have low thermal
expansion characteristic.
• The piston is an important component that receives higher
combustion pressure, So it is necessary to scrap it if the
head or pin hole part involves even a tiny scratch.
• Sometimes, the assembly can be done upside down since
the shapes of the top and bottom side are similar. So, the
assembly work requires attention.
• If the assembly is complete upside down, the piston may
run abnormally, which leads to higher consumption of oil,
increase of bypass gas, damage to the ring, and
sometimes even stand burn of the engine. Therefore, the
whole assembly process needs to take great care.
Parts List
2-1
2-2 2
2-3
Figure 169
Engine DX210W-5
4-1-88
Reference Reference
Number Number
1 Piston 2-3 Ring; Piston
2 Piston Ring Kit 5 Pin; Piston
2-1 Ring; Top 6 Ring; Lock
2-2 Ring; Second
Disassembly
Disassemble the piston according to the specified disassembly
steps.
Assembly
Assemble the piston according to the specified assembly steps.
Piston Inspection
Visual inspection
1. Visually inspect the piston for a crack, scratch and wear.
2. Especially, check if the ring groove is worn.
Clearance between piston and cylinder liner

1. Use an O.D. micrometer to measure the outside diameter
of the piston at the position 12 mm down from the bottom
of the piston in the orthogonal direction of the piston pin
hole.
12 mm
EX1403770
Figure 170
2. Use a cylinder I.D. gauge to measure the inside diameter

of the cylinder liner.
3. Perform the measurement at 3 locations of the cylinder
liner: the top ring contact section, middle section, and oil
ring contact section around the B.D.C. in the 45° direction.
4. Calculate the average value from the measurement results
and exclude the maximum and minimum values.
5. The clearance can be calculated by subtracting the outside
diameter of the piston from the inside diameter of the
cylinder liner. EX1403771
Figure 171
DX210W-5 Engine
4-1-89
6. If this value is over the allowable limit, replace either the
piston or cylinder liner which is worn more.
Clearance between Piston and Liner

Standard 0.079 ~ 0.101 mm
Piston Ring Inspection
Visual Inspection
If any worn or damaged piston ring is found during
disassembling the engine, replace it with a new one. Feeler Gauge
Piston Ring Gap

1. Insert the piston into the top of the cylinder at a right angle
to the cylinder liner wall. EX1403772
2. Use a feeler gauge to measure the piston ring gap. Figure 172
Allowable
Specification
Limit
Ring No. 1 0.30 ~ 0.45 mm 1.5 mm
Ring No. 2 0.60 ~ 0.80 mm 1.5 mm
Oil Ring 0.25 ~ 0.45 mm 1.5 mm
3. If the piston ring gap is over the allowable limit, replace the
piston ring with a new one.
Piston Ring Side Clearance

1. Install the compression ring and oil ring to the piston's ring
groove.
2. Use a feeler gauge to measure the side clearance of the
ring.
Allowable
Standard
Limit
Ring No. 1 - -
Ring No. 2 0.05 ~ 0.09 mm 0.15 mm
Oil Ring 0.03 ~ 0.07 mm 0.15 mm

ring or piston.
Piston Ring Tension

1. Use a tension gauge to measure the tension of the piston
ring.
piston ring.
Engine DX210W-5
4-1-90
Standard
Ring No. 1 1.47 ~ 2.21 kg
Ring No. 2 1.49 ~ 2.23 kg
Oil Ring 4.08 ~ 5.52 kg
Piston and Piston Pin Inspection

1. Measure the wear amount of the piston pin.
pin.
Standard Value for Piston Pin Allowable Limit

ø39.994 ~ ø40.000 mm ø39.94 mm
EX1403773
Figure 173
3. Measure the clearance between the piston pin and

connecting rod bushing.
4. If the measurement is over the allowable limit, replace
either one of them which is worn more.

0.008 ~ 0.020 mm 0.08 mm
EX1403774
Figure 174
5. Check the mounting status of the piston and piston pin.
IMPORTANT
If the piston needs to be replaced, replace the piston
pin as well.
EX1403775
Figure 175
DX210W-5 Engine
4-1-91
Connecting Rod
General Description
The connecting rod is designed to convert the vertical
reciprocating motion of the piston into the rotating motion of the
crankshaft. As it is subject to powerful explosive force, it needs
to be rigid.
Its one end matched with the piston is called "small end" while
its the other end matched with the crankshaft is called "big end."
The big end is split in two parts which are put together with a
bolt. As the big end is connected to the rotating crankshaft, its
inner side is fitted with a replaceable metal bearing.
Parts List
2
1
1-1
3
1-3
CRANKSHAFT
Reference Reference
Number Number
1 Connecting Rod Assembly 2 Metal; Con-rod
1-1 Rod; Connecting 3 Metal; Con-rod
1-3 Bolt; Connecting Rod
Engine DX210W-5
4-1-92
Inspection
Distortion
1. Check the distortion of the connecting rod.
2. Fit the connecting rod to its measuring device and use a
feeler gauge to check its distortion. Feeler
Gauge
3. If the connecting rod is distorted, do not reuse it, but
replace it with a new one.
EX1403776
Figure 177
Hole Parallelization
1. Measure the parallelization of the small end bushing hole
and big end bearing hole of the connecting rod.
NOTE: Use the connecting rod measuring device and
feeler gauge for this measurement.

0.02 mm 0.1 mm or below
Wear
1. Install the connecting rod to the crankshaft.
2. Use a feeler gauge to measure the side clearance at the
big end of the connecting rod.
3. Install the connecting rod to the piston.
4. Measure the side clearance at the small end of the
connecting rod.
connecting rod.

0.17 ~ 0.30 mm 0.50 mm
DX210W-5 Engine
4-1-93
Crankshaft
General Description
The crankshaft is used to convert power from the piston to
rotating torque through the connecting rod and transfer this
torque through the flywheel. Other than in the explosion stroke, it
transfers movement back to the piston, and it transfers rotating
torque to it to drive the oil pump, water pump and high-pressure
fuel pump.
Parts List
CRANKSHAFT
1
Reference Reference
Number Number
1 Pulley; Crankshaft 3 Bolt; Socket
2 Washer; Plain
Inspection
Inspection for Defect

1. Visually check the crankshaft journal and crank pin for a
scratch or crack.
2. Perform the magnetic particle test or dye penetrant test
(color check) to check the crankshaft for a crack. If the
crankshaft is cracked, replace it.
Engine DX210W-5
4-1-94
Wear Measurement
1. Use a O.D. micrometer to measure the journal and pin of
the crankshaft in the specified direction as illustrated to
check its wear amount.
2. If the wear amount is over the allowable limit, grind the
crankshaft to install an undersized bearing.
3. However, if the wear amount is within the allowable limit,
correct it with an oily whetstone or fine oily sandpaper.
NOTE: Use a sandpaper soaked in oil.
Allowable
Standard
Limit
ø79.905 ~
Journal O.D. ø78.905 mm
ø79.925 mm EX1403777
ø68.924 ~ Figure 179
Pin O.D. ø67.924 mm
ø68.944 mm
4. If the pin wear amount is over the allowable limit, grind the
crank journal and crank pin and use an undersized A
bearing.
NOTE: Use a sandpaper soaked in oil to grind the B B
crankshaft.
B B
5. There are four types of undersized bearings. The
crankshaft can be reused by grinding it according to the
undersized bearing to be used.
• Standard A
EX1403778
– 0.25 (I.D.: 0.25 mm smaller than standard) Figure 180
– 0.50 (I.D.: 0.50 mm smaller than standard)
6. Standard for section "R"
• Crank pin section "R": 3.5 ~ 4.0 "R"
• Crank journal section "R": 3.5 ~ 4.0

"R"
IMPORTANT
When grinding the crankshaft, the section "R" at the
end of the bearing should be precisely ground. There Normal Abnormal Abnormal
should be no step or rough surface. EX1403779
Figure 181
DX210W-5 Engine
4-1-95
Crankshaft Deflection
1. Place the crankshaft on two V-blocks.
2. Place a dial gauge on the surface plate. While turning the
crankshaft, measure the deflection of the crankshaft.

0.06 mm 0.15 mm or below
EX1403780
Figure 182
Crankshaft Bearing and Connecting Rod Inspection
Visual Inspection
Visually check the crankshaft bearing and connecting rod
bearing for a scratch, abnormal wear or damage.
Oil clearance between crankshaft and bearing (method 1: using

dial gauge):
1. Main bearing clearance
A. Install the main bearing to the cylinder block, tighten
the bearing cap to the specified torque, and measure
the inside diameter.
Torque 294.1 N.m (30 kg.m, 216.9 ft lb)
B. Compare the inside diameter of the main bearing with

the outside diameter of the crankshaft journal to
calculate the oil clearance.
EX1403781
Main Bearing Oil Clearance Figure 183
0.052 ~ 0.122 mm 0.15 mm
2. Connecting rod bearing clearance

A. Install the connecting rod bearing to the connecting
rod bearing cap, tighten the bolt to the specified A
torque, and measure the inside diameter.
B
Torque 95.6 N.m (9.75 kg.m, 70.5 ft lb)
IMPORTANT 1
2
EX1403782
When tightening the connecting rod bolt, tighten it Figure 184
with a hand until its head touches the bolt seat of the
connecting rod. Then, tighten it finally with a torque
wrench.
Engine DX210W-5
4-1-96
B. Compare the two values obtained from measurement
of the inside diameter of the connecting rod bearing
with the outside diameter of the crankshaft pin to
calculate the oil clearance.

0.030 ~ 0.081 mm 0.15 mm
C. If the clearance is over the allowable limit, grind the

crankshaft journal and pin sections to install an
undersized bearing. EX1403783
Figure 185
Oil Clearance between Crankshaft and Bearing

(Method 2: Using Plastigauge):
1. Install the crankshaft onto the cylinder block.
2. Place a plastigauge onto the journal and pin sections of the
crankshaft.
3. Install the bearing cap and tighten the bolt to the specified
torque.
4. Unscrew the bolt to remove the bearing cap.
5. Measure the thickness of the flat section of the plastigauge
with a plastigauge measuring ruler.
6. This is the oil clearance.
Bearing Spread and Crush

1. Inspection
A. When installing the bearing, check if a large crush is
felt.
EX1403784
Figure 186
OA OB
Spread = O A - O B
EX1403785
Figure 187
DX210W-5 Engine
4-1-97
2. Bearing cap crush
A. Install the bearing and cap to the cylinder block.
B. Tighten the bolt to the specified tightening torque.
C. Unscrew one bolt completely and use a feeler gauge
to measure the clearance between the bearing cap
and cylinder block.
EX1403786
Figure 188
3. Connecting rod bearing crush

A. Install the bearing and cap to the big end of the
connecting rod.
B. Tighten the bolt to the specified tightening torque.
C. Unscrew one bolt completely and use a feeler gauge
to measure the clearance between the bearing cap
and connecting rod big end.

EX1403787
Figure 189
4. Axial play of crankshaft

A. Install the crankshaft onto the cylinder block.
B. Use a dial gauge to measure the axial play of the
crankshaft.

0.14 ~ 0.33 mm 0.4 mm
EX1403788
Figure 190
Engine DX210W-5
4-1-98
Timing Gear
Overview
4-1
5
4
Reference Number Reference Number

Number of Tooth Number of Tooth
1 Oil Pump Gear 33 High-pressure Pump
5 18
2 Crankshaft Gear 44 Idle Gear
3 Camshaft Driving Gear 56 High-pressure Pump
6 33
driving Gear
4 Intermediate Gear (A) 44
4-1 Intermediate Gear (B) 25
Function
The timing gears are located at the rear end of the engine.
Important components such as the unit injector and valve
mechanism require precise control. They are attached to the
rear end of the crankshaft, close to the flywheel, where the
crankshaft rotation is the smoothest.
The crankshaft gear drives intermediate gear. The intermediate
gear drives camshaft gear and high-pressure pump idle gear.
DX210W-5 Engine
4-1-99
LUBRICATION SYSTEM
General Information
General Description
This engine is a forced lubrication type. Oil pressure is
generated and supplied by rotation of the oil pump gear which is
engaged with the crankshaft gear on the back of the cylinder
block. The oil pump receives oil from the oil pan through the
suction pipe to send it to the main passage of the cylinder block
through the oil filter and oil cooler. Then, it is distributed to the
crankshaft bearing, camshaft bearing and rocker arm for
lubrication. Also, as the turbocharger is connected to the engine
lubrication circuit, it receives oil for engine brake operation.
Lubricant is sprayed around the cylinder block and timing gear.
Each cylinder is equipped with its own oil spray nozzle to cool
down the internal section of the piston. Engine oil is filtered by
the oil filter.
Overview
Turbo Charger
Oil Spray Nozzle Rocker Arm Shaft

(For Piston Cooling)
Oil Cooler
Air Compressor
Oil Filter
(Bypass Valve 2.1 kg/cm2
(2.1 bar, 30.5 psi))
Camshaft Bush
Oil Pressure Adjustment Valve

(5.1 kg/cm2 (5 bar, 72.5 psi))
Oil Pump Oil Pump Relief Valve

(10.2 kg/cm2 (10 bar, 145 psi))
Engine DX210W-5
4-1-100
Purpose of Lubrication by Oil
1. Reduction of friction (Prevention of abrasion)
Lubrication maintains the least possible level of friction,
and forms a stronger oil film in a critical state to prevent the
surface friction on the perturbed section and subsequent
defacement.
2. Sealing function
Prevents the leak of gas under a high-pressure in
concurrence with the piston ring, just as in the cylinder
lubrication.
3. Cooling function
Regionally absorbs the heat from parts located on higher
spots, and discharge the heat again in a proper
temperature through the oil cooler and other units
4. Stress dispersing function
Provides momentarily and regionally a great pressure to
lubricated parts to destroy the oil film and raise adherence.
At this point, the lubricant disperses the local pressure
across the entire liquid
5. Anti-rust function
Forms a lubricant film to keep any moisture from infiltrating
into the lubricated surface to produce rust.
6. Oil purifying function
This absorbs alien materials such as carbon or metals
produced at lubricated parts and store them in the oil filter
DX210W-5 Engine
4-1-101
Applicable Oil
Use only specified engine oil according to the environment and
condition of the area.
Engine Oil Viscosity by Temperature
SAE 10 W-30
SAE 0 W-30
SAE 5 W-30
Ambient
Temperature
SAE 0 W-40
SAE 5 W-40
SAE 10 W-40
SAE 15 W-40
Make sure to use proper engine oil according to the following

recommendation.
Capacity (L/U.S.gal.)
Oil Classification Oil Grade
Maximum Minimum Total
SAE 15W40 API CJ-4 or Higher 27/7 17/4.5 29/7.6
NOTE: Make sure to use the recommended genuine oil.

Total capacity of engine oil includes 2.0 liter in
engine.
Engine DX210W-5
4-1-102
Oil Lubricant Circuit
Return
Relief Valve
1 2 3 4
8 7 6 5
By Pass Valve
9
10A
10B
Figure 194
EX1403792
Reference Reference
Number Number
1 Oil Pan 7 Oil Cooler
2 Strainer 8 Oil Filter
3 Oil Pump 9 Oil Cooler
4 Cylinder Block 10A Turbo Charger
5 Timing Gear Case 10B Cylinder Block
6 Cyliner Block
DX210W-5 Engine
4-1-103
Oil Pan
Parts List
10
8
11 8-6
8-5
8-2
9 8-4
8-3
OIL PUMP
5
3
2
EX1403607
Figure 195
Reference Reference
Number Number
1 Pan, Oil 8-2 Bracket; Oil Suct. Pipe
2 Joint; Drain 8-3 Clip; Pipe
3 Seal; Ring 8-4 Bolt M8 x 25
4 Gasket, Oil Pan 8-5 Washer
5 Bolt Assembly M8 x 45 8-6 Nut
6 Tube; Oil Level Gauge 9 Gasket
7 Gauge; Oil Level 10 Bolt Assembly M8 x 25
8 Oil Pipe Assembly 11 Bolt Assembly M8 x 40
Engine DX210W-5
4-1-104
Tightening Sequence
13 9 5 1 3 7 11
17 15
21
19
22
20
16 18
12 8 4 2 6 10 14
Figure 196
EX1403793
DX210W-5 Engine
4-1-105
Oil Pump
General Description
Engine oil is sucked from the oil pan by the gear type oil pump
and then all of the oil is forcibly delivered to the oil cooler and
filter for filtering. The filtered oil passes through the main oil path
of the cylinder block and lubricates bearing parts and the
turbocharger of the engine in order to maintain normal engine
performance.
Parts List
1-4
1-1
1 : 1-1 ~ 1-7
1-5
1-2
1-6
1-3
1-7
EX1403608
Figure 197
Reference Reference
Number Number
1 Oil Pump Assembly 1-5 Pin; Dowel 6M6 x 10
1-1 Housing; Oil Pump 1-6 Cover; Oil Pump
1-2 Gear; Oil Pump 1-7 Bolt Assembly M8 x 22
1-3 Gear; Oil Pump 2 Pin; Dowel 6M6 x 12
1-4 Gear; Drive; Oil Pump 3 Bolt; Collared Hex.
Engine DX210W-5
4-1-106
Disassembly
1. Remove the oil pump drive gear.
A. Loosen the screw to remove the oil relief valve.
B. Unfold the lock washer of the oil pump drive gear to
remove the mounting nut and washer.
C. Remove the drive gear.
2. Unscrew the mounting nut of the oil pump cover to remove
the oil pump cover.
NOTE: The oil pump cover is fixed to the body with 2 Cover Fixing Bolt
retaining pins. EX1403794
Figure 198
3. Remove the drive gear and driven gear.
Assembly
Assemble in the reverse order of disassembly.
Inspection
1. Use a steel ruler and feeler gauge to measure the axial
play of the oil pump gear. If the measurement is over the
allowable limit, replace it.
Allowable Limit 0.03 ~ 0.136 mm
Steel Plate
Feeler Gauge
EX1403795
Figure 199
2. Use a feeler gauge to measure the backlash between the

drive gear and driven gear of the oil pump. If the
measurement is over the allowable limit, replace it.
Standard 0.312 - 0.476 mm

Allowable Limit 0.64 mm
3. Measurement of clearance between drive shaft and bushing

A. Measure the outside diameter of the drive shaft and
drive shaft. If any measurement is below the
allowable limit, replace the corresponding part. EX1403796
Figure 200
Standard ø21.936 ~ ø21.95 mm
Allowable Limit ø21.90 mm
B. Measure the inside diameter of the pump body bushing

and the outside diameter of the shaft. Compare this
measurement with the standard oil clearance value to
determine the necessity of replacement.
Allowable Limit 0.05 ~ 0.085 mm
DX210W-5 Engine
4-1-107
Oil Filter
General Description
As engine oil is sent from the oil pump to each part, it circulates in the engine for lubrication, rust prevention,
cooling, cleaning, sealing and stress dispersion. After it circulates in the engine, it may contain foreign materials.
Therefore, an oil filter is installed between the oil pan and cylinder or in the middle of the flow passage to remove
foreign materials from it.
Parts List
1-6
1-5
1-4
1 : 1-1 ~ 1-6 1-3
4
2
1-2 3 10
11
10 13
12
13 14
1-1
9
OIL COOLER
5
5 7
6 8
Reference Reference
Number Number
1 Oil Filter Assembly 5 O-ring
1-1 Filter; Oil 6 Adapter
1-2 Head; Oil Filter 7 Adapter
1-3 Valve 8 O-ring
1-4 Spring 9 Hose; Oil Cooler
1-5 Seal; Ring 10 O-ring
1-6 Screw; Plug 11 Adapter
2 Washer; Spring 12 Adapter
3 Washer; Plain 13 O-ring
4 Bolt; Hex 14 Hose; Oil Cooler
Engine DX210W-5
4-1-108
Replacing Oil Filter
1. Remove the oil filter using its service wrench.
2. Wipe the head and cartridge contact area of the oil filter
clean.
Oil Cooler
3. Seat the cartridge of the oil filter properly.
4. Apply a small amount of oil to the O-ring section of the
cartridge. Oil Filter
5. Fit a new oil filter loosely by screwing it with a hand.
6. Remove the oil filter using its service wrench.
EX1403647
Figure 202
IMPORTANT
• When replacing the cartridge of the oil filter,
make sure to use the specified genuine one.
• The oil filter should be installed to the engine
without oil in it. Never fill the new oil filter with oil
drained from the used oil filter.
DX210W-5 Engine
4-1-109
Troubleshooting
Phenomenon Causes Troubleshooting

Bad oil Replace oil with specified oil.
Oil leakage from the oil seal ring and packing
Replace it
part
Worn or damaged piston and piston ring Replace it
Too much Oil Consumption
Worn cylinder liner Replace it
Burnt piston ring Replace it
Worn valve guide oil seal, valve guide, or
Replace it
valve stem
Burnt oil pump relief valve Replace it
Clogged oil pump strainer Cleanse the strainer
Worn oil pump gear Replace it
Low Oil Pressure
Cracked oil delivery pipe of the oil pump Replace it
Defect oil pump Repair or replace it
Oil pressure gauge fault Repair or replace it
Worn bearings Replace it
Clogged oil filter Replace the oil filter with a new one
Contaminated Oil Gas leakage Replace piston ring with a new one
Engine DX210W-5
4-1-110
EXHAUST SYSTEM
Turbocharger
General Description
The turbocharger uses heat energy of exhaust gas in the engine
to draw in high density air into the cylinders to increase the
engine power.
Power of the engine is determined by the amount of fuel supply
and the engine's efficiency.
A sufficient amount of air should be supplied to the cylinders to
burn fuel completely and convert this energy to effective work.
Power of the engine is actually determined by the size of the
cylinders. The larger the cylinders are, the more the air is
delivered to burn more fuel, resulting in increase of engine
power.
Supercharging is a process to compress and supply air into the
engine's cylinders. The turbocharger is a device to supply extra
air for combustion with energy of exhaust gas in the combustion
chamber which is usually released and disappeared into the air.
Turbine Wheel and

Shaft Assembly
Oil Inlet
Compressor Housing
Turbine Housing
Exhaust Gas Discharge
Exhaust Pipe
Fresh Air Inlet
Compressor Wheel
Oil Outlet
Intake Manifold
EX1403797
Figure 203
DX210W-5 Engine
4-1-111
Function
1. Turbine:
As exhaust gas discharged from the combustion chamber
passes through the turbine housing, its energy is
transferred to the turbine blades to deliver the rotating
force to the turbine shaft. These series of motions are
occurred in a component called turbine. The turbine is
equipped with the seal ring and heat shield to prevent
exhaust gas from affecting its bearing.
2. Compressor:
As it is connected to the same shaft with the turbine, it
rotates together to receive rotating force from the turbine
shaft in order to receive, compress and send air to the
intake manifold. This is the basic principle of a compressor.
3. Bearings:
Thrust bearing: The turbine wheel is applied with axial
force. This axial force keeps the shaft from moving.
Journal bearing:
This bearing is a floating type and has double oil film on its
inside and outside so that it can rotate independently. As
its double oil film acts as a cushion, the sliding speed on
the bearing surface becomes lower than the rotating speed
of the shaft, ensuring dynamic stability.
4. Seal ring of compressor shaft:
The shaft is equipped with the seal plate and seal ring in a
dual structure to prevent leakage of compressed intake air
and lubricant.
Engine DX210W-5
4-1-112
Parts List
EXHAUST MANIFOLD
A 5
2
6
15
11
A 7
10
9
10 13
12
8
14
13
CYLINDER BLOCK
EX1403610
Figure 204
Reference Reference
Number Number
1 Charger Assembly, Turbo 9 Hose; Rubber
2 Gasket 10 Clamp
3 Nut 11 Gasket; Flange
4 Pipe; Oil Delivery 12 Gasket; Pipe-block
5 Ring; Seal 13 Bolt Assembly M8 x 22
6 Hollow Screw M12 x 1.5 14 Bolt Assembly M8 x 25
7 Pipe; Oil Return 15 Gasket; Exhaust Pipe
8 Pipe; Oil Return
DX210W-5 Engine
4-1-113
Structure
1 2
3 D
A B
4
E
C
EX1403798
Figure 205
Reference Reference
Number Number
1 Impeller Casing A Intake Air Inlet
2 Turbine Casing B Gas Outlet
3 Bearing Casing C Gas Inlet
4 Impeller D Oil Supply
5 Turbine E Oil Discharge
Engine DX210W-5
4-1-114
Troubleshooting

Rotating part is contacted Repair or replace it
Unbalanced rotation of a rotor Repair or replace it
Burn Repair or replace it
Loose joint Check or repair it
Deformed or damaged intake unit hose Replace it
Poor clamping state Adjust and tighten the clamp
Replace and check if the impeller of the
Contaminated or damaged air filter
turbocharger is damaged
Leakage of coolant from the turbocharger or
Replace the hose and the gasket
oil from the oil hose
Leakage of gas from the exhaust manifold Replace the gasket or tighten the fixing nut
Noise or Vibration Poor turbo actuator operation Replace the turbocharger
Leakage from the engine block and the
Check the engine
exhaust manifold
Contaminated blowby gas and abnormal oil Check the turbo impeller and the turbo intake
amount outlet
Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
interference with the wall substance
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance
Damaged wheel and shaft of the Check if there is any sand or metallic foreign
turbocharger substance
Poor rotating force of the turbocharger wheel
substance
DX210W-5 Engine
4-1-115
Leakage of gas from each part of the exhaust
Check or repair it
system
Clogged air filter element Replace or clean it
Contaminated or damaged turbocharger Repair or replace it
Leakage of air from the discharging part of
Check or repair it
the compressor shaft
Poor turbo actuator operation Replace the turbocharger
Lowered Output
Check the engine
exhaust manifold
amount outlet
substance
substance
Oil Leakage turbocharger is damaged
Check the engine
exhaust manifold
amount outlet
Oil Leakage
substance
substance
Engine DX210W-5
4-1-116
Check the engine
exhaust manifold
amount outlet
Oil Consumption Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
substance
substance
Black and White amount outlet
Emissions
substance
substance
Blue Emissions Check the engine
exhaust manifold
Oil leakage to the turbine or compressor Repair or replace it
Too much Fog Worn or damaged seal ring due to worn
Repair or replace it
bearing
Clogged air filter element Replace or clean it
Clogged air duct Check or repair it
Air leakage from the intake system Check or repair it
Too much
Exhaust The turbocharger cannot rotate because of
Emissions burning
A turbine blade or compression wing contacts
with the other one or is damaged
Deformed or clogged exhaust system pipe Check or repair it
DX210W-5 Engine
4-1-117
How to Maintain Turbocharger
Cautions for Engine Operation

Observe the followings when starting, operating, and stopping
an engine.
Item Cautions Reasons

Check the oil amount
Therefore, start the engine with the starter
Overhasty start of engine leads to engine
motor to check the rise of oil pressure (until
rotation without lubricating turbocharger and
the gradation of the oil pressure gauge
other engine parts, causing abnormal wear
moves or the pressure indicator lamp is
or burning of bearings.
turned on).
Starting an Engine If you replace oil, oil filter cartridge, or
lubrication system parts or use an engine in
cold areas, or the engine has stopped for a
When an engine has stopped or kept cold
long period, loosen the oil pipe joint at the
for a long period, circulation of oil in the pipe
inlet of the turbocharger and run the starter
gets poor.
motor until oil flows out. After completing the
work, tighten the oil pipe joint again and start
the engine.
When the engine is suddenly loaded while
the engine and the turbocharger have not
Operate the engine at idle for five minutes
been smoothly rotated after starting the
from starting it.
After Starting an engine, parts with insufficient oil may be
Engine burnt.
Leakage of oil, gas, or air (especially oil)
Check if oil, gas, or air is leaked from each
reduces oil pressure and loss of oil cause
part. If so, take proper action.
burning of bearings.
check the following.
Oil pressure
At idle: 1.5 ~ 3.0 kg/cm2 (1.5 ~ 3.0 bar, 21.3 Too low oil pressure causes abnormal
~ 42.7 psi) wearing or burning of bearings. Too high oil
During Operation pressure causes oil leakage.
Fully loaded: 3.0 ~ 5.5 kg/cm2 (3.0 ~ 5.5 bar,
42.7 ~ 78.2 psi)
When abnormal noise or vibration occurs, Operating an engine with noise or vibration
slowly reduce the rotate count until the may cause irreversible damage of the
engine stops and then figure out the causes. engine.
Sudden engine stop after operating the
engine under high load allows the heat from
Operate the engine at idle for five minutes the red-heated turbine blade to be delivered
Stopping an Engine
before stopping it. to the bearing system. Then oil burns and
the bearing metal and rotation shaft are
burnt.
Engine DX210W-5
4-1-118
Cautions for Maintenance
1. When the rpm is rapidly increased after starting the engine,
the journal bearings in the crankshaft is excessively
rotated, the crankshaft is rotated at excessive speed
before the journal bearing of the crankshaft is lubricated
fully. If the turbocharger rotates in this situation, bearings
are not smoothly cooled and lubricated, causing bearing
burn and damage of the related parts.
2. Please operate the engine for two minutes or more in order
to lubricate the turbocharger fully after replacing the engine
oil or oil filter.
3. If an engine has been operated at high speed for a long
period, fully operate the engine at idle and then stop the
engine. Otherwise, the turbine wheel continuously runs
without oil pressure in the turbocharger. Therefore, no oil
film is created on the center bearings and the journal
bearings of the turbocharger, causing bearing, wearing out
and shortening of the turbocharger lifetime.
4. If an engine is not operated for a long period during cold
weather or in areas with cold climate, operate the engine at
idle after starting the engine until the engine oil pressure is
normal.
5. The turbocharger turbine spins at high speed of 50,000 ~
200,000 rpm. Therefore, lubrication of bearings may
determine the turbocharger lifetime. Please use only
recommended genuine engine oil and check and replace
the engine oil periodically.
6. Prolonged usage of contaminated air cleaner may cause a
critical damage of the turbocharger. Regularly check and
replace the air cleaner.
7. A turbocharger is a very complex and precise part. Only
certified and skilled technicians should work on it.
8. If a turbocharger is operated without intake and exhaust
pipe, serious human injury may occur and critical faults of
the engine performance may occur. Please operate a
turbocharger only when all of parts are exactly mounted on
the specified position.
9. Do not lift up a turbocharger by grabbing the actuator. The
actuator may be damaged because of the weight of the
turbocharger.
10. The weight of a turbocharger is about 4.0 kg or more. To lift
up a turbocharger for installing or removing it, the worker
should lower the center of gravity or press his body close
to the turbocharger. Otherwise, worker may drop the
turbocharger, causing damage of the part and injury.
DX210W-5 Engine
4-1-119
Inspection Items during Disassembly/Assembly of Turbocharger
Possible Problem
Consumption
Blue Smoke
Power Drop
Oil Leakage
White/black
No. Inspection Items Action
Smoke
Noise
Oil
Before Removal
1 Is the intake hose torn or deformed? ○ ○ ○ ○ Replace hose
2 Is the clamp tightened firmly? ○ ○ ○ ○ Tighten bolt/nut correctly
Replace air filter and check
3 Is the air filter intact? ○ ○ ○ ○ turbocharger impeller for
damage
4 Does turbocharger or oil hose leak? ○ ○ ○ ○ Replace hose and gasket
5 Is gas leaked from exhaust manifold gasket? ○ Replace nut and gasket
Replace solenoid and EGR
6 Do solenoid valve and EGR system intact? ○ ○ ○ valve
Does the turbocharger actuator operate
7
correctly? ○ ○ ○ ○ Replace turbocharger
During Removal
Is there a sign of leak between the engine block
1
and exhaust manifold? ○ ○ ○ ○ ○ Check engine
Check turbocharger impeller

Is the amount of oil and foreign material led with
2
blow-by gas normal? ○ ○ ○ ○ ○ and turbocharger intake air
outlet
Is there a sign of interference of the wheel with Check for foreign materials
3
the wall due to excessive play of the wheel? ○ ○ ○ ○ ○ (sand, metallic object)
Check for foreign materials
4 Is the wheel damaged? ○ ○ ○ ○ ○ (sand, metallic object)
After Removal
Check for foreign materials
1 Is the wheel damaged or is the shaft broken? ○ ○ ○ ○ ○ (sand, metallic object)
2 Does the wheel rotate properly? ○ ○ ○ ○ ○
Inspection
Daily Inspection and Service

It is important to handle the engine and maintain its optimum
condition according to the instructions as the performance of the
turbocharger is highly affected by the maintenance condition of
the engine.
1. Intake system
In the intake system, the air filter should be maintained with
care. For a wet type air filter, if the oil level is below the
specified level, its filtering performance is deteriorated. On
the other hand, if the oil level is too high, it sucks in oil and
contaminates the case. Especially, if the rotor is
contaminated, the precisely adjusted balance is destroyed
and the bearing is applied with large force, resulting in
vibration, seizure and abnormal wear. Therefore, the air
filter should be well-maintained and handled with care. A
Engine DX210W-5
4-1-120
dry air filter should feature low possible intake air
restriction.
2. Exhaust system
If exhaust gas is leaked from the exhaust pipe or
turbocharger connection in the exhaust system, the
turbocharger's performance is deteriorated. Extra care is
needed to prevent a gas leak and seizure. A heat resisting
steel nut is used for parts, which can become hot during
driving, such as the turbine housing. Make sure not to mix
it with a general nut, and apply screw's anti-seize
compound to the specified mounting nut.
3. Lubrication system
In the lubrication system, the oil quality and the cartridge
replacement interval of the oil filter should be monitored
with care. Degraded engine oil can affect not only the
engine body, but also the turbocharger negatively.
Periodic Inspection and Service

Check the turbocharger for its condition and contamination
periodically.
1. How to check rotating condition of rotating part
When checking the rotating condition of a rotating part,
check for abnormal noise. When using a sound bar, touch
the turbocharger housing with its tip and rev up the engine
slowly. If a high pitch note is continuously heard, it is
abnormal. If abnormal condition is found, it is possible that
the bearing or rotating part is defective. In this case,
replace or repair the turbocharger.
2. How to check play of rotating part
Separate the turbocharger from the engine and check the
axial play and circumferential play of the rotating part.
When separating the turbocharger, make sure to seal the
oil inlet and outlet with plastic tape.
• Axial play of rotating part
C
B
Reference
Description
Number
A Dial Gauge
B Magnet Vice D
C Turbine Compartment A
Move the Turbine Shaft in the Axial
D
Direction.
E Service Standard (0.038 ~ 0.093 mm) E (F)
EX1403799
F Wear Limit (0.24 mm) Figure 206
DX210W-5 Engine
4-1-121
• Circumferential play of rotating part
B
Reference C
Description
Number A
A Oil Outlet
B Dial Gauge
C Magnet Vice D
Move the Turbine Shaft to the Left and
D F (G)
Right in the Circumferential Direction.
E
Standard Circumferential Play
E EX1403800
(0.326 ~ 0.496 mm) Figure 207
F Standard Wear (0.50 mm)
• If the axial or circumferential play is over the wear

limit, replace or remove and repair the turbocharger.
3. Tips for turbocharger disassembly and inspection
Remove the turbocharger from the engine to clean or
check it. Make sure to seal the oil inlet and outlet with
plastic tape after its removal.
4. Cautions for turbocharger installation
When or after installing the turbocharger to the engine,
make sure keep the followings: Make sure that no foreign
material enters the turbocharger.
• Lubrication system
Before installation to the engine, add new oil through
the oil filler hole and turn the turbine shaft with a hand
to lubricate the journal bearing and thrust bearing.
Clean the pipes between the engine and oil inlet and
between the pipe and oil outlet thoroughly and check
them for damage and foreign materials.
Tighten each connection of the oil pipes firmly to
prevent an oil leak.
• Intake system
Check if there is no foreign material in the intake
system.
Install each connection of the intake system and air
filter firmly to prevent an air leak.
• Exhaust system
Check if there is no foreign material in the exhaust
system.
Make sure to use only heat resisting bolts and nuts.
Be careful not to mix them with general bolts and nuts
during assembly. Apply anti-seize compound to the
bolt and nut before installing them.
Tighten each connection of the exhaust system firmly
to prevent any gas leak.
Engine DX210W-5
4-1-122
EGR (Exhaust Gas Recirculation) System
General Description
The EGR (Exhaust Gas Recirculation) system recirculates a
portion of exhaust gas back to the intake system to cool it down
and supply it to the engine for re-combustion in order to reduce
NOx emission.
To reduce NOx and other emissions from the engine, it
circulates exhaust gas containing almost no oxygen toward the
intake system to decrease the density of oxygen supplied to the
engine and induce combustion at a low temperature. As a result,
a reduced amount of NOx is produced.
This system is equipped with the EGR cooler to reduce the
temperature of hot exhaust gas in order to reduce the amount of
NOx and enhance engine combustion efficiency.
1 3
EX1403801
Figure 208
Reference Reference
Number Number
1 EGR Cooler 3 EGR Valve
2 Exhaust Pipe 4 Exhaust Manifold
DX210W-5 Engine
4-1-123
Function
The EGR system is active between approximately 900 rpm and
the maximum engine speed with a positive torque and when the
coolant temperature exceeds approximately 50°C.
The principle of the EGR system is that some of the exhaust
gases are returned to the engine. The quantity of oxygen is
reduced by mixing the intake air with exhaust gases resulting in
a lower combustion temperature. In this way, the quantity of
nitrogen oxides.
NOx, in the exhaust gases is reduced.
The reduced nitrogen oxide emissions make it possible to meet Figure 209
emissions regulations and to optimize engine power and fuel
consumption.
Flow of Air and Exhaust Gases

Part of the exhaust gases leaving the engine by the exhaust
manifold are led by the EGR valve through the EGR cooler,
where they are cooled.
The cooled exhaust gases are drawn back to the intake and
mixed with the intake air.
Controlling the Flow

The engine control unit controls the flow of exhaust gases. The
control unit regulates EGR content, i.e. the volume of exhaust
gases that are returned to the engine. The level is measured in
percent 10% EGR content means that 10% of the total flow into
the engine is exhaust gas and 90% is air.
The mass flow sensor detects and informs the control unit of
how much air passes into the engine. The control unit also
receives information from the charge air pressure and
temperature sensors and the exhaust gas pressure sensor. The
control unit uses information from the sensors to calculate the
total volume of gas (air and exhaust gases) which enter the
cylinders. By measuring the total volume of gases and
subtracting from this the airflow from the mass flow sensor, the
control unit calculates the EGR content.
To increase measurement accuracy and to avoid incorrect
values, the control unit shuts the EGR valve for a preset time
interval, to avoid any gases flowing back to the cylinders. The
control unit compares the value from the mass flow sensor with
the calculated gas volume entering the cylinders. These two
values must be the same. If the values do not agree, the control
unit calibrates the mass flow sensor. The system is set in motion
when the engine is started and warmed up.
If a fault occurs in the system which results in the control unit not
being able to control the components as expected, fault codes
are generated and the control unit reduces the engine power
until fault is rectified.
Engine DX210W-5
4-1-124
Cold Engine
The EGR valve is closed until engine has been warmed up. No
exhaust gases are then circulated.
Warm Engine
Once the engine has been warmed up, the EGR valve is open
and exhaust gases then circulate in the EGR system. Where the
throttle is rapidly opened, the engine control unit reduces the EGR
content. This is intended to compensate for the shortage of
induction air that occurs before the turbocharger begins to charge.
Shut-off Conditions
• The control unit shuts down the EGR system if:
• The charge air temperature falls below a specific value.
There is then a risk of freezing in the intake manifold.
• The engine is at such a high altitude that air pressure
affects its performance.
• Coolant temperature is too high. At very high coolant
temperature, the control unit closes the EGR valve to avoid
loading the engine with additional heat from the EGR
cooler.
• The white smoke limiter is active.
• There is a risk of the EGR system freezing if the ambient
temperature is very low.
DX210W-5 Engine
4-1-125
Parts List
INTAKE STAKE
18
19
17
35
2
38
39
3 5 37
2
6 36
4
1
14
A
16 39
15
B
16 34
C 31
D 28
8
23 34
7
11 A
10 20
11 26 33
32
9 41
30 29
12
B
13
C 33
32
COOLING WATER PIPE
CONNECTION
D
40 42
EXHAUST MANIFOLD 30 29
25
24
25
22
WATER 21
PUMP 27
EX1403726
Figure 210
Engine DX210W-5
4-1-126
Reference Reference
Number Number
1 Cooler; EGR 22 Bolt Assembly M8 x 25
2 Gasket; EGR Cooler 23 Bolt Assembly M8 x 25
3 Adapter; Connector 24 Hose; Cooling Water
4 Seal; Ring 25 Clamp; Hose
5 Screw; Plug M10 x 1.5 26 Pipe Assembly; Cooling Water
6 Ring; Seal 27 Gasket; Water Pipe
7 Pipe Assembly; Cooling Water 28 Bolt Assembly M8 x 25
8 Gasket; Water Pipe 29 Adapter
9 Bolt Assembly M8 x 25 30 Ring; Seal
10 Hose; Rubber 31 Valve; EGR
11 Clamp; Hose 32 Adapter
12 Bracket 33 Ring; Seal
13 Bolt; Collared Hex. 34 Gasket; EGR Valve
14 Bolt Assembly M10 x 140 35 Exhaust Pipe Assembly
15 Hose; Rubber 36 Bolt; Stud
16 Clamp; Hose 37 Nut
17 Pipe Assembly; Exhaust 38 Pipe; Exhaust
18 Gasket; Manifold 39 Bolt; Hex.
19 Bolt Assembly M8 x 30 40 Pipe Assembly; Cooling Water
20 Gasket; Water Pipe 41 Pipe Assembly; Cooling Water
21 Pipe Assembly; Cooling Water 42 Bolt Assembly M8 x 18
Disassembly
1. Remove the EGR valve and disconnect the elbow pipe.
NOTE: Perform the process with the heat shield and
bellows pipe removed.
CAUTION
AVOID INJURY
As the EGR system is hot by exhaust gas, it should be
disassembled after it is sufficiently cooled down.
A. Remove the nut from the stud bolt.

B. The cooling pipe should be disconnected to remove
the EGR valve.
2. Remove the EGR bracket.
NOTE: Components available for removal after removal
of exhaust manifold
DX210W-5 Engine
4-1-127
Assembly
CAUTION
AVOID INJURY
Any used gasket should be replaced with a new one.
EGR Cooler Disassembly and Assembly
Disassembly
As the EGR system becomes hot by exhaust gas while the
engine is running, it should be disassembled after it is
sufficiently cooled down.
1. Disconnect the coolant inlet/outlet pipes and hoses.
2. Remove the gas pipe outlet and hose.
3. Remove the heat shield.
4. Disconnect the bellows pipe.
5. Remove the EGR cooler mounting bolts.
6. Remove the EGR cooler from the EGR bracket.
Assembly
CAUTION
AVOID INJURY
Any used gasket should be replaced with a new one.
Engine DX210W-5
4-1-128
Checking EGR System
Leak test and functional inspection of the EGR system
components
It is normal to find a certain amount of soot coating in engines
with EGR systems.
Component How
Search for heavy soot accumulation. Check that EGR valve is
EGR Valve properly closed. Check that EGR valve springs back to the closed
position.
The Pipe between the EGR Valve and
Check that there is no abnormally large leakage.
the EGR Cooler
The Pipe between the Cooler and the
Inlet Pipe
EGR Cooler Searching for leakage in the EGR cooler.
The Hoses to and from the Air-cooled
EGR Cooler
Check using checking tool that EGR valve control cylinder is working
Control Cylinder to EGR Valve
properly.
If it does leak, the EGR components may need cleaning.
DX210W-5 Engine
4-1-129
DNOx System
General Description
The Doosan engine is equipped with the DOC (Diesel Oxidation
Catalyst) and SCR (Selective Catalytic Reduction) systems in
order to comply with Tier 4 final (and stage IV) emission control.
This SCR system consists of the dosing module, supply module,
ECU (Engine Control Unit) and other components. The DEF
(Diesel Exhaust Fluid) is stored in the DEF tank. Once it is
needed, it is pressurized by the supply module and is delivered
to the dosing module under a certain level of pressure. The
dosing module is attached to the exhaust manifold to spray DEF
into the exhaust manifold in front of the SCR system.
EX1403802
Figure 211
Engine DX210W-5
4-1-130
Aftertreatment Muffler and Catalyst
The aftertreatment muffler consists of the DOC muffler, SCR
muffler, mixer pipe and other pipes. The DOC muffler contains 3
DOC (Diesel Oxidation Catalyst) while the SCR muffler contains
SCR (Selective Catalytic Reduction).
Reference
Description
Number
1 DOC Converter
2 Mixer
2
3 SCR Muffler
1 EX1403803
Figure 212
DNOx2.2 System
The DNOx2.2 system is used to reduce NOx in emissions by
spraying urea into the SCR catalyst. It consists of the SM
(Supply Module), which functions as a pump, DM (Dosing
Module) to spray urea, DCU to control the overall system, urea
tank to store urea and urea/cooling water line.
Coolant Out
Coolant In
Coolant In
Urea Urea Press Line

Suction Line
Urea
Back Line
Urea Tank
Coolant Out
Coolant Heat
SM
(Supply Module)
Electrical Heat
EX1403804
Figure 213
DX210W-5 Engine
4-1-131
Urea Tank
The urea tank is used to store urea liquid. Connect lines to the
specified positions. Also, be careful not to apply impact to the
urea tank during its service.
3
12
13 6
1
7
14
11 8
2
9
5 10
4
15
EX1403805
Figure 214
Reference Reference
Number Number
1 +24 V (Pin No. 1) 9 Coolant Inlet
2 Ground (Pin No. 2) 10 Level Indicator
3 CAN High (Pin No. 3) 11 Urea Tank Cap
4 CAN Low (Pin No. 4) 12 Inlet
5 Coolant Inlet 13 Backflow
6 Coolant Outlet 14 Outlet
7 Urea Outlet 15 Drain Plug
8 Urea Inlet
Engine DX210W-5
4-1-132
Urea Filter Replacement
IMPORTANT
The replacement interval of the DEF (urea solution) filter is
different by the amount of foreign materials in DEF.
Make sure to use only the specified DEF and container and
keep the surrounding area of the tank clean to prevent
possible foreign materials.
1. Remove filter cover.
Figure 215
2. Remove equalizing element.
Figure 216
3. Check the color (gray/green) in the filter.
Figure 217
DX210W-5 Engine
4-1-133
4. Set the color of the mark on the end of the filter removing
tool in the same direction with the filter color section.
Figure 218
5. Insert the end of the filter removing tool until a clicking

sound is heard or engagement with the filter is felt.
Figure 219
6. Pull the filter removing tool to remove filter.
Figure 220
7. The surface must be kept clean. It can be cleaned with

water only.
Figure 221
Engine DX210W-5
4-1-134
8. Apply oil to the O-ring and install a new filter.
CAUTION
AVOID INJURY
Use Mobil Velocite No. 6 oil from Bosch.
Figure 222
9. Install a new equalizing element.
Figure 223
10. Tighten the filter cover to 20 N.m + 5 N.m.
CAUTION
AVOID INJURY
Check that filter surface is clean. It can be cleaned with
water only.
Figure 224
DX210W-5 Engine
4-1-135
Supply Module
The supply module is used to pressurize DEF in the DEF tank to
a certain level and supply this pressurized DEF to the dosing
module.
Pin 8 Pin 2
7 Pin 12 Pin 6
2
6
3
5
4
EX1403806
Figure 225
Reference Reference
Number Number
1 Connector 5 Cover Plate
2 Adblue Inlet 6 Detail Marking
3 Adblue Backflow Outlet 7 Filter Cover
4 Adblue Outlet
Engine DX210W-5
4-1-136
Dosing Module
The dosing module is attached to the exhaust manifold in front
of the SCR system to receive DEF from the supply module and
spray it into the exhaust manifold.
1 2
7 4
EX1403807
Figure 226
Reference Reference
Number Number
1 Coolant Outlet 5 Cooling Adapter
2 Coolant Inlet 6 Dosing Valve
3 Head Shield 7 Adblue Inlet
4 Protective Cap
DX210W-5 Engine
4-1-137
Checking DNOx2.2 System
Dosing Module
Dosing Moduel fault is cause of the high temperature exposure
of nozzle tip injecting urea, electric harness contact failure, urea
hose line break or poor contacet, and more. Visual inspection of
dosing module failure are as follows.
1. When replacing dosing module, dosing module and bolts is
the leakage or damage caused by under tightening bolts or 1 2
over tightening.
3
2. Electric connector misassembly or debris contamination
inside of connector.
5
3. Urea leakage is caused by urea line misassembly.
4
4. Coolant leakage is caused by coolant line misassembly.
The high temperature exposure of dosing module is
caused by disconnected.
EX1403808
5. The high temperature exposure of dosing module is Figure 227
caused by gasket misassembly.
6. Urea leakage is caused by gasket reuse.
Supply Module
The supply module (SM) failure mode is associated with urea
line and electric connector damage and poor connection. When
replacing urea main filter regularly, supply module failure can
occur caused by disassembly.
CAUTION
AVOID INJURY
When replacing new filter, open the package on the verge of
replacement.
1. When connecting urea line, the failure caused by urea line

2
misassembly. 3
2. Electric connector misassembly or debris contamination

inside of connector. 4
3. When replacing supply module filter, the damage caused
by not using the special tool. Also, it caused by filter
remnants inside supply module filter.
1
4. When replacing filter, the urea cap damage is caused by
1
overtihgtneing and the filter detachment is caused by not
1 EX1403809
tightening.
Figure 228
Engine DX210W-5
4-1-138
Urea Tank
Urea Tank is keeping the urea solution. Assembly connected
line to correct location. When maintenance of urea tank, be
careful not to external impacts.
3
12
13 6
1
7
14
11 8
2
9
5 10
4
15
EX1403805
Figure 229
1. Urea inlet hose and backflow hose are incompatible, do

not use them together. Be careful to damage the
connector, assemble the connector.
CAUTION
AVOID INJURY
Urea inlet hose is marked red color, backflow hose is
marked yellow color.
2. Make sure that urea tank fixing bracket mount is tightened.

If it is not tightened, it could occur the damage caused by
vibration.
3. Make sure that the connection condition of tank
temperature and level sensor connector. Be careful to
damage connector and be contaminated debris.
4. Assembly coolant line to correct location. If it is not
tightened, it could leak coolant.
DX210W-5 Engine
4-1-139
5. Make sure that the connection condition of urea line heater
(2-pin). Not running a heater in winter season there is a
danger of frost.
Muffler and Other Pipes

It is no necessary to replace, disassemble and move mounted
muffler and other pipes except by failure caused by external
impact. Tighten the each parts at tightening torque not to
leakage, when replacing, disassembling and moving muffler and
other pipes caused by failure.
Engine DX210W-5
4-1-140
COOLING SYSTEM
General information
General Description
This engine is a water-cooled type. Combustion heat from the
combustion chamber and heat from engine oil are absorbed by
coolant and dissipating them to the outside air to ensure
optimum engine operation.
In the cooling system, coolant supplied from the coolant pump is
sent to the oil cooler through the coolant pipe to absorb heat
from oil before it passes through the coolant jacket of the
cylinder block and through the cooling passage of the cylinder
head to absorb combustion heat.
After this coolant absorbs oil heat and combustion heat, it is led
to the thermostat through the coolant pipe. If the coolant
temperature is below the valve opening temperature of the
thermostat, the coolant flows into the coolant pump. If the
temperature is over the opening temperature, it flows into the
radiator. In the radiator, it releases heat and returns back to the
coolant pump in a low temperature condition again.
Turbo Charger Actuator
Thermostat Cylinder Head

Radiator
EGR
Cylinder Block EGR Valve
Cooler
HC Dosing
Water Pump Oil Cooler Injector
EX1403810
Figure 230
DX210W-5 Engine
4-1-141
Thermostat
General Description
The thermostat maintains water temperature in the engine
consistently and prevents heat loss to improve heat efficiency of
the engine.
When the coolant temperature is below the normal temperature,
the thermostat is closed and the coolant is bypassed and directly
flows into the water pump. When the coolant temperature
reaches the normal temperature or is higher than the
temperature, the thermostat is fully open and the bypass circuit
is closed. So the coolant flows into the radiator.
CAUTION
AVOID INJURY
• The wax pellet type thermostat shows slower
response to the change of cooling water than the
bellows type thermostat. This happens because the
heat capacity of the wax pellet type thermostat is
larger than that of the bellows type thermostat.
Therefore, to prevent a rapid increase in the engine
coolant's temperature, you must first operate the
engine at idle until the engine is fully warmed up.
When the weather is very cold, do not operate the
engine in an overloaded condition or at a high speed
after starting the engine.
• When draining water from the engine cooler or
injecting water to the engine cooler, work slowly to
ensure that all air inside the cooler is expelled.
• When a defect is found in the thermostat, replace it
with a new one.
Reference
Description 1
Number
1 Heat Exchanger
2 Bypass Valve
3 Water Pump
4 Coolant Pipe
4 2
3
EX1403811
Figure 231
Engine DX210W-5
4-1-142
Parts List
1 : 1-1 ~ 1-4
13
10
11
1-1
12
1-3
5
4 6
1-2
8
1-4 7
3
9
EX1403727
Figure 232
Reference Reference
Number Number
1 Thermostat Assembly 6 Gasket
1-1 Housing; Thermostat 7 Connection
1-2 Thermostat 8 Bolt Assembly M8 x 60
1-3 O-ring 9 Bolt Assembly M8 x 45
1-4 Bolt; Hex 10 Outlet; Water
2 Gasket; Thermostat 11 Gasket; Water Pump
3 Bolt; Hex 12 Bolt Assembly M8 x 30
4 Washer; Spring 13 Connection; Screw
5 Washer; Plain
DX210W-5 Engine
4-1-143
Cautions for Replacement and Handling of Thermostat
1. Cautions for handling
A wax pellet type thermostat features relatively slow
response for change in coolant temperature compared to a
bellows type. This is because the wax pellet type has
larger thermal capacity. Therefore, it needs to idle the
engine sufficiently before running it in order to prevent
surge of engine coolant temperature. In cold weather,
never overload the engine or speed drive.
2. When adding or draining coolant to/from the engine cooling
system, do it slowly to let air in the system escape.
3. Thermostat replacement
If any defect is found on the thermostat, replace it with a
new one.
Thermostat inspection
1. Check if the wax pellet and spring are damaged.
2. Put the thermostat into water and heat the water gradually
to check for operation of the thermostat. Ruler Thermometer
If the thermostat starts to open at 83°C (water

temperature) and it is fully open at 95°C, it is normal.
3. Check if there is any foreign material in the thermostat. Wood Plate
NOTE: Clean the inside of the thermostat using a air
gun.
4. Check the hose for internal or external damage or foreign EX1403812
materials. Figure 233
Engine DX210W-5
4-1-144
Cooling fan
General Description
The speed of the cooling fan is controlled by the electronic fan
clutch in order to maintain its optimum speed. The electronic fan
clutch adjusts the cooling fan speed electrically according to the
coolant temperature, hydraulic oil temperature, CAC (Charge Air
Cooler) temperature and engine speed to reduce cooling fan
noise and obtain superior efficiency.
Specification
Weight Approximately 9.0 kg

Tightening Torque for M8 bolt 21.6 N.m (2.2 kg.m, 15.9 ft lb)
Tightening Torque for M10 bolt 43.1 N.m (4.4 kg.m, 31.8 ft lb)
Parts List
10
2 7
4
3
5
Figure 234 1 EX1403728
Reference Reference
Number Number
1 Fan Clutch Assembly 7 Pulley; Fan
2 Fan; Cooling 8 Fan Drive Assembly
3 Bolt Assembly M8 x 18 9 Bolt Assembly M10 x 40
4 Flange; Fan 10 V Belt
5 Bolt Assembly
DX210W-5 Engine
4-1-145
Troubleshooting

Not enough coolant Replenish the coolant
Defective radiator cap Replace it
Contaminated radiator Clean the exterior of the radiator
Defective V-belt offset Adjust or replace it
Contaminated or damaged V-belt Replace it
Damaged impeller Replace the water pump
Overheated Engine
Defective impeller fix Replace the water pump
Bad water pump operation Replace it
Bad thermostat operation Replace it
Bad coolant flow Clean the coolant path
Improper injection time Check it with the failure diagnosis unit
Damaged cylinder head gasket Replace it
Bad thermostat operation Replace it
Overcooled Engine
Too low ambient temperature Heat the block
Damaged radiator Repair or replace it
Loosened or damaged radiator
Repair or replace the connection
connection
Defective radiator cap Replace it
Badly mounted water pump Repair or replace it
Leaking Coolant
Bad or damaged water pump gasket Replace the gasket
Badly mounted thermostat Repair or replace it
Bad or damaged thermostat gasket Replace the gasket
Damaged cylinder head gasket Replace the gasket
Damaged cylinder head or block Replace it
Bad water pump bearing Replace the bearing
Bad or damaged cooling fan Repair or replace it
Noise
Bad rotation of the cooling fan Replace it
Defective V-belt offset Adjust or replace it
Engine DX210W-5
4-1-146
FUEL SYSTEM
General Information
This diesel engine compresses air delivered into its cylinders
and sprays fuel with its injection nozzles to burn fuel with
compression heat.
When the high-pressure pump produces high-pressure fuel, this
fuel is kept by the common rail and its injection timing and
injection amount are calculated by the ECU (Electronic Control
Unit). The ECU (Electronic Control Unit) operates the solenoid
valves of the injectors on each cylinder to inject fuel.
This common rail fuel injection system has the high-pressure
producing part and the fuel injection part separated. The ECU
determines the fuel injection amount, injection timing and
injection pressure according to the operating condition of the
engine before injecting fuel into the cylinders in order to ensure
optimum engine performance.
As the high-pressure pump produces high-pressure fuel, this
fuel is kept by the common rail. When a driver operates the
vehicle, the optimum fuel injection timing and injection amount
are determined by the ECU (Electronic Control Unit) based on
the preset data, vehicle speed and driving condition. Then the
ECU operates the solenoid valves of the injectors on each
cylinder to inject a proper amount of fuel into the cylinders.
The fuel tank should be made of non-corrosive material, and the
fuel low-pressure pump should not leak at twice the operating
pressure. Also, the pressure in the tank should not exceed
0.3 bar (0.3 kg/cm2, 4.4 psi).
Injector
Common Rail
Cylinder Head
Main Fuel Filter
High-pressure Fuel Pump
Water Separator & Fuel Cooler

Pre Fuel Filter
Fuel Tank
DX210W-5 Engine
4-1-147
Fuel High-pressure System Components
The common rail fuel injection system consist of the low-
pressure stage for low-pressure fuel delivery, high-pressure
stage for high-pressure fuel delivery, and electronic control unit.
1. Fuel high-pressure pump
The fuel high-pressure pump pressurizes fuel up to
approximately 1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi)
and sends this pressurized fuel to the common rail (pipe
shape) through the high-pressure line.
2. Common rail
Even after the injector uses fuel from the common rail to
inject fuel, the fuel pressure in the common rail is still
maintained at a constant level. The common rail pressure
sensor detects the fuel pressure while the pressure control
valve maintains the fuel pressure at the desired level. The
fuel pressure in the common rail is controlled to max.
1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi) by the pressure
control valve.
3. Injector
As the solenoid valve is operated, fuel flows to the injector
nozzle which then sprays fuel directly into the combustion
chamber. When the injector nozzle opens and sprays the
commanded amount of fuel, the excess fuel is returned to
the tank through the return line. Also, fuel returned from the
fuel pressure control valve and low-pressure stage and fuel
used to lubricate the high-pressure pump are returned
back to the fuel tank through the return line as well.
4. Fuel high-pressure pipe
The fuel high-pressure pipe carries high-pressure fuel at
1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi). Therefore, this
pipe is made of special material to be able to withstand the
maximum pressure of the system and fluctuation of high
pressure occurred during fuel injection. The high-pressure
pipe has 8.0 mm of outside diameter and 3.5 mm of inside
diameter. Also, the fuel high-pressure pipes installed
between the common rail and injectors should be in the
same length and they are installed as short as possible.
Engine DX210W-5
4-1-148
Injector
General Description
The injector uses the nozzle to inject fuel to the combustion
chamber directly. To control the injection, the solenoid valve is
used. Fuel is delivered as much as required from the open
injector nozzle and the remaining fuel is returned to the fuel tank
through the fuel return line. In addition, the fuel which has been
used to lubricate the high-pressure pump and returned from the
fuel pressure adjustment valve is returned to the fuel tank
through the return line.
The solenoid valve controls the fuel injection timing and amount.
The injector works instead of the nozzle and the nozzle holder
mounted on the existing engine. Fuel is delivered to the injector
through the high-pressure connector mounted on the cylinder
head and then delivered to the valve control chamber through
the delivery hole.
The valve control chamber is opened by the solenoid valve. It is
connected to the fuel return line via the discharge hole. The
hydraulic force which has been increased by the valve control
plunger with closed discharge hole exceeds the pressure value
of the nozzle needle. As a result, fuel delivery to the combustion
chamber is blocked by the force given to the contact surface of
the nozzle needle.
When the solenoid valve of the injector is pulled, the discharge
hole is opened. This lowers the pressure in the control chamber
and the hydraulic power given to the plunger. When hydraulic
force is lower than the force given to the nozzle needle pressure,
the nozzle needle is opened. Finally, fuel is injected to the
combustion chamber through the injection nozzle hole.
The reason that the nozzle needle is controlled by hydraulic
force is that the power required to open the needle quickly
cannot be directly generated from the solenoid valve. Fuel
control amount required to open the nozzle needle is added to
the fuel amount injected. The used fuel is discharged to the fuel
return line through the hole of the valve control chamber.
Fuel loss occurs on the nozzle needle, the valve plunger guide
as well as the valve control chamber. The control leakage fuel
and the fuel gathered from the line, which connects the over flow
valve, the high-pressure pump, and the pressure control valve,
is returned to the fuel tank through the fuel return line.
DX210W-5 Engine
4-1-149
Parts List
1-2
CYLINDER HEAD
EX1403729
Figure 236
Reference Reference
Number Number
1 Injector Assembly 3 Fixture
1-2 O-ring 4 Bolt; Collared Hex.
2 Ring; Seal
Engine DX210W-5
4-1-150
How to Operate an Injector
Injector operation is classified into four operation stages to
operate the engine and create pressure in the high-pressure
pump.
• The injector is closed (high fuel pressure state)
• The injector is open (starting fuel injection).
• The injector is fully open (injecting fuel).
• The injector is closed (ending fuel injection). These
operation stages are decided by balancing the force given
to the injector components. If there is no pressure on the
common rail or the engine is stopped, the injector nozzle
does not work.
1. The injector is closed (pause state)
Under the pause state that no power is provided to the
solenoid valve of the injector, the injector does not operate.
The surface where the discharge hole exists is tightly
closed with the valve ball by the force from a valve spring
or magnet. High pressure in the common rail is kept by the
fuel control valve and the same pressure is generated in
the nozzle chamber of the injector. The common rail fuel
pressure, which is given to the end face of the valve control
chamber of the injector, and the injector nozzle spring
force are larger than the force to open the nozzle.
Therefore, the injector is closed.
2. The injector is open. (starting fuel injection)
When power is supplied while the injector solenoid valve is
closed, the fuel discharge hole is open by the pulling force
of the solenoid valve. Almost simultaneous with that, the
high current given to the solenoid valve is reduced to the
low current. This is because the air gap of the
electromagnet circuit gets smaller. Fuel in the valve control
chamber flows to the discharge valve hole on the upper
side and then goes into the fuel tank via the fuel return line.
The discharge hole completely breaks the pressure
balance and lowers the pressure in the valve control
chamber. As a result, the pressure in the valve control
chamber is lower than the nozzle chamber pressure which
has been equal to the common rail pressure. The lowered
pressure of the valve control chamber lowers the force
from the control plunger. So the nozzle needle is open and
fuel injection starts.
3. The injector is fully open. (injecting fuel)
The valve control plunger is stopped at the upper position
because fuel is full as fuel flows from the fuel delivery hole.
At this time, the injector nozzle is fully open and fuel is
injected to the combustion chamber at the pressure equal
to that of the common rail.
DX210W-5 Engine
4-1-151
4. The injector is closed. (ending fuel injection)
As soon as the supply to the solenoid vale of the injector is
blocked, the valve spring applies force to the armature
downward and the valve ball closes the discharge hole.
The armature consists of two components. The armature
plate is guided by the driving shoulder and pressed
downward. However, in this case, an overspring is used. It
is a return spring that prevents the force from being applied
to the armature and the valve ball. As the discharge hole is
closed, fuel is delivered from the delivery hole and
generates pressure in the control chamber. This fuel
pressure is equal to the pressure of the common rail and
puts pressure on the valve control plunger through the end
face of the valve control plunger. As a result, the force of
the spring is added to the pressure exceeding the pressure
of the nozzle chamber. Therefore, the nozzle needle is
closed. The speed of closing the nozzle needle is decided
by the flow that passes through the delivery hole. As soon
as the nozzle needle is positioned to the stop position, fuel
injection is blocked.
Injector Protrusion
1. Insert the seal ring to the cylinder cylinder head, and install
the injector.
Cylinder Head
NOTE: Refer to the engine assembly instruction for Injector
installation steps.
2. Measure the protrusion of the injector from the cylinder
head, and adjust it as necessary.
A (Seal Ring Thickness) 2.0 mm A

B (Injector Protrusion) 3.0 mm B
EX1403814
Figure 237
Engine DX210W-5
4-1-152
Common Rail
General Description
This common rail fuel injection system has the high-pressure
producing part and the fuel injection part separated.
The ECU determines the fuel injection amount, injection timing
and injection pressure according to the operating condition of
the engine before injecting fuel into the cylinders in order to
ensure optimum engine performance.
The common rail stores fuel under high pressure delivered from
the high-pressure fuel pump.
Even after the injector uses fuel from the common rail to inject
fuel, the pressure pulse in the common rail is still maintained by
the volume of the rail to keep the fuel pressure at a constant
level.
The common rail pressure sensor detects the fuel pressure
while the pressure control valve maintains the fuel pressure at
the desired level. The fuel pressure in the common rail is
controlled to max. 1,835.5 kg/cm2 (1,800 bar, 26,106.8 psi) by
the pressure control valve.
High Fuel Pressure Connector
High Pressure Pipe

Common Rail
Common Rail Pressure

Sensor
Fuel High Pressure Pump
EX1403815
Figure 238
DX210W-5 Engine
4-1-153
The common rail fuel injection system consists of the following
main components:
1. ECU (Electronic Control Unit)
2. Crankshaft speed sensor
3. Camshaft speed sensor
4. Accelerator pedal sensor
5. Fuel temperature sensor
6. Boost pressure and temperature sensor, oil pressure and
temperature sensor
7. Common rail pressure sensor
8. Coolant temperature sensor
• As a driver depresses the accelerator pedal, the ECU
(Electronic Control Unit) receives information from
various sensors mentioned above to operate the
engine and vehicle according to the operating
condition instantly. Also, the ECU operates the open/
closed circuits and circulation circuit of the vehicle
and engine based on such information.
• The crankshaft speed sensor detects the engine
speed while information from the camshaft speed
sensor is used to determine the ignition order. The
potentiometer of the accelerator pedal sensor
produces an electric signal to inform the ECU of how
deep the pedal is depressed. Also, the turbocharger
and intake pressure sensor are installed, and the
intake pressure sensor is used to measure the intake
air pressure.
• When the engine temperature is low in cold weather,
the ECU receives information from the coolant
temperature sensor and air temperature sensor to
operate the engine ideally based on the current
operating condition.
Fuel Injection from the Injection Pump Common Rail Fuel Injection
Main Injection Pressure Max Injection Pressure Main Injection Pressure Common Rail Pressure
Fuel Delivery Start

Fuel Injection Fuel Injection
Start
Injection Pressure
Injection Pressure
Time Time
EX1403816
Figure 239
Engine DX210W-5
4-1-154
The common rail features the injection characteristics as follows:
1. Compared to the conventional system's injection
characteristics, the common rail manages the fuel injection
amount and injection pressure separately to satisfy with
any engine condition in order to ensure optimum fuel
injection.
2. In the initial fuel injection period, i.e. the ignition delay from
the beginning of fuel injection until the beginning of
combustion, the fuel injection amount should be adjusted
to a low level.
3. The common rail system is a modular type and has the
following major components for is injection characteristics:
A. Injector solenoid valve (installed to cylinder head)
B. Common rail
C. Fuel high-pressure pump
D. ECU (Electronic Control Unit)
E. Crankshaft speed sensor
DX210W-5 Engine
4-1-155
Parts List
10
10-1
11
13
A
B
1
10-2A C
12 3
E
10-2
D
F 4
5
14
15
7
HIGH PRESS
PUMP
8
8-1
CYLINDER HEAD F
EX1403730
Figure 240
Engine DX210W-5
4-1-156
Reference Reference
Number Number
1 Pipe; Injection 10 Rail; Common
2 Pipe; Injection 10-1 Sensor; Pressure
3 Pipe; Injection 10-2 Valve; Pressure Limits
4 Pipe; Injection 10-2A O-ring
5 Pipe; Injection 11 Bracket; Common Rail
6 Pipe; Injection 12 Bolt Assembly M8 x 30
7 Pipe; Injection 13 Bolt Assembly M8 x 35
8 Connector; High Pressure 14 Clip; Pipe
8-1 O-ring 15 Bolt Assembly M8 x 12
9 Nut
DX210W-5 Engine
4-1-157
Fuel Injection Pump
General Description
The fuel high-pressure pump uses a radial shaped piston pump
to produce high pressure. Pressure is independently generated
during the fuel injection process. The speed of the fuel high-
pressure pump is directly connected to the engine RPM,
regardless of the transmission's speed ratio. Compared to the
conventional injection system, the common rail injection system
delivers a certain amount of fuel constantly.
The injector is connected to the common rail with the high-
pressure pipe. It consists of the nozzle and solenoid valve which
is energized by the ECU when the ignition switch is operated.
When the ignition switch is blocked, the solenoid valve ends the
injection operation.
As the switching (opening/closing) operation of the injector's
solenoid valve is performed by high voltage and current, the
injectors' solenoid valves are operated in sequence according to
the preset value in the ECU. The crankshaft speed sensor and
camshaft speed sensor are used to detect the engine speed in
order to adjust the fuel injection timing and the beginning of fuel
injection correctly.
Fuel High Pressure Valve Fill Fuel at 60 ml

Before Reassemble Fuel
Pump Piston
Gear Pump Outlet
Eccentric Cam
Fuel
Inlet
Driving Shaft Metering Unit
Lubrication of Driving Shaft by Fuel

Fuel High Pressure Line
Fuel Low Pressure Line

EX1403817
Figure 241
Function
The fuel high-pressure pump has both low pressure stage and
high pressure stage. It carries high pressure fuel under any
operating circumstance during the service life of the vehicle.
Engine DX210W-5
4-1-158
Also, it supplies a proper amount of fuel to the common rail to
handle any harsh condition, such as abrupt vehicle start or rapid
change of pressure in the common rail. The fuel high-pressure
pump produces the system pressure required in the common rail
constantly.
Structure Fuel High-pressure Pump

The fuel high-pressure pump has three pump pistons set 120°
apart from each other in it to compress fuel in the circumferential
direction. As every rotation creates three compression strokes,
the pump drive system's stress is maintained steadily and it
needs low driving force. The common rail needs low pump
driving force which is only approximately 1/9 of force required for
the conventional pump system.
Operation
The fuel feed pump supplies fuel to the high-pressure pump
through the fuel inlet and safety valve. Then, this fuel is
transferred to the high-pressure pump's lubrication and cooling
circuits through the safety valve. The drive shaft is equipped with
the eccentric cam to move the pump's piston up and down
according to the shape of the cam.
If the fuel pressure delivered from the fuel feed pump exceeds
the fully open pressure of the safety valve, fuel moves the pump
piston downwards through the intake valve of the fuel high- EX1403818
pressure valve to the intake stroke position of the pumping Figure 242
chamber. When the pump piston passes the B.D.C., the valve is
closed. Then, as fuel cannot escape the pumping chamber, it is
compressed further over the delivered pressure.
As soon as the fuel pressure reaches the common rail pressure,
it opens the exhaust valve. Then, this compressed fuel enters
the high-pressure circuit. The pump piston continues to carry
fuel until it reaches the T.D.C. Then, as soon as the pressure
drops, the exhaust valve is closed. Then, fuel left in the pumping
chamber is depressurized and the pump piston moves
downwards again. When the pressure in the pumping chamber
drops below the pressure of the fuel feed pump, the intake valve
opens and the above steps are repeated.
Fuel Return
The fuel high-pressure pump is designed to supply a large
amount of fuel. While the engine is running at an idle speed or
with partial load, excess fuel is returned to the tank through the
pressure control valve.
Fuel High-pressure Pumping Cut-off Valve

When the switch of the fuel high-pressure pumping cut-off valve
is turned off, the fuel amount delivered to the common rail is
increased. When the switch is turned off, the fuel pumping
solenoid valve is pulled, so the pin attached to an electric
magnet keeps the valve open. Therefore, fuel led into the
DX210W-5 Engine
4-1-159
pumping valve cannot be compressed during the delivery stroke.
As this fuel is returned to the low-pressure passage, no pressure
is produced. Since the pumping cut-off valve is operated only
with a small amount of force, it is possible to switch between the
delivery phase and cut-off phase at short intervals.
Parts List
4 5
4
1
4
5
1-1
2 1-3
1-4
1-2
1-5 TIMING GEAR CASE
EX1403731
Figure 243
Reference Reference
Number Number
1 Injection Pump Assembly 2 Bolt Assembly M10 x 45
1-1 O-ring 3 Washer; Plain
1-2 Flow Meter; Fuel 4 Ring; Seal A14 x 20
1-3 O-ring 5 Nipple
1-4 O-ring 6 Adapter
1-5 Bolt
Engine DX210W-5
4-1-160
ELECTRICAL SYSTEM
Electrical Parts
5
8
10
7
9
6
2
3
12
11
Reference Reference
Number Number
EGR (Exhaust Gas Recirculation) Oil Pressure and Temperature
1 6
Motion Sensor Sensor (OPTS)
Boost Pressure and 7 Resistance Connector
2
Temperature Sensor (BPTS) 8 Rail Pressure Sensor (RPS)
Throttle Valve Position Sensor 9 Crankshaft Speed Sensor (CRS)
3
(TVA)
10 Camshaft Speed Sensor (CAM)
Coolant Temperature Sensor
4 11 Air Heater Relay
(CTS)
12 Fan Clutch
5 Injector Connector (INJ)
DX210W-5 Engine
4-1-161
Switches and Sensors
ECU (Electronic Control Unit)
Shape Symbol Pin No. Circuit name

Fuel Metering Unit 2.58 Fuel Metering Unit (O_V_MEU)
FMU
1
2.58 2.83
2
2.83 Fuel Metering Unit (O_T_MEU)
2.06 Oil Pressure/Temperature Sensor GND (G_R_OPS)

Oil Press Temp Sensor
2.13 Oil Temperature Sensor SIG (I_A_OTS)
Oil Pressure/Temperature Sensor Voltage
OPTS 2.31
(V_V_5VSS1F)
2.06 2.13 2.31 2.35
2.35 Oil Pressure Sensor SIG (I_A_OPS)
Rail Press Sensor

2.60 Rail Pressure Sensor GND (G_R_RAILPS)
2.36 Rail Pressure Sensor SIG (I_A_RAILPS)
1 3
RPS
2.60 2.36 2.11
2.11 Rail Pressure Sensor Voltage (V_V_5VSS3B)
2.34 Throttle Valve Voltage (V_V_5VSS3C)

Throttle Plate
Actuator / Position Sensor 2.29 Throttle Valve Motor - (O_T_DCNEG1)
TVA 2.40 Throttle Valve GND (G_R_TVA)
2.15 Throttle Valve SIG ( I_A_TVA)
4
2 ECU#1 ECU#1 6
2.29 2.05
2.34 2.40 2.15

1 ECU#1 ECU#1 ECU#1 5
2.05 Throttle Valve Motor + (O_T_DCPOS1)

3
Boot Press Temp Sensor 2.90 Boost Pressure/Temperature Sensor GND (G_R_BPS)
2.37 Boost Temperature Sensor SIG (I_A_BTS)
BPTS Boost Pressure/Temperature Sensor Voltage
2.07
2.90 2.37 2.07 2.86 (V_V_5VSS1A)
2.86 Boost Pressure Sensor SIG (I_A_BPS)
2.39 Coolant Temperature Sensor SIG (I_A_CTS)

Coolant Temp Sensor
CTS Fuel Temperature/Coolant Temperature Sensor GND

1 2
2.59
2.39 2.59
(G_R_AN18)
Crank Shaft Speed Sensor

2.66 Crankshaft Speed Sensor POS (I_F_CRSPOS)
2.65 Crankshaft Speed Sensor NEG (I_F_CRSNEG)
CRS
2.66 2.65 2.69 Crankshaft/Camshaft Speed Sensor Protective GND
2.69
(G_C_GND)
Cam Shaft Speed Sensor

2.68 Camshaft Speed Sensor POS (I_F_CASPOS)
2.67 Camshaft Speed Sensor NEG (I_F_CASNEG)
CAM
2.68 2.67 2.69 Crankshaft/Camshaft Speed Sensor Protective GND
2.69
(G_C_GND)
Engine DX210W-5
4-1-162
Shape Symbol Pin No. Circuit name
EGR Valve
Vbat 24 V Battery Voltage (O_V_RH32)
GND Body GND
EGR
4
2.17 2.18 GND Vbat

1 2.18 CAN 2 Low (B_D_CAN2L)
2.17 CAN 2 High (B_D_CAN2H)
2.49 Cylinder 1, Injector 1 High (O_P_SVH11)

2.73 Cylinder 1, Injector 1 Low (O_P_SVL11)
Injector Connector
4
2.75 2.51 2.73 2.49

1
INJ 2.27 Cylinder 2, Injector 3 High (O_P_SVH23)

8 5

2.03 2.27 2.74 2.50
12 9
2.02 2.26 2.01 2.25

Fuel Temp Sensor

2.12 Fuel Temperature Sensor SIG (I_A_FTS)
FTS Fuel Temperature/Coolant Temperature Sensor GND

2.59
(G_R_AN18)
1 2
2.12 2.59
2.30 HFM Sensor GND (G_R_AMS)

2.38 HFM Sensor Temperature SIG (I_A_IATS)
2.54 HFM Sensor (I_A_IATS)
2.09 HFM Sensor PWR (V_V5VCAH)
Inter Connector 1.65 Fan Speed Sensor GND (G_R_FSS)
for Vehicle Interconnector Vbat 24 V Battery Voltage
(HFM, FAN
GND 1.64 1.87 1.67 Fan Speed Sensor PWR (O_V_5VSS2A)
1.65 Vbat 1.67 1.74 Clutch)
2.30 2.38 2.54 2.09 1.74 Fan Actuator Control SIG (O_V_RH21)
GND Body GND
1.64 Fan Speed Sensor SIG (I_F_FSS)
Fan Actuator Control SIG (O_T_FAN1)
1.87
Resistance 2.17 CAN 2 High (B_D_CAN2H)
Resistance
2.18 CAN 2 Low (B_D_CAN2L)
1 2
2.17 2.18
DX210W-5 Engine
4-1-163
Boost Pressure and Temperature Sensor
1. The boost pressure and temperature sensor is connected
to the intake manifold with the O-ring to measure the
absolute pressure and temperature in the intake manifold.
2. Its output signal is sent to the ECU which then calculates
the boost pressure based on the programmed
characteristic curve.
Engine Oil Pressure and Temperature Sensor

The engine oil pressure and temperature sensor detects the
pressure and temperature of engine oil and sends these
information to the ECU (Electronic Control Unit).
Engine Coolant Temperature Sensor

The engine coolant temperature sensor detects the temperature
of engine coolant and sends this information to the ECU
(Electronic Control Unit).
Common Rail Pressure Sensor

Fuel passes through the passage in the common rail before it
heads to the common rail pressure sensor.
The tip of this pressure sensor is sealed with the diaphragm.
After fuel is pressurized, it reaches the diaphragm of the sensor
through the hole.
A sensor to convert a fuel pressure value into an electric signal
is connected to this diaphragm. This sensor produces a signal
by amplifying the detected value before it delivers the signal to
the ECU (Electronic Control Unit) and evaluation circuit.
Electric Connections
Evaluation Circuit
Diaphragm
High Pressure
Connection
Mounting Thread
EX1403833
Figure 245
Engine DX210W-5
4-1-164
Crankshaft Speed Sensor
The position of the pistons in the combustion chamber has a
major role in the fuel injection process.
All pistons in the engine are connected to the crankshaft by the
connecting rod.
The flywheel housing is equipped with the crankshaft speed
sensor to supply information for the position of all pistons.
This speed sensor detects the rotation per minute of the
crankshaft, and this information is used by the ECU (Electronic
Control Unit) for calculation as an important factor.
Camshaft Speed Sensor

The camshaft speed sensor is used to control the intake and
exhaust valves of the engine.
This rotates at half speed of the crankshaft. When the piston is
moving toward T.D.C., it determines whether the camshaft
position is in the compression stage or in the exhaust stage.
This information cannot be detected by the crankshaft speed
sensor.
On the other hand, during normal operation, information
supplied by the crankshaft speed sensor is enough to tell the
condition of the engine.
In other words, if the camshaft speed sensor cannot detect the
camshaft position while the engine is running, the ECU
(Electronic Control Unit) receives engine condition information
from the crankshaft speed sensor.
Pressure Limiter Valve

1. The pressure limiter valve is connected to the end of the
common rail, and its body houses a conical plunger valve
in it. This valve is normally closed by force of the spring at
a normal operating pressure (1,800 bar (1,835.5 kg/cm2,
26,106.8 psi)) to keep the pressure in the common rain.
2. As soon as the pressure exceeds the operating pressure
limit, load is applied to the spring of the valve to keep the Common O-ring
Rail Side (65.96501-0431)
fuel pressure at a normal level. After fuel passes through
the valve, it is returned to the fuel tank through the return EX1404193
pipe. Figure 246
DX210W-5 Engine
4-1-165
ECU (Electronic Control Unit)
ECU (Engine Control Unit) Connector

There are two ECU (Engine Control Unit) connectors: one for
connection to the vehicle and one for connection to the engine.
1 2
Vehicle Side Connector Engine Side Connector

EX1403835
Figure 247
Engine DX210W-5
4-1-166
Operational Conditions of Electronic Control Unit (ECU)
Engine Start
1. Sets the reference temperature for determining preheat to
the lowest temperature among coolant temperature, fuel
temperature, intake air temperature, and oil temperature.
2. Sets the reference temperature for determining fuel
volume by setting the engine cooling temperature.
3. Determines the appropriate fuel volume to start the engine,
delivers the fuel to the engine, and measures the rpm
signal by using the crankshaft rev-count sensor.
Vehicle Driving
Calculates the required data for driving a vehicle, such as CAN
data and the rpm transferred from the vehicle control unit.
Driver-requested Adjustment of rpm

Controls the rpm based on request from the driver and controls the
engine based on the rpm requested by the vehicle control unit.
Limp Home
1. A function that allows drivers to drive their vehicle to the
repair center safely with the minimum conditions for driving
the vehicle when a fault code occurs.
2. Limp Home function is applied under the following
conditions.
• Accelerator pedal has failed: Regardless of pressing
the accelerator pedal, the vehicle is driven at a
consistent RPM.
• Sensor has failed: When sensors have failed, the
vehicle is driven with the consistent alternative
values.
• Output is limited: According to the fault type, the fuel
volume delivered to the engine is limited. The limit is
classified into four levels. The fuel volume is limited
according to the severity of the fault.
• Diagnosis Information display lamp: Provides
information of fault state to drivers for safe driving.
Failure Diagnosis
1. When a fault occurs, the failure diagnosis information
display lamp on the gauge board is turned on.
2. With the failure diagnosis information display lamp, drivers
can see the fault code.
NOTE: It can be checked from the failure diagnosis
information on the gauge board.
DX210W-5 Engine
4-1-167
3. It can be diagnosed by connecting the diagnosis unit to the
check connector at the back of the driver's seat.
Driving Record
1. Writes the information related driving to the ECU.
2. The information on fuel consumption, engine use time, and
ECU use time is written in the ECU.
3. The information can be monitored with the ECU diagnosis
device.
Starter
General Description
The start motor is installed behind the flywheel housing. When
disassembling the engine, soak the start motor's pinion gear and
ring gear into fuel and clean them with a brush thoroughly. Then,
apply grease to them prevent their corrosion.
24V X 6.0kW
EX1403836
Figure 248
IMPORTANT
The start motor should always be protected from moisture
and humid condition.
Engine DX210W-5
4-1-168
Circuit Diagram
Circuit Diagram
Battery Terminal
Solenoid Motor
Magnetic Switch
Solenoid Terminal
Switch Terminal
Ground Terminal
EX1403837
Figure 249
IMPORTANT
Before working on any electric system, make sure to
disconnect the negative battery cable in advance. Connect
the ground cable last after work to avoid a short circuit
during work.
DX210W-5 Engine
4-1-169
Exhaust Gas Reduction
General Description
Connector
1
1. Mark by connector part 2 3
Reference
Description
Number
1 Wire Cover
2 Cable Tie
3 C/Tube 4
4 Tube (White) EX1403838
Figure 250
2. If the connector has no cover, wrap end of the connector

with plastic tape.
Taping End of Connector
Tolerance for Allowable Wiring Distance

1. Between fixed points: +5 mm
2. Between fixed points before junction: +5 mm
3. Connector end or fixed point or junction of terminal type:
+10 mm
NOTE: End of injector junction: +5 mm
Symbol Description
1 Apply Aluminum Tape
2 Apply Manifold
3 Apply Cross Taping
Apply Heat Resisting

4 Transparent Tape
(125 or Higher)
5 Apply Corrugate Tube
Engine DX210W-5
4-1-170
Circuit Diagram
EX1403845
Figure 252
Aftertreatment Connector
Wiring Wiring From To

Circuit Name Remark
Label Size Name No Name No
1.23 1.50 Dosing Valve High Side a 1 b 1
1.96 1.50 Dosing Valve Low Side a 2 b 2
1.16 0.75 DOC Upstream (T4) Signal c 1 b 3
1.18 0.75 DOC Upstream (T4) Ground c 2 b 4
1.32 0.75 SCR Upstream Signal d 1 b 5
1.43 0.75 SCR Upstream Ground d 2 b 6
1.09 0.75 SCR Downstream Signal e 1 b 7
300 0.75 SCR Downstream Ground e 2 1.43 S01 SPLICE_1.43
301 0.75 Master NOx Sensor Ubatt f 1 b 8
302 0.75 Master NOx Sensor GND f 2 b 9
303 0.75 Master NOx Sensor CAN Low f 3 b 11
304 0.75 Master NOx Sensor CAN High f 4 b 10
305 0.75 Secondary NOx Sensor Ubatt g 1 301 SPLICE_301
306 0.75 Secondary NOx Sensor GND g 2 302 SPLICE_302
307 0.75 Secondary NOx Sensor CAN Low g 3 303 SPLICE_303
308 0.75 Secondary NOx Sensor CAN High g 4 304 SPLICE_304
309 0.75 GND NOX PIN2 Common g 5 305 SPLICE_305
a. Dosing Module (DOS)

b. Inter Connector (INT)
c. DOC Temperature Sensor (DOC1)
d. SCR Upstream Sensor (SCR2)
e. SCR downstream sensor (SCR2)
f. Master NOx Sensor (NOX1)
g. Secondary NOx Sensor (NOX2)
DX210W-5 Engine
4-1-171
Switches and Sensors
NOX1
SCR1
SCR2
DOC1
NOX2
DOS
INT
EX1403846
Figure 253
1. Dosing module (DOS)
1 2
1.23 1.96
EX1403850
Figure 254
2. Master NOx sensor (NOx1)
5 1
304 303 302 301
EX1403851
Figure 255
Engine DX210W-5
4-1-172
3. Secondary NOx sensor (NOx2)
5 1
309 308 307 306 305
EX1403852
Figure 256
4. SCR downstream temperature sensor (SCR1)
1 2
1.09 300
EX1403853
Figure 257
5. SCR upstream temperature sensor (SCR2)
1 2
1.32 1.43
EX1403854
Figure 258
6. DOC temperature sensor (DOC1)
1 2
1.16 1.18
EX1403855
Figure 259
DX210W-5 Engine
4-1-173
7. Inter connector (INT)
7 12
1.09 301 302 304 303
1.43 1.32 1.18 1.16 1.96 1.23

6 1
EX1403856
Figure 260
Circuit Diagram
General Description
1. It is possible to identify the circuit number for the connector
and engine wire harness information.
2. The wiring colors can be identified as follows:
Symbol Color
B Black
Brn Brown
G Green
EX1403857
Gra Gray
Figure 261
L Blue
O Orange
P Purple
RW Red and White
W White
Y Yellow
3. The ECU pin No. means each pin number of an engine

connector.
4. The sensor pin No. means each pin number of a sensor
connector.
Engine DX210W-5
4-1-174
ECU (Engine Control Unit) Engine Connector
Wiring Wiring Wiring Wiring ECU Sensor

Circuit Name Remark
Label Size Color Type Pin No. Pin No.
2.01 1.50 Y a Injector 1, Bank 2 Low 1 10 Twist Pair (2.01/2.25)
2.02 1.50 G a Injector 2, Bank 2 Low 2 12 Twist Pair (2.02/2.26)
2.03 1.50 L a Injector 3, Bank 2 Low 3 8 Twist Pair (2.03/2.27)
2.05 0.75 R a Throttle Plate Actuator POS 5 6 Twist Pair (2.05/2.29)
Oil Pressure/Temperature Sensor

2.06 0.75 B a 6 1
GND
Boost Pressure/Temperature Sensor
2.07 0.75 O a 7 3
PWR
2.09 0.75 R a HFM Sensor PWR 9 4
2.11 0.75 O a Rail Pressure Sensor PWR 11 3 Shield 2.11/2.36
2.12 0.75 R a Fuel Temperature Sensor SIG 12 1
2.13 0.75 Brn a Oil Temperature Sensor SIG 13 2
2.15 0.75 B a Throttle Plate Position Sensor SIG 15 5
2.17 0.75 O b CAN 2 High 17 Joint, Shield 2.17/2.18
2.18 0.75 W b CAN 2 Low 18 Joint, Shield 2.17/2.18
2.19 0.75 B a CAN 2 GND 19 Shield Drain (2.17/2.18)
2.25 1.50 W a Injector 1, Bank 2 High 25 9 Twist Pair (2.01/2.25)
2.29 0.75 Y a Throttle Plate Actuator NEG 29 2 Twist Pair (2.04/2.29)
2.30 0.75 Brn a HFM Sensor GND 30 1
Oil Pressure/Temperature Sensor

2.31 0.75 R a 31 3
PWR
2.34 0.75 W a Throttle Plate Position Sensor PWR 34 1
2.35 0.75 Y a Oil Pressure Sensor SIG 35 4
2.36 0.75 W b Rail Pressure Sensor SIG 36 2 Shield 2.11/2.36
2.37 0.75 Y a Boost Temperature Sensor PWR 37 2
2.38 0.75 O a HFM Sensor SIG 38 2
2.39 0.75 W a Coolant Temperature Sensor SIG 39 1
2.40 0.75 Brn a Throttle Plate Position Sensor GND 40 3
2.54 0.75 W a HFM Sensor Frequency Output 54 3
2.58 0.75 R a Fuel Metering Unit 58 1 Twist Pair (2.58/2.83)
DX210W-5 Engine
4-1-175
Circuit Name Remark
Fuel Temperature/Coolant Tempera-
2.59 0.75 B a 59 Joint
ture Sensor GND
2.60 0.75 B a Rail Pressure Sensor GND 60 1 Shield Drain (2.11/2.36)
2.65 0.75 O b Crankshaft Speed Sensor NEG 65 2 Shield 2.65/2.66
2.66 0.75 W b Crankshaft Speed Sensor POS 66 1 Shield 2.65/2.66
2.67 0.75 Brn b Camshaft Speed Sensor NEG 67 2 Shield 2.67/2.68
2.68 0.75 Y b Camshaft Speed Sensor POS 68 1 Shield 2.67/2.68
Shield Drain
2.69 0.75 B a Crankshaft/Camshaft Sensor Shield 69 3
(2.65/2.66, 2.67/2.68)
2.73 1.50 Gra a Injector 1, Bank 1 Low 73 2 Twist Pair (2.49/2.73)
2.74 1.50 O a Injector 2, bank 1 Low 74 6 Twist Pair (2.50/2.74)
2.75 1.50 Brn a Injector 3, Bank 1 Low 75 4 Twist Pair (2.51/2.75)
2.83 0.75 Brn a Fuel Metering Unit 83 2 Twist Pair (2.52/2.83)
2.86 0.75 W a Boost Pressure Sensor SIG 86 4
Boost Pressure/Temperature Sen-

2.90 0.75 B a 90 1
sor GND
Vbat 0.75 R a 24 V (Vbat) ICV PIN 6
GND 0.75 B a Ground ICV PIN 10
1.64 0.75 O a Fan Speed Sensor Output (FSS Out) 1 ICV PIN 11
1.65 0.75 B a Fan Speed Sensor GND 2 ICV PIN 5
1.67 0.75 Y a Fan Speed Sensor Supply (U Sensor) 5 ICV PIN 7
1.74 0.75 W a Solenoid Coil High (Coil +) 4 ICV PIN 8
1.87 0.75 Brn a Solenoid Coil High (Coil -) 3 ICV PIN 12
13B 0.75 O a Start S INT 1 PIN 5
145B 0.75 Brn a Preheat Relay C INT 1 PIN 6
145F 0.75 R a Diode 5K
146D 0.75 R a Preheat Relay D - INT 1 PIN 7
146C 0.75 B a Diode 5A
99I 8.00 B a Alternator E Engine Ground
4A 8.00 W a Alternator B
4J 5.00 W a Alternator B INT 3 PIN 1
4M 5.00 W a Alternator B INT 3 PIN 2
14A 1.25 W a Alternator R INT 1 PIN 1
9A 2.00 W a Alternator I INT 1 PIN 2

29C 0.75 Y a Compressor + + Pin 1 Pin 3
99H 0.75 B a Compressor - -
99G 0.75 B a Diode 4A INT 2 PIN 1
Engine DX210W-5
4-1-176
Circuit Name Remark
29B 0.75 W a Diode 4K INT 2 PIN 2
1.23 1.50 L a Dosing Valve High Side 1 INT 2 PIN 3
1.96 1.50 B a Dosing Valve Low Side 2 INT 2 PIN 4
1.16 0.75 Y a DOC Upstream (T4) Signal 1 INT 2 PIN 5
1.18 0.75 Brn a DOC Upstream (T4) Ground 2 INT 2 PIN 6
1.32 0.75 W a SCR Upstream Signal 1 INT 2 PIN 7
1.43 0.75 B a SCR Upstream Ground 2 INT 2 PIN 8
1.09 0.75 R a SCR Downstream Signal 1 INT 2 PIN 9
301 1.50 O a Master NOx Sensor Ubatt 1 INT 2 PIN 10
302 1.50 Gra a Master NOx Sensor GND 2 INT 2 PIN 11
303 0.75 O b Master NOx Sensor CAN Low 3 INT 2 PIN 12
304 0.75 W b Master NOx Sensor CAN High 4 INT 2 PIN 13
DX210W-5 Engine
4-1-177
Engine DX210W-5
4-1-178
ECU
ENGINE VEHICLE 1-03 99 0.85B
CONN CONN 99 0.85B
1-05
1-28 99 0.85B
DX210W-5
1-29 99 0.85B 0.85B
1-52 99 0.85B 99
1-75 99 0.85B
1-76 99 0.85B
INJECTOR
SOLENOIDS
2-49
30B 1-31 1.25RL 30A 1
INJECTOR1, BANK1
ECU CIRCUIT
2-73 TANK TANK

4
LEVEL TEMP
2-50 31B 1-08 0.85YB 31A 3
SIGNAL SIGNAL For EU
INJECTOR3, BANK1 2-74 0.85RG E28C 2
2-51 UREA TANK

INJECTOR2, BANK1 2-75
INTER 2
2-25 CONN 2-1 SCR DOWNSTREAM
1 °t
INJECTOR5, BANK2 2-01 E30A 1-09 0.85Or E30B TEMPERATURE SENSOR
7 V
2-26 E28A 1-43 0.85RG E28B 2
6 SCR UPSTREAM
1 °t
INJECTOR6, BANK2 2-02 E29A 1-32 0.85Y E29B TEMPERATURE SENSOR
5 V
2-27 E27A 1-23 0.85G E27B 1
1 DOSING
INJECTOR4, BANK2 2-03 E26A 1-96 0.85GB E26B 2
2 VALVE
E32A 1-18 0.85Gr E32B 2
2-58 4
FUEL METERING °t DOC UPSTREAM(T4)
E31A 1-16 0.85GrR E31B 1
2-83 3 V TEMPERATURE SENSOR
UNIT(ZME)
TANK HEATING VALVE
E34A 1-62 0.85L E34B 2 1 E1E 0.85W

2-11
P
RAIL PRESS. 2-36
UREA SUPPLY MOUDLE
SENSOR V 2-60
E25A 1-68 0.85RW E25B 2
P
2-31 E24A 1-07 0.85Y E24B 3 REDUCTION AGENT
P& 0.85L E23B 4 PRESSURE SENSOR
OIL PRESS. 2-35 E23A 1-39 V
SENSOR t°
2-06 E15A 1-50 0.85WR 0.85WR E15D 9
(ODFT)
2-13 E22A 1-84 0.85G E22B 10 REDUCTION
V M
1-89 0.85BW E21B 8 AGENT PUMP
2-07 E21A
P& 1-85 0.85W E20B 12
BOOST PRESS. 2-86 E20A
SENSOR t° REDUCTION AGENT
2-90 0.85WR E15E 11
(LDF 6T) REVERTING VALVE
2-37 E19A 1-02 0.85B E19B 5
V SUPPLY MODULE
HEATER
2-05 6 E14E
THROTTLE PLATE 1-04 0.85BY E18B 1 2 E14D
2-29 E18A 0.85R
ACTUATOR M OUTLET
2-34 E17A 1-48 0.85LW E17B 1 2 E14C 0.85R LINE HEATER
INLET
THROTTLE POSITION 2-15
E16A 1-72 0.85L 0.85L E16B 1 2 E14B 0.85R LINE HEATER
FEEDBACK SENSOR 2-40 BACK FLOW
0.85WR LINE HEATER
3R
ENGINE BRAKE ACTUATOR1 2-95 E15C E14A

INTERNAL, ENGINE 2-70 86 30
DECOMPRESSION VALVE AUXILIARY
2-93 RELAY
N
TURBINE WHEEL 2-94
SPEED SENSOR
V 2-78
CAN H2 2-17 E13B 85 87

E13A 1-93 0.85RY 0.85RY
F17C
CONTROLLER AREA CAN L2 2-18
F14F 1-01 0.85R
NETWORK 2 SHIELD 2-19
F14E 1-25 0.85R 2R
3RL
BAT+ F14D 1-26 0.85R 2R

FUSE BOX
F14C 1-49 0.85R
F14B 1-73 0.85R
T1D 1-46 0.5Y CAN H0

CAMSHAFT SPEED SENSOR 2-43
OUTPUT SIGNAL T2D 1-47 0.5YB CAN L0 CONTROLLER AREA
CRANKSHAFT SPEED SENSOR 2-44 NETWORK 0
T3B 1-10 SHIELD SHIELD
OUTPUT SIGNAL
2-12 T12A 1-71 0.5W CAN H1
FUEL
t° 0.5B CAN L1
TEMPERATURE 2-59 T13A 1-95 CONTROLLER AREA
SENSOR V NETWORK 1
SHIELD
2-39 PREHEAT SIGNAL (EPOS 2-101)
COOLANT t° V58B 1-06 0.5LW
TEMPERATURE 1-69
V ST2C 0.85Br KEY-ON (STARTER SWITCH ''BR'')
SENSOR 2-69
1 F11C 1.25RL
1 2-66 TANK TANK 4 T2F 0.5YB
N 2 2-65 LEVEL TEMP 3 T1F 0.5Y
CRANKSHAFT SPEED SENSOR
V SIGNAL SIGNAL
SHIELD 2 99
2B
2 UREA TANK
2-68
N 1 For NA
CAMSHAFT SPEED SENSOR 2-67
V SHIELD
2B
99
T1G 0.85Y
T2G 0.85YB
F11D 1.25RL
8 11 10 9
INTER
CONN 2-2
1
3
MASTER 4
96P
NOX SENSOR 5
2
AIR FLOW METER ECU JOINT
CN1
3 E12A 0.85B E12B 2-84 1

12
1 E11A E11B 2-38 3
0.85BrY
10
4 E10A E10B 2-54 SECONDARY 4
0.85BrW
11 NOX SENSOR
2 E9A 0.85Br E9B 2-30 5
9 EPOS 2-102
1.25RL F11B 1 2
7
99 2 EGR E/G EMERGENCY
40A 1-58 Inhibit 0.5BrR
1.25B 3 STOP SWITCH
41A 1-59 Regen 0.5BrW 1
4 V59B 1-11 0.5R 0.5R V59C 2 3 E1B 0.85W
0.85W E1D 5 +
0.85WB E5B 3 E1A 1-74 0.85W
1 -
0.5WL E6B 5 E2A 1-83 0.85BW PREHEAT RELAY
6 + FAN
0.5WR E7B 1 CLUTCH V1D 1-38 0.5LW A/C REQUEST
2 SIG
0.5WG E8B 2 ST10C 1-63 0.5BG KEY SW 'START'
8 -
E5A 1-87 0.85WB
E6A 1-67 0.5WL
DeSOx REGEN SWITCH
E7A 1-64 0.5WR 9 10 3R 0.5WR
E8A 1-65 0.5WG
0.5BrR 40B 1 0
2 E1C 0.85W
0.5BrW 41B 3 I
7 8 3Q 0.5WR
99
EX1403941
4-1-179
Engine
1Upper Structure
+
1Cabin
Edition 1
DX210W-5 Cabin
5-1-1
MEMO
Cabin DX210W-5
5-1-2
Table of Contents
Cabin
Cabin Identification .........................................5-1-5
Roll-over Protective Structure (ROPS)...................... 5-1-5
Removal .........................................................5-1-7
Installation ....................................................5-1-12
Completing work ...........................................5-1-13
Dimensions of Cabin Glass ..........................5-1-14
Removal and Installation of Cabin Glass......5-1-18
Removal of Cabin Glass.......................................... 5-1-18
Installation of Cabin Glass....................................... 5-1-20
Installation of Upper Door Glass ............................. 5-1-25
Installation of Upper Front Glass............................. 5-1-25
DX210W-5 Cabin
5-1-3
Cabin DX210W-5
5-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
CABIN IDENTIFICATION
Roll-over Protective Structure (ROPS)
General ROPS Instructions 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 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,
DOOSAN. Changes to the cabin can cause loss of
operator protection from rollover and falling objects, and
operator may suffer 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 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.
DX210W-5 Cabin
5-1-5
ROPS Certification
This DOOSAN excavator has an operator's cabin that meets
ROPS requirements. The seat belt must be worn for roll-over
protection.
The ROPS certification plate 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.
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 roll-over and falling objects, and result in
death or serious injury.
Cabin DX210W-5
5-1-6
REMOVAL
1. Make the machine swing about 120° rightward on the flat
ground as shown in Figure 1 before lowering all the
attachments on the ground and then stop engine.
2. Set wheel chocks in front and behind each tire to prevent
the machine from moving.
WE1401487
Figure 1
3. Move safety lever to "RELEASED" (UNLOCK) position. O ACC

I
(Figure 2)
4. Turn starter switch to "I" (ON) position.
LOCK
WARNING OFF OFF
ON
ON
If engine must be running while performing ON OFF
maintenance, always use extreme caution. Always EX1500510
have one person in the cabin at all times. Never leave Figure 2
the cabin with engine running.
5. To relieve pressure from accumulators, fully stroke work

levers in all directions. Movement can occur.
6. Move safety lever to "LOCK" position. (Figure 2)
7. Set parking brake switch to the "I" position. (Figure 3)
8. Apply the service brake with full stroke several time to O
relieve pressure from accumulate functioning braking.
9. Turn key to "O" (OFF) position and remove from starter I
switch.
10. Attach maintenance warning tag on controls.
WE1400464
Figure 3
DX210W-5 Cabin
5-1-7
11. Turn battery disconnect switch to "OFF" position.
(Figure 4)
OFF
ON
Figure 4 WE1500101
12. Remove bolts and washers (1, Figure 5) (6 ea) with under
cover (2) on bottom of main frame.
• Tool: 19 mm ( )
1
• Torque: 107.9 N.m (11 kg.m, 79.6 ft lb)
2
• Under cover weight: 9 kg (20 ft lb)
Figure 5 Bottom of Main Frame WE1500563
13. Disconnect washer hose.
Figure 6 Bottom of Cabin WE1400432
14. Remove floor mat from the cabin.
Figure 7 WE1400742
Cabin DX210W-5
5-1-8
15. Remove cover (1, Figure 8), bolt and washer (2) with
safety lever assembly (3) from control stand.
• Tool: 4 mm ( )
1
3 2
EX1403564
Figure 8
16. Remove duct covers (1 and 2, Figure 9).
1 2
Figure 9 WE1400435
17. 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 10
18. Remove air ducts (1 thru 6, Figure 11) on right-hand side

of operator's cabin. 5
3
4
1
Figure 11 WE1400437
DX210W-5 Cabin
5-1-9
19. Remove glove box pad (1, Figure 12), and two bolts under
pad. 4
Remove caps and bolts (2, Figure 12) (3 ea) from top of
rear cover.
1 2
Remove bolts (3, Figure 12) (2 ea) from bottom of rubber
mounts in rear cover.
Remove rear cover (4, Figure 12).
3
WE1400438
Figure 12
20. Remove air ducts (1 thru 3, Figure 13) and atmospheric air
duct (4).
2 4
3
WE1400439
Figure 13
21. Remove all bolts (1, Figure 14) (17 ea) with brackets (2
thru 4) from body of operator cabin.
• Tool: 13 mm ( ) 2
3
1
4
WE1400440
Figure 14
Cabin DX210W-5
5-1-10
22. Disconnect connectors of interior lights, speakers and
antenna.
WE1400441
Figure 15
23. Using a suitable lifting device, attach slings to four lift

points on top of cabin (Figure 16)
• Lifting hole size: M12 x 1.75, depth: 15 mm
• Cabin weight: about 485 kg (1,069 lb)
WE1400442
Figure 16
24. Remove bolts and washers (1, Figure 17) (11 ea).
• Tool: 19 mm ( )
• Torque: 88.3 N.m (9 kg.m, 65.1 ft lb) 1 1
2 2
25. Remove nuts and washers (2) (4 ea) from cabin floor.
1 1
• Tool: 24 mm ( ) 2 1 2
1 1
WE1400443
Figure 17
DX210W-5 Cabin
5-1-11
26. Remove bolts which is fixing the plate to prevent loosening
of ROPS bolt (1, Figure 18).
• Tool: 19 mm ( ) 2

27. Remove ROPS bolt (2, Figure 18).
• Tool: 60 mm ( )
1
• Torque: 127.5 N.m (13 kg.m, 94 ft lb)
WE1400444
Figure 18
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. Figure 19 WE1400445
INSTALLATION
1. Using a suitable lifting device, attach slings to four (4) lift
points on top of cabin (Figure 20).
• Cabin weight: 485 kg (1,069 lb)
2. Lower cabin into position on cabin floor.
Figure 20 WE1400445
3. Install mounting nuts (Figure 21) (4 ea) and washers in four

corners of cabin floor.
When install the nut, apply Loctite (#262) to nut.
• Tool: 24 mm ( )
Perform installation in the reverse order to removal.
Figure 21 WE1400446
Cabin DX210W-5
5-1-12
COMPLETING WORK
1. Start the engine and run at low idle for about 5 minutes.
2. Perform the machine performance test.
DX210W-5 Cabin
5-1-13
DIMENSIONS OF CABIN GLASS
Front Glass
816 7
993
824
454.5
27.6
27.6
169.6
169.6
7
58.3 707.4
EX1403138
Figure 22
NOTE: Unit: mm (1 mm = 0.039 in)
Cabin DX210W-5
5-1-14
Left Glass
399.5 5 270.7 5
786.4
786.4
20.3
410.6
437.5 131.6 402.3
850.2 5
210.7
367
468.8
436.1
470
642.3
722.8
871.7
EX1403139
Figure 23
DX210W-5 Cabin
5-1-15
Rear Side Glass
786.7 5
601.2
391.1
5
1026.2
958.2
452.9
EX1403140
Figure 24
Cabin DX210W-5
5-1-16
Right Glass
1330.8 5
83.2
527.5
957.1
1407.6
505.1
419.7
306.6
30.8
918.7 207.9 163.3
1534.8
EX1403141
Figure 25
DX210W-5 Cabin
5-1-17
REMOVAL AND INSTALLATION OF CABIN GLASS
Removal of Cabin Glass

Procedures to remove right-hand glass (1, Figure 26), 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 26
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
4 Rear Left-hand Glass 5
2
5 Resin Panel
EX1301296
Figure 27
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 28
Cabin DX210W-5
5-1-18
3. Pass a piano wire (1, Figure 29) (or a wire) through the
hole.
EX1301299
Figure 29
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
30) between cabin (1) and glass (2). 1 2
Remove glass (2, Figure 30) 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 30
DX210W-5 Cabin
5-1-19
Installation of Cabin Glass
1
Procedures to install right-hand glass (1, Figure 32), 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 31). 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 31
1 Cabin
2 Knife
EX1301295
Figure 32
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
4 Rear Left-hand Glass 2
5 Resin Panel EX1301296

Figure 33
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).
3. Apply the damper on cabin body before applying adhesive.
Cabin DX210W-5
5-1-20
Damper - Front Upper Glass
787
Length: about 3,530 mm
Adhesive Sides 5
975
5
A
Section A - A
EX1301354
Figure 34
Damper - Rear Glass
758
Adhesive Sides 5
573
A
Section A - A
EX1301355
Figure 35
DX210W-5 Cabin
5-1-21
Damper - Right-hand Glass
1,492
A
Adhesive Sides 5
1,376
7
Section A - A
EX1301356
Figure 36
Damper - Lower Glass of Door
800
7
184
329
R4,329 A
Adhesive Sides
429
5
R94
606 Section A - A
685
EX1301357
Figure 37
Damper - Rear Left-hand Glass
A
Adhesive Sides
5
Section A - A
EX1301358
Figure 38
Cabin DX210W-5
5-1-22
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.
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. 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 39).)
NOTE: The painting primer must be applied evenly to
2
leave no blemishes.
Reference 3
Description
Number
1 Cabin
EX1301303
2 Application Brush Figure 39
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 -21.)
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 39).)
DX210W-5 Cabin
5-1-23
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 40

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
Cabin DX210W-5
5-1-24
Installation of Upper Door Glass
1. Before installing the glass, remove garnish (2, Figure 41) 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 41) 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 41
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 42
DX210W-5 Cabin
5-1-25
Cabin DX210W-5
5-1-26
Counterweight
Edition 1
DX210W-5 Counterweight
5-2-1
MEMO
Counterweight DX210W-5
5-2-2
Table of Contents
Counterweight
General ...........................................................5-2-6
Warning for Counterweight and 
Front Attachment Removal........................................ 5-2-6
Removal .........................................................5-2-8
Installation ......................................................5-2-9
5-2-3
5-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
5-2-5
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.
WE1400011
Never rotate the upper structure once the counterweight or 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 of counterweight
– STD: 3,200 kg (7,055 lb)
– OPT: 4,000 kg (8,820 lb)
5-2-6
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
Figure 3 WE1400143
5-2-7
REMOVAL
O ACC
I
WARNING
LOCK
Death or serious injury can occur from a counterweight
falling during removal or installation. Do not allow OFF OFF
ON
ON
personnel under or around the counterweight during
removal or installation.
ON OFF
Use certified cables and shackles of adequate load rating.
Improper lifting can allow the load to shift and cause death EX1500510
or serious injury. Figure 4
1. Park on firm and level ground.

2. Lower front attachment (bucket) to ground.
3. Stop engine.
4. Move safety lever to "UNLOCK" position.
1
WARNING
AVOID DEATH OR SERIOUS INJURY 6
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.
8. Turn key to "O" (OFF) position and remove from starter switch. 7
5
4
9. Attach maintenance warning tag on controls.
10. Turn battery disconnect switch to "OFF" position. 8
11. Make sure all electrical lines and other items are disconnected. 3
3
12. Using a suitable lifting device capable of handling a heavy
load, partially support counterweight from lifting holes (6, 2
Figure 5), counterweight (1) before loosening four bolts (2). 2
Stop lifting with assist crane as soon as lifting slings are taut.
13. Remove four bolts (2, Figure 5), spacers (3) and washers WE1500004
(4, 5 and 7) from counterweight (1). Figure 5
• Tool: 46 mm ( )
• Weight:
– 3,200 kg (7,055 lb)
– 4,000 kg (8,820 lb)
5-2-8
NOTE: Heat bolts, if necessary, to free them.
14. When bolts (2, Figure 5), spacers (3) and washers (4, 5
and 7) have been removed, lift counterweight (1) a very
short distance above support frame (8) and stop. Check
slings and make sure counterweight is being supported
evenly.
INSTALLATION 1
1. Using suitable lifting device capable of handling the weight
of the counterweight, support counterweight from lifting
holes (6, Figure 6). Raise counterweight (1) into position 6
just above support frame (8) leaving counterweight
suspended. Verify that counterweight is level and even.
NOTE: Leave counterweight (1, Figure 6) suspended
3 mm (0.125") above support frame (8) until all
four mounting bolts (2) are started in
counterweight mounting holes.
2. Align spacers (3, Figure 6) and washers (4, 5 and 7) onto
bolts (2). Apply Loctite #242 to mounting bolt threads.
3. Install four bolts (2, Figure 6) with spacers (3) and washers 7
5
(4, 5 and 7) into counterweight until washers contact 4
support frame. Fully lower counterweight onto support
frame and finish tightening bolts. 8
• Tool: 46 mm ( ) 3
3
• Torque: 1,471 ±196 N.m 
(150 ±20 kg.m, 1,085 ±145 ft lb) 2
2
NOTE: As assembling counterweight into main frame,
adjust the gap of height between counterweight
and side door assembly using shim (7, Figure 4) WE1500004
suitably. Figure 6
4. Remove lifting device from counterweight lifting holes. (6,

Figure 6)
5. Make sure all electrical lines and other items are connected.
6. Turn battery disconnect switch to "ON" position.
5-2-9
5-2-10
Hydraulic Oil Tank
Edition 1
DX210W-5 Hydraulic Oil Tank

5-3-1
MEMO
Hydraulic Oil Tank DX210W-5

5-3-2
Table of Contents
Hydraulic Oil Tank

General ...........................................................5-3-5
Specification .............................................................. 5-3-5
Parts List ................................................................... 5-3-6
Air Breather ............................................................... 5-3-8
Removal .........................................................5-3-9
Installation ....................................................5-3-16
Completing Work ..........................................5-3-17

5-3-3
5-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Volume (Full) 207 L (54.7 U.S. gal)
Optimum Volume 128 L (33.8 U.S. gal)
Tank Size (mm) 491 x 652 x 872
Tank Weight about 141 kg (311 lb) (Empty)
Size 10 m, 1.6 m2 (ø150 x 415)
Operation Pressure 0 ~ 15 bar (0 ~ 15.9 kg/cm2, 0 ~ 217.6 psi)
Return Filter (5, Figure 1)
Bypass Valve Setting 1.5 bar (1.5 kg/cm2, 21 psi) at 40 L/min
Flow Rate 600 L/min (158.5 U.S. gpm)
Filter 10 m, 270 cm2
Air Breather (14, Figure 1)
Cracking Pressure 0.04 ~ 0.05 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) Filtration Rating 177 
Flow Rate 750 L/min (198.1 U.S. gpm)
Actuation Pressure 1.5 bar (1.5 kg/cm2, 21 psi)
Pressure Switch (101, Figure 1)
Rating 4 A Resistance at 24 V DC Max.

5-3-5
Parts List
27
17
14-2 14
29 FR
14-1 ON
2 17 T
29
3 7
4 8
12
6
11
22
15
5
10
28
13
21 101
24
23 25
25
20 26
26 19
16
9
18
17
WE1500436
Figure 1

5-3-6
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, Filter 19 Plug
6 Valve; By-pass 20 O-ring
7 Cover, Tank 21 Sensor; Hydraulic Oil Temp
8 O-ring 22 Strainer; By-pass
9 Pipe; Suction 23 Shim
10 Filter; Suction 24 Shim
11 Rod 25 Spacer
12 Spring; Compress 26 Bolt
13 Gauge; Level 27 Bolt
14 Breather, Air 28 Bolt M12 x 1.75 x 16
14-1 Gasket 29 Washer
14-2 Element; Air Breather 101 Pressure Switch

5-3-7
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.

5-3-8
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 30° leftward 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. Lower all the attachments to ground.
4. Stop engine. WE1500293
5. Set wheel chocks in front and behind each tire to prevent Figure 3

5-3-9
(Figure 4) I
LOCK
WARNING OFF OFF
ON
ON
8. Operate the joystick levers and pedals several times to

release the remaining pressure in the hydraulic piping.
switch.
13. Attach a maintenance warning tag on controls.
WE1400464
Figure 5

(Figure 6)
OFF
ON
Figure 6 WE1500101
NOTE: Removal (installation) procedure of the bolts.

3
5 8
1 2
7 6
4
EX1401809
Figure 7

5-3-10
WARNING
Release any pressure in the hydraulic oil tank before
doing any work.
15. Loosen the oil tank air breather slowly to release the
pressure inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar) Figure 8 WE1500550
opens, and the air is discharged to the atmosphere from
the top of the hydraulic oil tank.
16. Oil drain method.
NOTE: Check the level on the oil level gauge before
draining the oil.
Figure 9 WE1500551
A. Remove cover (2 ea) on oil tank (bolt: 12 ea) and

drain hydraulic oil using oil pump. (Figure 10) 
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)
Suction Filter Cover
Figure 10 WE1500552
B. Drain hydraulic fluid using drain plug. (without oil

pump) (Figure 11)
• Tool: 27 mm ( )
• Torque: 93.1 N.m (9.5 kg.m, 68.7 ft lb)
• Hydraulic oil tank volume
– Approximately: 207 L (54.7 U.S. gal)
– Effective level: 128 L (33.8 U.S. gal)

5-3-11
17. Remove bolts and washers (1, Figure 12) (10 ea) with
guard rail (2).
• Tool: 19 mm ( )
1 2
• Guard rail weight: about 18 kg (39.7 lb)
Figure 12 WE1500303
18. Remove bolts and washers (1, Figure 13) (4 ea) with cover
2
(2) of control valve. 1
• Tool: 19 mm ( )
• Control valve cover weight: 15 kg (33.1 lb)
Figure 13 WE1500554
19. Install eyebolts (2 ea) on the oil tank. (Figure 14)

And tie the rope to the bolts to lift oil tank.
• Thread of hole: M12 x 1.75
Figure 14 WE1500555
20. Remove bolts (1, Figure 15) (9 ea) with air compressor
2
covert (2) and air compressor support (3).
• Tool: 19 mm ( )
• Support weight (with cover): 17 kg (37.5 lb)
3 1
Figure 15 WE1500556

5-3-12
21. Remove bolts (1, Figure 16) (2 ea) from fuel tank.
• Tool: 19 mm ( )
Figure 16 WE1400838
22. Remove bolts (2 ea) (Figure 17) with tank side cover.
• Tool: 19 mm ( )
• Tank side cover weight: 18 kg (39.7 lb)
Figure 17 WE1500557
23. Remove bolts and washers (1, Figure 18) (6 ea) under
• Tool: 19 mm ( ) 1
• Under cover weight: 3 kg (6.6 lb)
24. Remove oil tank mounting bolts and spacers (1, Figure 19)
(4 ea) from the main frame.
• Tool: 24 mm ( ) 2

25. Remove bolts (2, Figure 19) (6 ea) of suction pipe from the
oil tank.
1
• Tool: 17 mm ( )

5-3-13
26. Disconnect the connector of oil temperature sensor (1, Figure 20) and pressure switch (2).
27. Remove bolt (3, Figure 20) (2 ea) and clips with harness.
• Tool: 12 mm ( )
1 Remove Clip Pressure

Switch
2
2
3
1 Temperature 1
Sensor 2
Figure 20 WE1500560
28. Remove hoses, pipes and adapters (Figure 21) 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 2 3 4
5 6 7 13
10 11
8 9
12
14 15 16
Figure 21 WE1500561

5-3-14
• Hoses and plugs ports
Plug/Flange Size Torque
Port Name
(Hose) (mm) (mm) N.m kg.m ft lb
1 Plug PF 3/8" 22 49 5 36.2
2 Plug PF 3/8" 22 49 5 36.2
from Center Joint "15" UNF 9/16"-16-2B 19 25.5 2.6 18.2
3
from Control Valve "L3" UNF 9/16"-16-2B 19 25.5 2.6 18.2
4 Plug PF 1/4" 19 39.2 4 28.9
5 from Brake Pedal Valve "T1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
6 from Brake Pedal Valve "T2" UNF 11/16"-16-2B 22 38.2 3.9 28.2
from Control Valve "L2" UNF 9/16"-16-2B 19 25.5 2.6 18.2
7
from Control Valve "Po" UNF 9/16"-18-2B 19 25.5 2.6 18.2
8 from PT Block "T" UNF 13/16"-16-2B 24 55.9 5.7 41.2
9 from PT Block "T" UNF 13/16"-16-2B 24 55.9 5.7 41.2
10 from T/M Control Valve "T" UNF 11/16"-16-2B 22 38.2 3.9 28.2
11 Plug PF 3/8" 22 49 5 36.2
12 Oil Temperature Sensor M16 x 1.5 19 14.7 1.5 10.8
13 from Radiator SAE 1 1/2", D38 10 107.9 11 79.6
14 from Logic Valve "T" UNF 9/16"-16-2B 19 25.5 2.6 18.2
15 from Solenoid Valve "T" UNF 13/16"-16-2B 24 55.9 5.7 41.2
16 Plug PF 3/8" 22 49 5 36.2
• Fitting
Size Torque
Port Name
A B (C) (mm) N.m kg.m ft lb
3, 7 Tee PF 3/8" UNF 9/16"-18 22 49.0 5 36.2
5, 6, 10 Elbow PF 3/8" UNF 11/16"-16 22 49.0 5 36.2
8, 9, 15 Elbow PF 1/2" UNF 13/16"-16 27 93.1 9.5 68.7
14 Elbow PF 3/8" UNF 9/16"-18 22 49.0 5 36.2
1, 2, 11, 16 O-ring S8000145 (4D P14)
2180-1216D11
3, 7, 14 O-ring S8000145 (4D P14)
(ID:7.65, W:1.78, 1B)
4 O-ring S8000115 (4D P11)
5, 6, 10 O-ring S8000145 (4D P14) S8030061 (1B F-06)
8, 9, 15 O-ring S8000185 (4D P18) S8030081 (1B F-08)
DS2856005
Ring
13 (1 1/2", ID:47.6,
Seal
OD:54.6, 1B)
*A: Opposite side of hose, B (C): Hose side
29. Using a crane, lift the hydraulic oil tank slowly.

• Oil tank weight: about 141 kg (311 lb)
IMPORTANT
Make sure there are no other electrical wires or hoses
connected to tank.

5-3-15
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 22)
1. Install the oil tank with bolts and spacers (1, Figure 22) 2
(4 ea) to the main frame.
• Tool: 24 mm ( )
• Torque: 264.6 N.m (27 kg.m, 195.2 ft lb) 1
2. Install the bolts (2, Figure 22) (6 ea) through suction pipe to
the oil tank.
• Tool: 17 mm ( )
WE1500559
Figure 22 Bottom of Main Frame
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 23.
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 23

5-3-16
6. Location of air breather (1) must be as Figure 24 when
assembling cover (2).
Figure 24 WE1500562
COMPLETING WORK
1. Hydraulic oil tank volume:
• Approximately: 207 L (54.7 U.S. gal)
• Effective level: 128 L (33.8 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. WE1500293
Figure 25
B. Engine condition: Low idle
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.

5-3-17
5-3-18
1Fuel Tank
Edition 1
DX210W-5 Fuel Tank

5-4-1
MEMO
Fuel Tank DX210W-5

5-4-2
Table of Contents
Fuel Tank
General ...........................................................5-4-5
Specification .............................................................. 5-4-5
Parts List ................................................................... 5-4-6
Removal .........................................................5-4-8
Installation ....................................................5-4-14
Completing Work ..........................................5-4-15
DX210W-5 Fuel Tank

5-4-3
5-4-4
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) 292 L (77 U.S. gal)
Tank Size (mm) 612 x 732 x 979
Tank Weight about 158 kg (348.3 lb) (Empty)
Fuel Strainer Filter  Filtration Ratio 24 mesh
(3, Figure 1) Working Oil Temperature -40 ~ 80°C (-40 ~ 176°F)
0.25 ~ 0.05 bar
Positive Pressure
Fuel Cap (0.25 ~ 0.05 kg/cm2 , 3.63 ~ 0.73 psi)
Check Valve
(6, Figure 1) below 0.035 bar
Negative Pressure
(0.035 kg/cm2, 0.51 psi)
Working Voltage V max. 48 V
Fuel Sensor
Working Current I max. 300 mA
(14, Figure 1)
Rating Power 125 mW
DX210W-5 Fuel Tank

5-4-5
Parts List
ONT
6-1 FR
14
51
52
1
4
8
7
9
9
10
10
11
15
5
WE1500503
Figure 1

5-4-6
Reference Reference
Number Number
1 Tank, Fuel 8 Shim
2 Cover, Tank 9 Spacer
3 Filter; Fuel Strainer 10 Bolt
4 Gauge, Level 11 O-ring
5 Bolt M10 x 1.5 x 25 14 Sensor, Fuel
6 Cap, Fuel 15 Washer, Spring
6-1 Element (Fuel Cap) 51 O-ring
7 Shim 52 Plug
DX210W-5 Fuel Tank

5-4-7
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 seven 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
supply in tank has been run down as far as
possible. E F
E UREA
F
EX1300964
Figure 2
2. Park on firm and level ground (Figure 3).
WE1401484
Figure 3
3. Lower all the attachments to ground. O ACC

I
4. Stop engine.
LOCK
6. Move safety lever to "RELEASED" (UNLOCK) position.
OFF OFF

ON
ON
ON OFF
WARNING EX1500510
Figure 4
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.

5-4-8
switch.
WE1400464
Figure 5

(Figure 6)
OFF
ON
WE1500101
Figure 6

3
5 8
1 2
7 6
4
EX1401809
Figure 7
15. Clean area around fuel tank fill cap. Open fuel cap.
WE1500574
Figure 8
DX210W-5 Fuel Tank

5-4-9
16. Open drain valve (Figure 9) right side door and carefully
drain.
• Fuel tank capacity: 292 L (77 U.S. gal)
Figure 9 Pump Room WE1500295
17. Remove bolts and washers (1, Figure 10) (8 ea) with the
2
guardrail (2) (1 ea).
18. Remove bolts (3, Figure 10) (5 ea) and cover (4) from fuel 1
tank.
• Tool: 19 mm ( )
3
• Tank cover weight: 4 kg (8.8 lb) 4
• Guardrail weight: 16 kg (35.3 lb)
Figure 10 WE1500575
19. Remove bolts and washers (1, Figure 11) (7 ea) with the
1 3
handrail (2) from fuel tank and frame.
5
20. Remove bolts (3, Figure 11) (4 ea) with the tank front cover 2
(4) from fuel tank.
cover (6) from support.
• Tool: 19 mm ( ) 4
1
6
• Weight
WE1400848
Figure 11
Reference
Description kg (lb)
Number
2 Handrail 23 (50.7)
4 Tank Front Cover 4 (8.8)
6 Air Compressor Cover 5 (11)

5-4-10
support (2) from battery cover. 1
• Tool: 19 mm ( )
• Support weight: 13 kg (28.7 lb)
Figure 12 WE1500297
23. Disconnect the connector of fuel sensor (1, Figure 13).

24. Remove bolts (2, Figure 13) (5 ea) and clips with harness (3).
2
• Tool: 12 mm ( ) 1

3
Figure 13 WE1500297
How to disconnect the harness connector.
2
1
EX1402326
Figure 14
DX210W-5 Fuel Tank

5-4-11
25. Remove hose from fuel tank.
• Tool for clip (1): Driver
• Hoses and plugs ports 2 1
WE1500296
Figure 15

Port Name
(Hose) (mm) N.m kg.m ft lb
2 Plug PF1/2" 27 93.1 9.5 68.7
26. 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: 158 kg (348.3 lb)
Figure 16 WE1500299
27. Remove bolts (1, Figure 17) (2 ea) from fuel tank.
• Tool: 19 mm ( )
Figure 17 WE1400853
28. Remove bolts (2 ea) (Figure 18) with tank side cover.
• Tool: 19 mm ( )
• Tank side cover weight: 18 kg (39.7 lb)
Figure 18 WE1500557

5-4-12
• Tool: 19 mm ( )

2
WE1500576
30. Remove hoses and adapter from fuel tank.

NOTE: Cap the open ends of hose with plug.
2
3
WE1500577

Port Name
1 to Drain Valve UNF 11/16"-16 22 38.2 3.9 28.2
2 Supply Line UNF 13/16"-16 24 55.9 5.7 41.2
• Fitting
Size Torque
Port Name
A B (mm) N.m kg.m ft lb
S8030061
1 O-ring
(1B F-06)
S8030081
2 O-ring
(1B F-08)
* A: Opposite side of hose, B: Hose side
DX210W-5 Fuel Tank

5-4-13
31. Remove fuel tank mounting bolts and spacers (3, Figure 20)
(4 ea) from the main frame.
• Tool: 24 mm ( )
32. Lift tank 25 mm and make sure it is balanced.
IMPORTANT
connected to tank.
33. Completely remove tank after inspection

• Fuel tank weight: 158 kg (348.3 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 21)
1. Install the fuel tank with bolts and spacers (3, Figure 21)
(4 ea) to the main frame. 2
3
• Tool: 24 mm ( )
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
2. Connect fuel supply line (2, Figure 21) and drain valve line
(1) to fuel tank.
4. Make sure fuel tank drain valve (Figure 22) right side door
is closed.
5. Fill fuel tank and check for signs of leaks. Correct any
problems found.
6. Fuel tank capacity: 292 L (77 U.S. gal)
Figure 22 Pump Room WE1500295

5-4-14
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 23 WE1500302
3. Loosen plug (1, Figure 24) on top of fuel filter head.

1
4. Pump hand operated primer pump (2, Figure 24). Pump
primer until fuel is present at plug hole in fuel filter head. 2
5. Tighten plug in fuel filter head

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.
FG000431
Figure 24
DX210W-5 Fuel Tank

5-4-15
5-4-16
1Main Pump
Edition 1
DX210W-5 Main Pump

5-5-1
MEMO
Main Pump DX210W-5

5-5-2
Table of Contents
Main Pump
General ...........................................................5-5-5
Specifications ............................................................ 5-5-5
Overview ................................................................... 5-5-8
Hydraulic Circuit ........................................................ 5-5-9
Parts List ................................................................. 5-5-10
Theory of Operation ................................................ 5-5-14
Section View .................................................5-5-27
Removal .......................................................5-5-28
Installation ....................................................5-5-37
Completing Work ..........................................5-5-37
Assembly Guidelines for Tightening Torques..5-5-38
Bolts ........................................................................ 5-5-38
Plugs with Internal Hexagon and Profile Seal Ring... 5-5-39
Seal-lock - Sealing Nuts .......................................... 5-5-39
Disassembly and Reassembly......................5-5-40
General Repair Guidelines ...................................... 5-5-40
Seal Kits and Subassemblies.................................. 5-5-41
Sealing the Driveshaft ............................................. 5-5-45
Gear Pump Sealing ................................................. 5-5-47
Removing Control Housing ..................................... 5-5-48
Control Module ........................................................ 5-5-51
Removing the Controller.......................................... 5-5-53
Valve Plate with Valves ........................................... 5-5-55
Remove Rotary Groups........................................... 5-5-56
Remove Intermediate Wheel................................... 5-5-59
Remove Auxiliary Drive ........................................... 5-5-61
Inspection ................................................................ 5-5-64
Assembling the Rotary Group ................................. 5-5-68
Pump Assembly ...................................................... 5-5-70
Hydraulic Component - Measurement "D" .............. 5-5-73
Installation of Control Housing ................................ 5-5-76
DX210W-5 Main Pump

5-5-3
Assembly of Intermediate Wheel............................. 5-5-79
Installation of Gear Pump........................................ 5-5-80
Installation of Cover/Auxiliary Drive......................... 5-5-81
Troubleshooting ............................................5-5-82
How to Proceed for Troubleshooting....................... 5-5-82
Malfunction Table .................................................... 5-5-83

5-5-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Engine Power (P) 141 kW (192 PS) @ 1,900 rpm
Rated Speed (N) 1,900 rpm
High Idle (N) 2,200 rpm
2 x 224 L/min @ 1,900 rpm &
Max. Flow (Q max.)
350 bar (356.9 kg/cm2, 5,076.3 psi)
Min. Flow (Q min.) 104 L/min @ 1,900 rpm
Max. Displacement (V g max.) 118 cc/rev x 2
Weight 120 kg (265 lb)
Control Pressure
Beginning of Regulation (P) 10 bar (10 kg/cm2, 145 psi)

End of Regulation (P) 24.3 bar (24.7 kg/cm2, 352 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
DX210W-5 Main Pump

5-5-5
Performance Curves
1. P - Q Curve
250
0K
190 L
270 K
200 179 L
98 K 160 K
185 L 182 L 350 K
150 139 L
165 K
Q Flow (L/min)
118 L 230 K
116 L
68 K
100 122 L
350 K
74 L
50 350 K
52 L
350 K
22 L
0 50 100 150 200 250 300 350
P Discharge Pressure (kg/cm 2)
WE1500438
Figure 1
Secondary
Input Input Current
Mode Pressure Remarks
(rpm) (mA)
(bar (kg/cm2))
Travel 2,000 230 2.1 (2.1) Variable
Power Plus 1,700 250 2.6 (2.7) Variable
Power 1,600 275 3.4 (3.5) Variable
Standard 1,500 275 3.4 (3.5) Variable
Economy 1,400 300 4.7 (4.8) Variable
Low 800 700 25.1 (25.6) Variable

5-5-6
2. P - I Curve
A3
EPPR Valve
Input Current
R3
R1
M2
A2
M
Y3
Vg max Vg min X1
M3
X3
Vg max Vg min
X1
Y3
M
A1
M1
R2 S
27.5
25.0
22.5
Secondary Pressure (kg/cm2)
20.0
17.5
15.0
12.5
10.0
7.5
5.0
2.5
0.0
0 100 200 300 400 500 600 700
Controlled Current (mA) WE1500439

Figure 2
DX210W-5 Main Pump

5-5-7
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
Y3
R3 X1
M1
S
M2 R1
A2
A R2 A1
View A WE1500106
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 , 565.6 psi))
2 M18 x 1.5
X1 Control Pressure Ports for Positive Control 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
R1 Air Bleed Port
R2 Drain port M14 x 1.5
R3 Air Bleed Port
Y3 Pilot Pressure Port

5-5-8
Hydraulic Circuit
A3
EPPR Valve
R3
R1
M2
A2
M
Y3
Vg max Vg min X1
M3
X3
Vg max Vg min
X1
Y3
M
A1
M1
R2 S
WE1500192
Figure 4
DX210W-5 Main Pump

5-5-9
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

5-5-10
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
DX210W-5 Main Pump

5-5-11
Control Part
2Aj
2Ah
2Ag
2Am
2Ae
2Af 2An
2As
2Ao 2Ad
2Aq
2A 2Ar
2Aa
2Al
2
2Ac 2Ap 2A
2Ab
2C
2Ai 2O
2Ak
2P
2E
2D 2F 2N
2B
2M
2L
49 46 2G
2I
2
18 2H
50 10
2L 2J
48 11
2K
47
44
43
42
15 15
42
20 21
13
12
17
16
37
26 WE1500107
Figure 6

5-5-12
Reference Reference
Number Number
2 Module, Control 2I Spring
2A Module, Control 2J Spring
2Aa Housing; Control 2K O-ring
2Ab Piston; Control 2L O-ring
2Ac Bush; Control 2M Screw; Locking
2Ad Collar; Spring 2N Nut; Seal Lock
2Ae Collar; Spring 2O Bolt
2Af Spring; Pressure 2P Valve; Shuttle
2Ag Screw; Locking 10 Plate; Port
2Ah Pin; Threaded 11 Gasket
2Ai Pin 12 Piston; Positioning
2Aj Nut; Seal Lock 13 Trunnion; Positioning
2Ak O-ring 15 Spring
2Al O-ring 16 Piston
2Am O-ring 17 Pin; Threaded
2An Screw; Socket-head 18 Plug
2Ao Plug 20 Collar, Spring
2Ap Pin; Cylinder 21 Collar; Spring
2Aq Plug 26 Screw; Hex
2Ar Plug 37 Ring; Steel Sealing
2As Screw; Locking 42 Bolt; Socket
2B Housing; Control 43 Bolt; Socket M12 x 1.75 x 80
2C Piston; Control 44 Pin; Cylinder
2D Bush; Spring 46 Plug
2E Spring, Pressure 47 Nut; Seal Lock
2F Pin; Threaded 48 Pin; Threaded
2G Collar; Spring 49 O-ring
2H Collar; Spring 50 Screw
DX210W-5 Main Pump

5-5-13
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.

5-5-14
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
DX210W-5 Main Pump

5-5-15
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

5-5-16
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
DX210W-5 Main Pump

5-5-17
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
M
Y3
X1
M3
X3
X1
Y3
M
A1
M1
R2 S
Pilot
Pump High System
Pressure
Minimum Flow Position

WE1500193
Figure 10

5-5-18
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
M
Y3
X1
M3
X3
X1
Y3
M
A1
M1
R2 S
Pilot
Pump Low System
Pressure
Maximum Flow Position

WE1500194
Figure 11
DX210W-5 Main Pump

5-5-19
Flow Control
The pump's discharge flow rate is arbitrarily controlled according
to change in the pilot pressure.
The servo valve is a positive flow control type to increase 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.

5-5-20
Decrease Oil Flow
When the joystick valve is set to the neutral position, a low posicon pressure signal is delivered to the main
pump's ports (x1) and (x2) to operate the control piston in order to apply the main pump's operating pressure to
the large diameter chamber.
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 Low Posicon
A2 Pressure
M
Y3
X1
M3
X3
X1
Y3
M
A1
M1
R2 S
Low Posicon
Pressure
Pilot
Pump
Minimum Flow Position

WE1500195
Figure 12
DX210W-5 Main Pump

5-5-21
Increase Oil Flow
When an operator operates the joystick valve, the pilot pressure operates the spool of the control valve and the
high posicon pressure is delivered to the main pump's ports (x1) and (x2) through the shuttle valve.
As a result, this pressure operates the control piston, connecting the large diameter chamber to the 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 High Posicon
A2
Pressure
M
Y3
X1
M3
X3
X1
Y3
M
A1
M1
R2 S
High Posicon
Pressure
Pilot
Pump
Maximum Flow Position

WE1500196
Figure 13

5-5-22
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
R1 27.5
25.0
22.5
M2
A2 20.0
M 17.5
Y3 15.0
Vg max Vg min X1 12.5
10.0
7.5
M3
5.0
X3
Vg max Vg min
2.5
X1 0.0
0 100 200 300 400 500 600 700
Y3
Controlled Current (mA)
M
A1
M1
R2 S
WE1500440
Figure 14
Secondary Pressure Input Current

Mode
(bar (kg/cm2)) (mA)
Travel 2.1 (2.1) 230
Power Plus 2.6 (2.7) 250
Power 3.4 (3.5) 275
Standard 3.4 (3.5) 275
Economy 4.7 (4.8) 300
Low 25.1 (25.6) 700
DX210W-5 Main Pump

5-5-23
Power Shift (STD Mode/Economy Mode: 3.4 ~ 4.7 bar (3.5 ~ 4.8 kg/cm2, 50 ~ 68 psi)
A3
EPPR Valve
Input Current
275 ~ 300 mA
R3
R1
M2
A2
M
Y3
X1
M3
X3
X1
Y3
M
A1
M1
R2 S
WE1500511
Figure 15
Power shift pressure helps moving power control spool easily

with low system pressure.
275 ~ 300 mA
Check
Point
Pilot
Pump
WE1500512
Figure 16

5-5-24
Power Shift (Travel Mode/Power Plus Mode/Power Mode: 2.1 ~ 3.4 bar (2.1 ~ 3.5 kg/cm2, 30 ~ 50 psi)
A3
EPPR Valve
Input Current
230 ~ 275 mA
R3
R1
M2
A2
M
Y3
X1
M3
X3
X1
Y3
M
A1
M1
R2 S
230 ~ 275 mA
Pilot
Pump
Figure 17 WE1500513
To control flow, it needs more system pressure then standard mode pressure.
DX210W-5 Main Pump

5-5-25
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 18 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)

5-5-26
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 19
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
DX210W-5 Main Pump

5-5-27
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

attachments on the ground.
2. Stop the engine.
WE1400569
Figure 20

5-5-28
I
(Figure 21)
LOCK
WARNING OFF OFF
ON
ON

7. Move safety lever on "LOCK" position. (Figure 21)
switch.
WE1400464
Figure 22

(Figure 23)
OFF
ON
Figure 23 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 24
DX210W-5 Main Pump

5-5-29
WARNING
doing any work.
14. Oil drain method
NOTE: Check the level on the oil level gauge before Return Filter Cover
draining the oil.
A. Remove cover on oil tank (bolt: 6 ea) and drain
hydraulic oil using oil pump. (Figure 26)
• Tool: 17 mm ( )
Figure 26 WE1500552
B. Drain hydraulic fluid using drain plug.

(without oil pump) (Figure 27)
• Tool: 27 mm ( )
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1008
Figure 28 WE1500566

5-5-30
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 29
15. Remove bolt (1, Figure 30) (7 ea) and remove under cover
(2, Figure 30) under pump side. 1 2
• Tool: 19 mm ( )
• Cover weight: about 6 kg (13.2 lb)
Figure 30 Under Main Pump WE1500578
16. Open the right side door.
WE1500261
Figure 31
17. Remove bolts (1, Figure 32) (7 ea) and remove baffle
cover (2, Figure 32) from pump room.
• Tool: 19 mm ( )
1
• Cover weight: about 6 kg (13.2 lb) 2
WE1500262
Figure 32
DX210W-5 Main Pump

5-5-31
18. Remove bolts (1, Figure 33) (10 ea) with muffler cover (2)
and tail pipe cover (3).
• Tool: 19 mm ( )
1
• Cover weight: about 22 kg (48.5 lb) 2
Figure 33 WE1500263
19. Remove bolt (1, Figure 34) with clip.
• Tool: 12 mm ( )
20. Remove clamp (2, Figure 34) from exhaust pipe.
• Tool: 10 mm ( )
2
Figure 34 WE1500264
21. Disconnect the harness connector (Figure 35).
Figure 35 WE1500265
22. Remove water hoses (1, Figure 36) (2 ea) and urea hose
(2) from Dosing module.
Figure 36 WE1500266

5-5-32
23. Attach a lifting device onto lifting hole to support it.
• SCR-DOC assembly: about 90 kg (198 lb)
Figure 37 WE1500267
• Tool: 17 mm ( )
2 2
25. Remove bolt (2, Figure 38) (2 ea). 1
• Tool: 19 mm ( )
Figure 38 WE1500268
26. Lift the SCR-DOC assembly from support slowly and

carefully.
connected to th SCR-DOC assembly.
EX1402359
Figure 39
DX210W-5 Main Pump

5-5-33
27. Disconnect the connector of main harness from EPPR
valve and pressure sensor.
Figure 40 WE1500579
EX1404086
Figure 41
28. Remove bolts (4 ea) and suction pipe from pump. 

Drain the hydraulic oil of suction pipe to bowl.
• Tool: 14 mm ( )
Figure 42 WE1500270
29. Remove hoses and adapters from main pump.

X1 A3
NOTE: Attach an identification tags to the removed X1
hoses for reassembling.
After disconnecting hoses, plug them to prevent
dirt or dust from entering.
Disconnect the hoses from the bottom to top of
main pump.
Y3 A1
A2
WE1500580
M2 S M1
Figure 43

5-5-34
• Hoses and plug ports
Port Name
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
A3 to Pilot Filter UNF 13/16"-16-2B 24 55.9 5.7 41.2
X1 Connect with Logic Valve "PA" UNF 9/16"-16-2B 19 25.5 2.6 18.8
(Front) from Shuttle Valve "A1" UNF 9/16"-16-2B 19 25.5 2.6 18.8
X1
from Shuttle Valve "PT" UNF 9/16"-16-2B 19 25.5 2.6 18.8
(Rear)
from Pilot Filter "OUT"
Y3 (Connect with Solenoid Valve UNF 9/16"-16-2B 19 25.5 2.6 18.8
"P1")
M1, M2 Pressure Sensor PF 3/8" 27 6.0 0.6 4.4
• Fitting
Size Torque
Port Name
A B (C) (mm) (mm) N.m kg.m ft lb
A2 Block SAE 1", D25 SAE 1", D25 10 107.9 11 79.6
A3 Adapter M18 x 1.5 UNF 13/16"-2A 24 40.2 4.1 29.6
Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
X1
(Front) Shuttle
UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
Valve
X1 Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
(Rear) Elbow UNF 9/16"-18 UNF 9/16"-18 17 25.5 2.6 18.8
Y3 Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
M1, M2 Adapter UNF 9/16"-18 PF 3/8" 24 25.5 2.6 18.8
DS2856003
A1 Ring Seal
(1", ID:33.2, OD:40.2, 1B)
DS2856003
DS2856003
A2 Ring Seal (1", ID:33.2,
(1", ID:33.2, OD:40.2, 1B)
OD:40.2, 1B)
X1 2180-1216D11
O-ring
(Rear) (ID:7.65, W:1.78, 1B)
M1, M2 O-ring S8040061 (1B B-06)
2180-1026D33
S O-ring
(ID:98.02, W:3.53, Class1)
* A: Opposite side of hose, B (C): Hose side
DX210W-5 Main Pump

5-5-35
30. Remove bolts (10 ea) of pump without top bolts (2 ea).
• Tool: 17 mm ( )
Figure 44 WE1500272
31. 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 120 kg (264.6 Ib)
CAUTION
AVOID INJURY
Support the pump prior to removing remaining bolts to
prevent pump from falling. WE1500273
Figure 45
32. Remove remaining bolts (2 ea).
• Tool: 17 mm ( )
WE1500274
Figure 46
33. Lift the pump from engine slowly and carefully.
IMPORTANT
connected to main pump.
Figure 47 EX1403069

5-5-36
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.
COMPLETING WORK
1. If the hydraulic oil in the oil tank was removed, refill the
hydraulic oil tank.
IMPORTANT
Make sure the hydraulic oil tank is filled to an
appropriate level.
2. Stop the engine. Figure 48 WE1500581
3. Remove drain plug (Figure 48).
• Tool: 6 mm ( )
4. Keep pouring until the oil appears clean without gas
bubbles; tighten the plug.
• Tool: 6 mm ( )
• Torque: 30 N.m (3.1 kg.m, 22 ft lb)
DX210W-5 Main Pump

5-5-37
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

5-5-38
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
DX210W-5 Main Pump

5-5-39
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
3. Check all sealing and sliding surfaces for wear.
IMPORTANT
Using abrasive materials on sliding surfaces can
damage the surface.
HB7M3005
Figure 55

5-5-40
Seal Kits and Subassemblies
1. Seal kit for driveshaft.
ASS0070L
Figure 56
2. Peripheral seal kit.
ASS0080L
Figure 57
3. Rotary group 1, ready to install.
ASS0090L
Figure 58
4. Rotary group 2, ready to install.
ASS0100L
Figure 59
DX210W-5 Main Pump

5-5-41
5. Rotary group, hydraulic component (order rotary groups 1
and 2 separately).
IMPORTANT
Adjustment is necessary. 
Pay attention to direction of rotation.
ASS0110L
Figure 60
6. Rotary group 1, mechanical section, ready to install.
ASS0120L
Figure 61
7. Rotary group 2, mechanical section, ready to install.
ASS0130L
Figure 62

5-5-42
8. Control, pre-adjusted.
ASS0140L
Figure 63
9. Gear pump, complete.
ASS0150L
Figure 64
10. Intermediate gear.
ASS0160L
Figure 65
DX210W-5 Main Pump

5-5-43
11. Auxiliary drive.
ASS0170L
Figure 66
12. Valve plate with valves.
EX1401142
Figure 67
13. Pipe, complete with fittings.
EX1401143
Figure 68

5-5-44
Sealing the Driveshaft
ASS0200L
Figure 69
1. Protect driveshaft. (e.g. with tape).
ASS0210L
Figure 70
2. Remove retaining ring and shim.
ASS0220L
Figure 71
DX210W-5 Main Pump

5-5-45
3. Screw sheet metal screw(s) into holes fitted with rubber.
Pull out seal with pliers.
ASS0230L
Figure 72
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 73

5-5-46
Gear Pump Sealing
Figure 74 EX1403156
Remove gear pump.

Visually check
1. O-ring (1, Figure 75).
1 ASS0260L
Figure 75
2. Sealing surface of housing (2, Figure 76).
ASS0270L
Figure 76
DX210W-5 Main Pump

5-5-47
Removing Control Housing
Figure 77 EX1403157
1. Place pump into a disassembly / assembly device with a

crane and secure it into position.
Figure 78 ASS0290L

5-5-48
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 79 ASS0300L
4. Remove paper seal, and clean sealing surface.
ASS0310L
Figure 80
DX210W-5 Main Pump

5-5-49
2
2
1
1 ASS0320L
Figure 81
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 82

5-5-50
Control Module
Control Module LR
ASS0340L
Figure 83
Remove and disassemble control module LR.

* *
ASS0350L
Figure 84
DX210W-5 Main Pump

5-5-51
Control Module H
ASS0360L
Figure 85
Remove and disassemble control module H.
ASS0370L
Figure 86

5-5-52
Removing the Controller
Figure 87 EX1403158
1. Remove screws.
NOTE: Install control lens - torque support.
ASS0400L
Figure 88
DX210W-5 Main Pump

5-5-53
2. Remove locking screw and replace with a new one.
NOTE: Loosen adhesive with a "gentle" flame
(approximately 120°C).
ASS0410L
Figure 89
ASS0420L
Figure 90
3. Remove swivel pin.
ASS0430L
Figure 91

5-5-54
Valve Plate with Valves
Figure 92 EX1401144
1. Pressure relief valve.

2. Electro- proportional pressure reducing valve (EPPR).
DX210W-5 Main Pump

5-5-55
Remove Rotary Groups
EX1403160
Figure 93
1. Keep cylinder with device (Remove it completely with

driveshaft).
ASS0460L
Figure 94
2. Remove cylinder (remove driveshaft without cylinder).
ASS0470L
Figure 95

5-5-56
3. Remove cup springs 1 and spring cup 2.
ASS0480L
Figure 96
4. Note disassembly position: (1, 2 and 3, Figure 97).

3
2
Rotary Group 2
Rotary Group 1
ASS0490L
Figure 97
5. Press out rotary group with an appropriate device.
2
1
ASS0500L
Figure 98
DX210W-5 Main Pump

5-5-57
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 99
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.

5-5-58
Remove Intermediate Wheel
1. Press bolt (*, Figure 100) into gear wheel. (Installed
pressing fit).
NOTE: Can only be disassembled with a hydraulic
press. *
ASS0520L
Figure 100
2. Install sleeve.
NOTE: Press out bolt with a hydraulic press.
ASS0530L
Figure 101
DX210W-5 Main Pump

5-5-59
3. Remove gear wheel through side drive opening.
ASS0540L
Figure 102
4. Remove bearing with extraction device.
ASS0550L
Figure 103

5-5-60
Remove Auxiliary Drive
ASS0560L
Figure 104
1. Remove screws and auxiliary drive.
ASS0570L
Figure 105
2. Press off bearing cap.
ASS0580L
Figure 106
DX210W-5 Main Pump

5-5-61
3. In the event of oil leakage, visually check O-ring, housing
and groove.
ASS0590L
Figure 107
4. Install extractor device.
ASS0600L
Figure 108
5. Pull out output pinion.
ASS0610L
Figure 109
6. Install bearing extractor device.
ASS0620L
Figure 110

5-5-62
7. Completely mount device and pull out bearing.
ASS0630L
Figure 111
8. Pull out pinion bearing.
ASS0640L
Figure 112
DX210W-5 Main Pump

5-5-63
Inspection
1. Check to see that bearing bore is free of scores and there
is no evidence of wear.
ASS0650L
Figure 113
2. Visually check:
To ensure that bearing seats are free of scores.
ASS0660L
Figure 114
3. Visually check:
Check to see that bearing bores are free of scores and
there is no evidence of wear.
ASS0670L
Figure 115
4. Axial piston play:

Checked with retaining plate installed.
ASS0680L
Figure 116

5-5-64
5. Driveshafts:
Check to ensure that cups are free of scores and there is
no pitting (1, Figure 117).
Check to see there is no evidence of corrosion and wear
steps (2, Figure 117).
ASS0690L
Figure 117
6. Piston:
Check to ensure that they are free of scores and there is
no pitting.
ASS0700L
Figure 118
7. Central pin:
Check to ensure that it is free of scores and there is no
pitting.
ASS071L
Figure 119
8. Retaining plate:
Check to ensure that it is free of scores and there is no
evidence of wear.
ASS0720L
Figure 120
DX210W-5 Main Pump

5-5-65
9. Check cylinder block / control lens.
Bores (1, Figure 121) are free of scores, no evidence of
wear.
Faces (2, Figure 121) are even, there are no cracks, no
scores.
Side guides (3, Figure 121) show no evidence of wear, free
of scores.
ASS0730L
Figure 121
10. Check:
Control land (1, Figure 122), internal control drilling (2,
Figure 122) and pin cups (3, Figure 122).
ASS0740L
Figure 122
11. Check:
That sliding surfaces (1, Figure 123) are free of scores.
Seal (2, Figure 123).
ASS0750L
Figure 123

5-5-66
12. Complete rotary group.
NOTE: Adjustment of the hydraulic component is
necessary.
Mechanical component: driveshaft is adjusted with the
bearing (1, Figure 124).
Hydraulic component (2, Figure 124): Adjustment is
necessary (*, Figure 124).
2
1
1
ASS0760L
Figure 124
DX210W-5 Main Pump

5-5-67
13. Rotary group: All of the components.
* Adjustment (Figure 125).
For adjustment values and torque values, see service
information.
*
*
*
*
ASS0770L
Figure 125
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 126

5-5-68
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 127
3. Insert spring plate (1, Figure 128) and cup springs (2,
Figure 128) into their correct position (and orientation)
using grease to hold them into place.
ASS0800L
Figure 128
4. Ensure that all parts are assembled in correct order and

orientation.
ASS0810L
Figure 129
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 130
DX210W-5 Main Pump

5-5-69
Pump Assembly
1. Warm up housing to approximately 80°C.
ASS0830L
Figure 131
2. Insert preassembled rotary group 2, being sure to align

gear tooth marks.
ASS0840L
Figure 132
3. Insert rotary group 1. Align the marked gear teeth.
ASS0850L
Figure 133
4. Gear tooth marks must align with each other.
ASS0860L
Figure 134

5-5-70
5. Adjustment of measurement D.
NOTE: Hydraulic control portion.
Stop
D
A
A
D
Stop
ASS0870L
Figure 135
NOTE: Driveshafts with bearing set.

The assembly group is adjusted to dimension
(A). The tapered roller bearings are adjusted to
the stipulated breakaway torque.
DX210W-5 Main Pump

5-5-71
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.

5-5-72
Hydraulic Component - Measurement "D"
Measuring Device - Hydraulic Component
EX1403917
Figure 136
Measuring Device Centering Device Intermediate Ring Shim S.H.C.S

(*) (1) (4) (5) (6)
1x 2x 2x 2x
9452269 02797872 09452014 09083277 09083105
DX210W-5 Main Pump

5-5-73
Mounting Position
NOTE: Be sure that correct mounting position is used. The
numbers on the top of the measuring device (*,
Figure 136) refer to the piston diameter.
ASS0900L
Figure 137
Mounting Position Distance (mm)

22 168
ASS0890L
Figure 138
1. Install intermediate ring or plates onto the housing. 

(Figure 139)
Figure 139
2. Zero adjustment - measuring device.

Turn using the hand wheel until stop is reached. Set dial
gauge to zero. (Figure 140)
Figure 140

5-5-74
Measuring Procedure
1. Turn down by 4 turns on the dial gauge. (Figure 141)
Check: 2 mm clearance, set dial gauge to "Zero".
NOTE: Clearance: Size 28 ~ 160 0.4 mm ±0.1.
ASS0960L
Figure 141
2. Turn down, using the hand wheel, until resistance is met.

Read the measured value. (Figure 142)
NOTE: Do not use excessive force.
Figure 142
DX210W-5 Main Pump

5-5-75
Installation of Control Housing
EX1403161
Figure 143
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 144

5-5-76
2. Push on piston ring by hand. Install adjustment piston.
Take the tightening torques into account.
ASS1010L
Figure 145
3. Install control housing.
EX1403162
Figure 146
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 147
DX210W-5 Main Pump

5-5-77
ASS1040L
Figure 148
5. Install seal and controller.
ASS1050L
Figure 149

5-5-78
Assembly of Intermediate Wheel
1. Press bearing (1, Figure 150) into housing.
2. Install and align intermediate wheel (2, Figure 150) through 1
side drive opening. New Assembly
Position 3
3. Cool down bolt (3, Figure 150) with nitrogen and install it.
4. Press in bearing (4, Figure 150).
2
ASS1060L
Figure 150
5. Press bearing into housing.
ASS1070L
Figure 151
DX210W-5 Main Pump

5-5-79
Installation of Gear Pump
EX1403159
Figure 152
1. Assemble shaft seal, disk and safety ring. Press-in with

assemble sleeve.
IMPORTANT
Take note of press-in depth.
Figure 153 ASS024

5-5-80
Installation of Cover/Auxiliary Drive
ASS1100L
Figure 154
DX210W-5 Main Pump

5-5-81
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

5-5-82
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.
DX210W-5 Main Pump

5-5-83
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.

5-5-84
Drive Coupling
(Main Pump)
Edition 1
DX210W-5 Drive Coupling (Main Pump)

5-6-1
MEMO
Drive Coupling (Main Pump) DX210W-5

5-6-2
Table of Contents
Drive Coupling (Main Pump)

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

5-6-3
5-6-4
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

5-6-5
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)

5-6-6
5-6-7
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

5-6-8
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

5-6-9
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 EX1403072

5-6-10
REASSEMBLY
1. Install insert (3, Figure 5) (4 ea) and spring pin (7, Figure 6)
3
(4 ea) with socket bolts (5) (4 ea) to engine flywheel.
• : 14 mm
• Torque: 205.9 ~ 225.6 N.m

(21 ~ 23 kg.m, 151.9 ~ 166.4 ft lb) 5
Figure 5 EX1403073
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). 4
• Torque: 205.9 ~ 225.6 N.m

(21 ~ 23 kg.m, 151.9 ~ 166.4 ft lb) 5
1
EX1404097
Figure 7

5-6-11
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 5-6-9.
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 EX1403076
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).

5-6-12
Main Control
Valve
Edition 1
DX210W-5 Main Control Valve

5-7-1
MEMO
Main Control Valve DX210W-5

5-7-2
Table of Contents
Main Control Valve

General ...........................................................5-7-5
Specification .............................................................. 5-7-5
Overview ................................................................... 5-7-6
Parts List ................................................................. 5-7-12
Removal .......................................................5-7-48
Installation ....................................................5-7-59
Completing Work ..........................................5-7-59
Disassembly .................................................5-7-60
General Repair Instructions..................................... 5-7-60
Repair Instructions .................................................. 5-7-61
Reassembly ..................................................5-7-80
Maintenance and Repair ......................................... 5-7-87
Troubleshooting, Testing and Adjustment............... 5-7-93
Start-up Procedures .....................................5-7-96
Commissioning........................................................ 5-7-96

5-7-3
5-7-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
The two-circuit positive control block is an enhancement of the
standard OC control, with improved functionality and reduced
energy consumption. With the PC principle, the pumps receive
the highest pilot pressure signal from the remote control valves
by a hydraulic logic; they then prepare the oil flow for the system
according to the pump characteristics. The hydraulically
controlled PC system is made up of the double pump, the mono
block with seven main axis and a shuttle valve block. With the
PC control block design, the remote control signals are
connected to the control pistons by the shuttle valve block. The
shuttle valve chain is also used to control pumps P1 and P2 and
to control other functions including summation, etc.
Specification
Type Pilot Control (Positive Control)
Spool Diameter ø 32 mm
Spool Arrangement Option, Bucket, Boom, Dozer (Outrigger), Travel, Swing, Arm
Low 350 ±5 bar (356.9 ±5.1 kg/cm2, 5,076.3 ±72.5 psi)
Main Relief Valve Pressure
High 370 ±5 bar (377.3 ±5.1 kg/cm2, 5,366.4 ±72.5 psi)
Port Relief Valve Pressure 380 bar (387.5 kg/cm2, 5,512 psi)
P1 240 L/min
Max Flow Rate
P2 240 L/min
Accessory Valve Boom and Arm Holding Valve
Weight 225 kg (496 Ib)

5-7-5
Overview
Over Load Relief Valve b1 Po Pilot Control Valve

b2 Y
b3
BB
b4
b5
b6
b7
PC1
B1 L3
B2
B3
B4
B5 B6
L1 B7
A1
A2
A3
A4
A5
A6 A7
Main Relief Valve

b7
b6
b5
b4
BB
b3
b2
b1
P2
K P1
WE1500183
Figure 1

5-7-6
Port Name Size
P1 Idle Pump High-pressure
P2 Drive Pump High-pressure
SAE 1 1/4, 6,000 psi
B1 Arm Cylinder Tube Side
B5 Boom Cylinder Tube Side
T Return Port (to Tank)
SAE 1 1/4, 3,000 psi
K Return Port (to Oil Cooler)
A1 Arm Cylinder Rod Side Port
A2 Swing Motor Left Port
A3 Travel Forward
A4 Dozer Cylinder Rod Side
A5 Boom Cylinder Rod Side
A6 Bucket Cylinder Rod Side
SAE 1, 6,000 psi
A7 Option (LH)
B2 Swing Motor Right Port
B3 Travel Backward
B4 Dozer Cylinder Tube Side
B6 Bucket Cylinder Tube Side
B7 Option (RH)
L1 Drain Port (to tank)
L3 Drain Port (Boom)
PF 1/4
Y Pressure Up (Boost)
PC1 Bypass Cut Valve Port
BB Boom Summation Valve Port
b1 Arm Crowd Pilot
b2 Swing Right Pilot
b3 Travel Backward Pilot
b4 Dozer Down Pilot 9/16-18UNF
b5 Boom Up Pilot
b6 Bucket Crowd Pilot
b7 Option Pilot
Po Two Pump Signal Pilot

5-7-7
Pi
S
a7 a6 a5 a4 AB a3 a2 a1
PC2
L2
Arm Regeneration Valve
B1 B2 B3 B4 B6 B7 B8
B5
A7 A8
A1
A2 A3 A4 A5 A6
S8
S1 S2 S3 S4 S5 S6 S7
WE1500185
Figure 2

5-7-8
Port Name Size
PC2 Bypass Cut Valve Port
PF 1/4
L2 Drain Port (Arm)
AB Arm Summation Valve Port
a1 Arm Dump Pilot
a2 Swing Left Pilot
a3 Travel Forward Pilot
a4 Dozer Up Pilot 9/16-18UNF
a5 Boom Down Pilot
a6 Bucket Dump Pilot
a7 Option Pilot
Pi Travel Priority Pilot
S Return Port M33 x 2
Name Description
S1 Arm
S2 Swing
S3 Travel
S4 Dozer/Outrigger
S5 Boom
S6 Bucket
S7 Option
S8 Arti Boom

5-7-9
Hydraulic Circuit
Dozer/
Bucket Boom Outrigger Travel Swing Arm
Arti Boom Option
4 3
A5
B8 A8 b8 B7 A7 b7 B6 A6 b6 B5 L3 b5 B4 A4 b4 AB L1 PC2 b3 B3 A3 b2 B2 A2 b1 B1 A1
S12
PC14
NG26
S13 NG25
PC11
PC25
8
NG13
NG24
PC21
S1
S7 S6 7 S5 S4 S3 S2
S14 NG14
S11
PC22 NG21
NG23 NG22 NG11 NG12 S18

5
NG20
NG15
NG10
PC23
380±5bar 380±5bar 380±5bar PC21 PC13 380±5bar

380±5bar PC24
PC12
9 6
a8 a7 a6 a5 a4 PC1 BB a3 a2 L2 a1
S10
P1
PR1
PR3
3bar
1bar
PR2
S T pi P2 Po P1 YK
2 1 Lo: 350 ±5 bar

Hi: 370 ±5 bar
Figure 3 WE1500141
Reference Reference
Number Number
1 Main Relief Valve 6 Arm Brake Valve
2 Travel Priority or 2 Pump Spool 7, 8 Holding Valves
3 Bypass Cut Valve 9 Anticavitation Valve
4 Arm Summation Spool S1 ~ S7 Main Spools
5 Boom Summation Spool

5-7-10
5-7-11
Parts List
Valve
221
140
220
222
248 202 , 202A
100
372 201 210 , 210A

139
210 , 210A
133 130
202 , 202A
132
141
200
201 133
130
200
132
202 , 202A 372

139
111
111
111 133
130
113
114
120
WE1500186
Figure 4

5-7-12
Reference Reference
Number Number
100 Housing 201 Valve, Relief; Anti Cavitation
111 O-ring 202 Valve, Relief; Anti Cavitation
113 Plate 202A Seal Kit; Relief Valve
114 Washer; Plain 210 Valve; Pilot Control
120 Bolt; Socket 210A Seal Kit
130 Plug 220 Plate Assembly; Block
132 Plug 221 Bolt; Socket M16 x 2.0 x 70
133 O-ring 222 Valve, Main Relief
139 Valve, Check 248 Flange
140 Valve, Check 372 O-ring
141 Valve, Check * Seal Kit
200 Plug
*: 111, 133, 372

5-7-13
Spool
190 158
157
195
197
150
199 160
159
150
159 151
189
152
157 B1
Shuttle
171
187
196
159 186
160 BB 180
189
A1 159
231 , 232 , 233 , 234
158 235 , 236 , 237
A2
158
PC1 Shuttle
A3 181
150
B6
AB
160
170 159
A4
157
A5
152
A6
151
A7 150
B-side
159
160 A-side
PC2
157 Ax- A-Side Spool B-Side
is Shuttle Shuttle
158 Item.164 Item. 231 Item.164
TG Item. 232 TG
182
159 Item.163 Item. 233 Item.163
189 TG Item. 234 TG
180
ˀG Item. 235 ˀG
186 ˀG Item. 236 ˀG
187 ˀG Item. 237 ˀG
PC1 ˀG Item. 181 ˀG
PC2 ˀG Item. 182 ˀG
AB Item.165 Item. 170 ˀG
BB ˀG Item. 171 Item.165
WE1500187
Figure 5

5-7-14
Reference Reference
Number Number
150 O-ring 187 Bolt; Socket M6 x 50L
151 Retainer, Spring 189 Bolt, Hex Socket
152 Spring, Pressure 190 Spool
157 Cover 195 O-ring
158 Bolt; Socket 196 O-ring
159 O-ring 197 Cover
160 Bolt, Hex Socket 199 Bolt; Socket M6 x 50L
163 Valve, Throttle Check 231 Spool, Arm
164 Valve, Throttle Check 232 Spool, Swing
165 Valve; Throttle Check 233 Spool, Dozer
170 Spool; Arm Summation 234 Spool, Dozer
171 Spool; Arm Summation 235 Spool, Boom
180 O-ring 236 Spool, Bucket
181 Spool, Bypass Cut 237 Spool, Option
182 Spool, Bypass Cut * Seal Kit
186 Cover
*: 150, 159, 180, 195, 196

5-7-15
Valve Block
16
15
14
13
50
42 12
11
51
42
50
30
21
31
32
20
32
32
25
5 31 26
27
10
12
13
14
11
15
16
WE1500251
Figure 6

5-7-16
Reference Reference
Number Number
5 Housing 25 Poppet, Load Check
10 Spool 26 Spring, Pressure
11 O-ring 27 Valve, Check
12 Retainer; Spring 30 O-ring
13 Spring; Pressure 31 O-ring
14 Retainer; Spring 32 O-ring
15 Cover 42 Plug
16 Bolt; Socket 50 Plug
20 Valve; Road Check (3 bar) 51 Plug
21 Valve; Road Check (1 bar) * Seal Kit
*: 11, 30, 31, 32

5-7-17
Theory of Operation
General Description
Pump 1 (P1) supplies the travel (S3), swing (S2) and arm (S1)
sections. Pump 2 (P2) supplies the dozer/outrigger (S4), boom
(S5) bucket (S6) and option (S7) sections. Since the
downstream consumer sections can no longer be supplied by
the neutral gallery (NG) during simultaneous control of several
sections, parallel channels (PC) are integrated into the control
valve.
The boom (S5) is operated to full output, the bucket section (S6)
is supplied by the PC23 parallel channel. The same applies to
the swing (S2) and arm (S1) sections. To ensure the loaded
upstream and downstream sections are supplied with enough oil
even at different load pressures, orifices are assigned to the
parallel channels (PC).
The travel sections (S3) and dozer/outrigger (S4) boasts a
special feature. The axis are assigned in tandem to the
downstream (S2) and (S1) respectively (S5) and (S6) to ensure
the oil supply is provided consistently (as a priority) for the travel
section under different working conditions. If the travel section
(S3) is operated to full output thus interrupting the (P1) supply to
sections (S2) and (S1), the supply comes from pump 2 (P2) by
the parallel channels PC13 and PC 12 over the travel priority
spool (S10). If the dozer/outrigger (S4) is operated to full output
thus interrupting the (P2) supply to sections (S5, S6) and (S7) by
NG21, the supply comes from pump (P2) by the travel priority
spool (S10) and the parallel channels PC21, PC22, PC23 and
PC24. At the same time the travel section will be supplied by
pump1 (P1) by the travel priority spool.

5-7-18
Neutral Passage
When the spool is at the neutral position, the minimum
discharge flow from the pump is returned to the tank by the
center bypass line. (NGx  NGy  Tank)
When the spool is switched, the oil discharged from the pump
flows to the operator port by the load check valve and the
parallel channel, since the center bypass line is closed.
(The oil flows: NGx  NGy is cut off by the spool switching)
The oil returning after operating the actuator (cylinder and
motor) returns to the tank by the spool.
• NG: Neutral Gallery
• PC: Parallel Channel
Load Check Valve
A B
T T
NGa NGx NGy PCz
WE1500140
Figure 7 Neutral Spool Position

5-7-19
B8
A8 Arti Boom
a8 b8
NG24 B7
PC24
A7 Option
a7 S7
b7
NG23
B6 Bucket
A6
PC23
a6 b6
S6
Boom
NG22
B5
A5
a5 L3
S5
b5 Dozer/
PC14
PC22
NG21
B4 Outrigger
a4
A4
PC1
PC21
b4
S S4
PC21
T 3bar NG20 AB
S10
pi
S14
S13
NG15
NG25
P2
NG14
L1
PR2
PR3
S11
Po
S12
P1 P1
PC13
PR1 NG26
PC2
NG10
PC11
Y
K
1bar S3
Travel
b3
BB
a3 B3
A3
NG11
PC25
S2 Swing
b2
a2
B2
A2
NG12
PC12
S18
L2
S1
a1 b1
Arm
B1
A1
NG13
Figure 8 WE1500080

5-7-20
PC (Parallel Channel)
If no volumetric flow is needed for the consumers, both pumps
are swiveled back and pump the minimum volumetric flow set by
the factory (Qmin). The Qmin quantity now flows through the
"neutral gallery" (NG) of the control valve back to the tank
(Figure 8). Pump (P1) flows for Qmin through the control block by
P1  S3  NG11  S2  NG12  S1 NG13  S11 
NG14  NG15 into the tank channel. Qmin of pump 2 (P2) flows
through the control block by P2  S10  NG20  S4 
NG21  S5  NG22  S6  NG23  S7  NG24 
S13  NG25  S12  NG26 into the tank channel.
If no volumetric flow is needed for the consumers cut spools S12
and S14 are switched by pilot pressure in PC1 and PC2. 
NG15 and NG26 are closed, no connection to tank channel.
Tank and Cooler Valves

The tank valve (4) and the cooler valve (5) are used to provide
the necessary pre-load of the tank channel so as to avoid
cavitation in the consumers by the subsequent feed function of
the secondary valve. The spring value of the cooler valve is
selected at a lower level so as to ensure a permanent through-
flow of the oil cooler.

5-7-21
Summation and Cut Valves
The oil flow path from the P1 pump is as follows.
• P1 Pump  Travel Spool  Swing Spool  Arm Spool
 S11 (Boom Summation Valve)  S14 (Cut Valve) 
Tank
Cut Valve (S12) Cut Valve (S14)
NG26 NG25 NG14 NG15
T NG24 PC25 PC21 PC11 PC14 NG13 T
Arm Summation Valve Boom Summation Valve

(S13) (S11)
WE1500175
Figure 9
Two summing valves and two cut valves are integrated.

The summing valves enable summation of the pump volumes
when the boom is raised and the arm in or out. If the function of
raising the boom is activated, also the boom boost valve S11
(connection BB) must also be activated. When pump 1 (P1) is in
neutral, the connection between NG13 and NG14 on the S11
axis is open and the pump line is connected through the S14 cut
valve into the tank channel.
So that pump volume 1 (P1) can flow directly into the boom
cylinder supply when the boom is being raised, the neutral
gallery on S11 is closed (connection between NG13 and NG14),
and the connection between NG13 and PC14 and the parallel
connection between PC11 and PC14 is opened.
The supply orifices NG13  NG14, NG13  PC14 and PC11
 PC14 are integrated into the S11 summing piston for optimal
control of the boom. If the function of arm in or out is activated,
also the arm boost valve S13 (connection AB) must be
activated. When pump 2 (P2) is in neutral, the connection
between NG24 and NG25 on the S13 axis is open and the pump
volume flows through the S12 cut valve into the tank channel.
So that pump volume 2 (P2) can flow directly into the arm clip
when the arm is operated, the neutral gallery on S13 is closed
(connection between NG24 and NG25), and the connection
between NG24 and PC25 and the parallel connection between

5-7-22
PC21 and PC25 is opened. 
The supply orifices NG24  NG25, NG24  PC25 and PC21
 PC25 are integrated into the S13 summing piston for optimal
control of the arm.
A5 B5 L3 AB L1 Pc2 B1 A1
S13 S12
NG24 NG25 NG26
PC21 PC25
Arm
Dozer
Boom Outrigger Travel
S14 S11
NG15 NG14 NG13
PC14 PC11
Pc1 P2 P1 BB T(K) L2
WE1500216
Figure 10
• AB: Arm Summation Signal

• BB: Boom Up Signal
• Pc1, Pc2: Center Bypass Cut Off Signal

5-7-23
Boom Operation
Boom Up (2-pump Summation)

In single operation, the supply for raising the boom (S5) (B5
port) is provided by pump 2 (P2) by the NG20 and NG21 neutral
circulation. For the summation of both pump flows P1 and P2
form boom raising it is necessary to activate the boom
summation spool (S11) by the BB port (Summing and Cut
Valves) in parallel to the spool S5.
The oil from pump 1 (P1) is then added directly into the boom
bottom side by the NG10/NG11/NG12/NG13 neutral circulation
and the PC14 parallel channel.
The function of the pilot-controlled check valve is described in
"Check Function (Supply)". If other sections are actuated, which
are supplied by pump 1 (P1), at the same time as raising the
boom, the supply from NG13 to PC14 by the summing piston
(S11) is interrupted.
The parallel groove from PC11 to PC14 in the summing piston
(S11) can also be used to provide the boom raising function for
corresponding load pressures with an additional supply through
a partial flow from pump 1 (P1) by NG10/NG11/PC11 and the
PC14 parallel channel. If the dozer/outrigger section (S4) is
proportionally operated to full output at the same time as the
boom section (S5), the supply by the neutral gallery NG21 is
reduced for section S5.
In the opposite direction, the supply for S5 by the parallel
channel PC21 by pump 2 (P2) increases because the
connection between P2 and PC21 opens in proportion by the
travel priority (S10). At the same time the supply of section S4
will be taken over by pump 1 (P1) through the connection of P1
and NG20 which is opened by the travel priority (S10). Also the
necessary pressure in the pump circuit (P1) is established by
closing the cut valve (S14).
The pilot-controlled check valve (10) "Pilot-controlled Check
Valve (Antidrift Valve)" which is integrated into the boom supply,
ensures a leak-free boom shut-off against undesirable lowering
while the S5 piston is in neutral. Both the rod side (A) and the
piston side (B) are protected by a combined pressure
anticavitation valve.

5-7-24
Boom Cylinder Arm Cylinder
A5 B5 L3 b5 AB L1 Pc2 B1 A1
S13 S12
Dozer Arm
Outrigger Travel
Boom S14 Summatio

Summation
S11
380 ±5 bar 380 ±5 bar
a5 BB L2
S10
Pc1
3 bar
1 bar
Figure 11 S T Pi P2 Po P1 YK WE1500217
Port Relief
Anti-cavitation Valve Load Check Valve Anti-drift Valve
Boom Spool
Input Pilot Pressure
Boom Summation Valve WE1500176

Figure 12

5-7-25
Boom Down (Regeneration)
In single operation, the supply for lowering the boom (S5) is
provided by pump 2 (P2) by the NG20 and NG21. Parallel to
this, the pilot controlled check valve (10) "Pilot-controlled Check
Valve (Antidrift Valve)" is activated so return oil can drain from
the cylinder (B5 port) to the tank. The function of the
pilot-controlled check valve is described in "Pilot controlled
Check Valve (Antidrift Valve)". The regeneration function
integrated into the boom piston enables high lowering speeds on
the boom without cavitation on the rod also for overlapped
movements, since some of the oil draining away from the base,
in addition to the available pump oil, is fed into the rod side of the
boom cylinder. If the dozer/outrigger section (S4) is
boom section (S5), the supply by the NG21 is reduced for
section S5. In the opposite direction, the supply for S5 by the
parallel channel PC21 by pump 2 (P2) increases because the
connection between P2 and PC21 opens in proportion by the
travel priority (S10). At the same time the supply of section S4
will be taken over by pump 1 (P1) through the connection of P1
and NG20 which is opened by the travel priority (S10). Also the
necessary pressure in the pump circuit (P1) is established by
closing the cut valve (S14).
A5 B5 L3 b5 AB L1 Pc2 B1 A1
S13 S12
Boom Dozer Arm

Outrigger Travel
S14
S5 S4 S3
NG20
NG21
S11
PC21
380 ±5 bar 380 ±5 bar
a5 BB L2
S10
Pc1
3 bar
1 bar
S T Pi P2 Po P1 YK
WE1500218
Figure 13

5-7-26
Load Check Valve Anti-drift Valve
Port Relief
Anti-cavitation Valve
Input Pilot
Pressure
Regeneration Unit Inside
WE1500177
Figure 14

5-7-27
Arm Operation
Arm In (Retraction, Crowd)

In single operation, the arm extension function (S1) is supplied
by the NG10, NG11 and NG12 neutral gallery by pump 1 (P1).
For the summation of both pump flows P1 and P2 form arm out it
is necessary to activate the arm summation spool (S13) by the
AB port in parallel to the spool S1.
The oil from pump 2 (P2) is then added into the clip of the arm
section by the NG20/NG21/NG22/NG23/NG24 neutral gallery
and the PC25 parallel channel. The clip (5) of the arm section
(S1) can also be supplied by an orifice within the parallel
channel PC12.
The PC12 parallel channel is fed from the NG11 neutral gallery
once the pressure in the NG11/NG12 circulation has reached
the respective arm load pressure. If the boom and/or bucket are
activated at the same time as the arm, the supply from NG24 to
PC25 by the summing piston (S13) is interrupted.
The parallel groove from PC21 to PC25 in the sum piston (S13)
can also be used to provide the arm function for corresponding
load pressures with an additional supply through a partial flow
from pump 2 (P2) by NG20/NG21/PC21 and the PC25 parallel
channel. If the dozer/outrigger section (S4) is at maximum
control, no oil can flow to the arm by the parallel nut in the
summing piston (S13). The function of the pilot-controlled check
valve is described in section "Check Function (Supply)".
Both the rod side (A) and the piston side (B) can be secured by a
combined pressure anticavitation valve. The check valve
"Pilot-controlled Check Valve (Antidrift Valve)", which is
integrated into the rod side feed from the arm ensures a leak-
free shut-off and prevents the arm being retracted at the neutral
position of the piston (S1).
When the arm is retracted, in addition to the piston (S1) being
activated by (b1). The pilot-controlled check valve "Pilot-
controlled Check Valve (Antidrift Valve)" is controlled at the
same time so return oil can flow from the cylinder rod side to the
tank.
The function of the pilot-controlled check valve is described in
section "Check Function (Supply)". Both the rod side and the
piston side can be secured by a combined pressure

5-7-28
Arm Regeneration
A5 B5 L3 AB L1 Pc2 b1 B1 A1
S13 S12
NG13
PC14
PC25
Dozer
Boom Outrigger Travel Summati
Summation
Arm
NG24
S14
S5 S4 S3
NG22, 2a
23 NG21 NG11, 12 S1
S11
NG20
NG10
PC13 PC12
380 ±5 bar 380 ±5 bar
BB a1 L2
S10
Pc1
3 bar
1 bar
S T Pi P2 Po P1 YK
Arm Regeneration Unit
Figure 15 WE1500220
Port Relief Anti-drift Arm Load Port Relief

Anti-cavitation Valve Valve Spool Check Valve Anti-cavitation Valve
Arm Summation Valve
Input Pilot
Pressure
Regeneration Unit
Figure 16 Arm Holding Valve EX1400466

5-7-29
With the separate brake valve (11) (CB valve) and the optional
regeneration function (14) two functions are combined.
First, the brake valve prevents accidental retraction of the arm
even with large load pressure differences, as set when mounting
different arm types and adjustment units for tools.
Second, the return oil flows from the rod side (demand
connector A1) depending on the supply pressure to the cylinder
head (demand connector B1) either in the tank or is regenerated
in the head side.
FG026573
Figure 17
If the pressure in the piston side is lower than the resistance in

the tank, the return oil is regenerated in the piston side of the
arm cylinder. The oil of the rod side in this case does not flow to
the tank, but is re-used and helps increase speed and save
energy (Figure 17) (Regeneration function).
Once the pressure in the arm piston side increases, (e.g. during
digging) the brake valve opens, and the check valve for
regeneration closes. The return oil then flows directly into the
tank with minimum resistance, and allows maximum digging
force (Figure 18).
FG026574
Figure 18
Arm Out (Extension, Dump)

In single operation, the arm extension function (S1) is supplied
by the NG10, NG11 and NG12 neutral gallery by pump 1 (P1).
For the summation of both pump flows P1 and P2 form arm out it
is necessary to activate the arm summation spool (S13) by the
AB port "Summing and Cut Valves" in parallel to the spool S1.
The oil from pump 2 (P2) is then added into the clip of the arm
section by the NG20/NG21/NG22/NG23/NG24 neutral gallery
and the PC25 parallel channel. The clip (5) of the arm section
(S1) can also be supplied by an orifice within the parallel
channel PC12. The PC12 parallel channel is fed from the NG11
neutral gallery once the pressure in the NG11/NG12 neutral
circulation has reached the respective arm load pressure. If the
boom and/or bucket are activated at the same time as the arm,
the supply from NG24 to PC25 by the summing piston (S13) is
interrupted. The parallel groove from PC21 to PC25 in the sum
piston (S13) can also be used to provide the arm function for
corresponding load pressures with an additional supply through
a partial flow from pump 2 (P2) by NG20/NG21/PC21 and the
PC25 channel. If the dozer/outrigger section (S4) is at maximum
control, no oil can flow to the arm by the parallel nut in the
summing piston (S13). The function of the pilot-controlled check
valve is described "Check Function (Supply)". Both the rod side
and the piston side can be secured by a combined pressure

5-7-30
A5 B5 L3 AB L1 Pc2 b1 B1 A1
S13 S12
PC21
PC25
Arm
Dozer
Boom Outrigger Travel ) Summation
Summati
NG24
S14 S1
S5 S4 S3
NG22, 23
2a NG21 NG11, 12
S11
NG10
NG20
PC13 PC12
380 ±5 bar 380 ±5 bar
BB a1 L2
S10
Pc1
3 bar
1 bar
Figure 19 S T Pi P2 Po P1 YK WE1500219

Regeneration Unit
Input Pilot Arm Summation Valve

Pressure
Figure 20
EX1400467

5-7-31
Bucket Compound Operation
The regeneration valve (bucket in) is installed on bucket line.
A B
a6 b6
T T
5 NG24 NG22 NG23 PC22
WE1500178
Figure 21
In single operation, the bucket section (S6) is supplied by pump

2 (P2) by the neutral gallery NG20, NG21 and NG22, the clip
channel (5) and parallel channel (PC22). The PC22 parallel
channel is fed by the NG21 neutral circulation as soon as the
necessary load pressure is established in the NG21/NG22
circulation by controlling the bucket piston (S6).
In single operation, the bucket section (S6) is supplied by pump
2 (P2) by the NG20, NG21 and NG22 neutral circulation, the clip
channel (5) and parallel channel (PC22).
The PC22 parallel channel is fed by the NG21 neutral circulation
as soon as the necessary load pressure is established in the
NG21/NG22 circulation by controlling the bucket piston (S6).
If the dozer/outrigger (S4) is proportionally operated to full
output at the same time as the bucket section (S6), the supply
from pump 2 (P2) by NG21 is reduced for the S6 section. In the
opposite direction, the supply from pump 2 (P2) into the PC21/
PC22 by the straight travel valve increases. The connection
between P1 and NG20 opens in proportion by the travel priority
(S10) to supply the dozer/outrigger (S4).
The necessary pressure in the P2 pump circuit is established by
closing the cut valve (S14). Both the rod side and the head side
are protected by a combined pressure anticavitation valve.

5-7-32
Bucket Cylinder
B7 A7 b7 B6 A6 b6 B4 A4 b4 pc2 L1 b3 B3 A3 b2 B2 A2
S12
Dozer
Outrigger Travel Swing
NG24
Option
S14
Bucket
S7 S6 S4 S3 S2
NG23 NG21, 22
NG20
380 ±5 bar PC21

380 ±5 bar PC22
a7 Pc1 a6 a4 a2 a3
S10
3 bar
1 bar
Bucket Regeneration Unit
S T Pi P2 Po P1 YK
WE1500221
Figure 22

5-7-33
Swing Operation
In single operation, the swing section (S2) is supplied by pump 1
(P1). The swing section (S2) and arm section (S1) are
connected in parallel to the pump (P1) by PC12. With an
appropriately set restrictor in PC12, the swing gear retains the
necessary priority for acceleration in relation to the arm section
(S1). If the arm and blade sections are activated and supplied at
the same time. It is not possible to secure the (A2) and (B2) side
by the anticavitation valve or combined pressure/anticavitation
valve for the swing section (S2) because these are secured by
the swing motor.
Pressure Relief & Swing Load Pressure Relief &

Anti-cavitation Valve Spool Check Valve Anti-cavitation Valve
A2 B2
Input Pilot
a2 Pressure
b2
T T
Swing Right WE1500180
Figure 23

5-7-34
Swing Right/Left
Flowrate discharged from P1 is supplied to swing motor through
swing spool, whose opening area dependent on the swing pilot
signal. The direction of the swing motor rotation is dependent on
the pilot signal, right or left.
Swing Motor
S12
Dozer
Outrigger Swing
Option Bucket
S14
Travel
S7 S6 S4 S2
S3
380 ±5 bar PC21 PC12

380 ±5 bar PC22
a7 Pc1 a6 a4 a2 a3
S10
3 bar
1 bar
S T Pi P2 Po P1 YK
Figure 24 WE1500222

5-7-35
Travel Operation
Figure 25
Reference Reference
Number Number
Control Cover with Spring Plate, 6 Supply Orifice Clip  Consumer A
1
Control Spring and Stroke Stop 7 Supply Orifice Clip  Consumer B
3 Plug Outflow (Return Flow) Cross-
8
4 S3 Control Piston section Consumer A  Tank
Clip Connection for the Supply Outflow Cross-section Consumer
5 9
(Meter in) Orifice B  Tank
In single operation, the travel section (S3) supply is provided

directly by pump 1 (P1). To ensure operation with maximum
volumetric flow is not affected by other consumers, pump 1 (P1)
is available exclusively for travel function when the travel section
(S3) is operated to full output. The travel section (S3) therefore
takes priority over the swing section (S2) and arm section (S1),
which are supplied by the travel priority (S10) and the channels
PC13 and PC12 by pump 2 (P2) in this case. This priority is
established by closing the NG11 neutral circulation of the travel
section (S3).
A feed (anticavitation) valve (2) can be attached to both the
motor (A) and (B) side.

5-7-36
Travel Motor
S12
Dozer
Outrigger Travel Swing
Option Bucket
S14
S7 S6 S4 S3
S2
380 ±5 bar PC21 PC12

380 ±5 bar PC22
a7 Pc1 a6 a4 a2 a3
S10
3 bar
S T Pi P2 Po P1 YK 1 bar
WE1500223
Figure 26

5-7-37
Option Operation
Breaker and shear can be installed on option line.
The brake is one way and the shear is two-way.
The pump discharge rate related to option (spool) is set up at the
instrument panel.
A B
a7 b7
T T
NG24 NG23
Figure 27 WE1500179
In single operation, the option 1 section (S7) is supplied by

pump 2 (P2) by the neutral gallery NG20, NG21 and the parallel
channel PC22, PC23. If the dozer/outrigger section (S4) is
option section (S7), the supply from pump 2 (P2) by NG21 is
reduced for the (S7) section. In the opposite direction, the supply
from pump 2 (P2) into the PC21/PC22/PC23 by the travel
priority (S10) increases. The connection between P1 and NG20
opens in proportion by the travel priority (S10) to supply the
dozer/outrigger section (S4). The necessary pressure in the P1
and P2 pump circuit is established by closing the cut valve
(S14). Both the rod side (A) and the head side (B) are protected
by a combined pressure anticavitation valve.

5-7-38
S12
Dozer
Option Bucket Outrigger Travel Swing
S14
S7 S6 S4 S3 S2
NG20
380 ±5 bar PC21, 22 PC12
380 ±5 bar PC23
a7 Pc1 a6 a4 a2 a3
S10
3 bar
1 bar
S T Pi P2 Po P1 YK
WE1500224
Figure 28

5-7-39
Main Relief Valve and Port Relief Valve
Main Relief Valve

The pilot-operated primary pressure relief valve is screwed into
the side of the control block, and limits the maximum pump
(system) pressure to the set value as a safety valve. Pressure
peaks in the pump line can occur if the volume flow requested by
the orifices is used up more quickly than the volume flow
requested by the pump or if an error occurs in the system.
When the system is delivered, the pressure setting is set
according to the project, and must not be changed.
Port Relief Valve

The pilot-controlled pressure anticavitation valves of the
individual consumer connections A and B are screwed into the
individual sections as valves in cartridge form above the control
piston. The valve protects the consumer circuit from overloading
or damage, e.g. from external forces or abrupt delays (control
piston in neutral position) by removing the pressure peak to the
tank. It limits the maximum pressure in the consumer as a safety
valve and sets the connection to the directional control valve to
the individually set value. When the system is delivered, the
pressure setting is set according to the project, and must not be
changed.
1 2 3 4 5 6
380 ±5 bar
P
P T
(A, B)
14 13 12 11 10 9 8 7
WE1500182
Figure 29

5-7-40
Dozer/
Arti Boom Option
A5
B8 A8 b8 B7A7 b7 B6 A6 b6 B5 L3b5 B4 A4 b4 AB L1 PC2 b3 B3 A3 b2 B2 A2 b1 B1 A1
S12
PC14
NG26
S13 NG25
PC11
PC25
NG13
NG24
PC21
S1
S7 S6 S5 S4 S3 S2
S14 NG14
S11
PC22 NG21
NG23 NG22 NG11 NG12 S18
NG20
NG15
NG10
PC23
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar PC21 PC13 380 ±5 bar
PC24
PC12
a8 a7 a6 a5 a4 PC1 BB a3 a2 L2 a1
S10
P1
PR1
PR3
3bar
1bar
PR2
S T pi P2 PoP1 YK
Port Relief Valves Main Relief Valve

Relief Pressure: 380 ±5 bar Lo : 350 ±5 bar
Hi : 370 ±5 bar
WE1500225
Figure 30

5-7-41
Retraction Valve (1 bar, 3 bar Check Valve)
The mono block has central cooling and tank connections K and
T which are integrated in the inlet and outlet valve. These are
check valves and pre-tensioned by springs. The resulting
backlog in the outflow ensures oil feeds in the event of negative
external loads (e.g. lowering the boom, downhill travel or similar
movements creating extra demand) and avoids filling problems/
cavitation in the system.
The volume required for the post-feeds is fed from the demand
volume during consumer movements. If a consumer is delayed
abruptly, and the mass moment of inertia does not stop
immediately, e.g. slewing gear, the Qmin volume of pumps 1
(P1) and 2 (P2) ensure the required tank line volume in the
block. The lower pre-tensioning of the check valve on the K-
connection creates the priority of the non-return valve of the oil
by the cooler. With increasing volume flow, the resistance
increases in the cooler line, and a partial flow is fed in the
bypass by the T-connection to the tank.
Lo: 350 ±5 bar

Hi: 370 ±5 bar
3 bar
1 bar
S T Pi P2 Po P1 Y K
WE1500226
Figure 31

5-7-42
Shockless Valve (Throttle Check Valve)
The shockless valve (orifice, check valve) in the control valve
pilot line enables smooth control of the spool.
(Initial control of the spool)
• Total six valves are provided: arm, traveling and boom, arm
summation.
A. Circuit diagram
Unrestricted Restricted
Figure 32 EX1400500
B. Normal assembly
A B
Figure 33 EX1400510
C. Abnormal (wrong) assembly
A B
Figure 34 EX1400511

5-7-43
Load Holding (Antidrift) Valve
In the boom lowering and crowd line, load holding valves (lock
valve) are installed to cut off cylinder oil flow when the spool is at
the neutral position. (Maintain the intrinsic settlement of the
cylinder at minimum value)
Holding Valve Operation - Cylinder Locking

Pilot Pressure
Pilot pressure is 0 bar
Cylinder pressure is restricted behind holding valve with
high-pressure. The check valve prevents the fluid from leaking.
Spools
Cylinder
Tank
EX1400234
Figure 35
Dozer/
Arti Boom Option
A5
B8A8 b8 B7A7 b7 B6 A6 b6 B5 L3 b5 B4 A4 b4 AB L1 PC2 b3 B3 A3 b2B2 A2 b1 B1 A1
S12
PC14
NG26
S13 NG25
PC11
PC25
NG13
NG24
PC21
S1
S7 S6 S5 S4 S3 S2
S14 NG14
S11
PC22 NG21
NG23 NG22 NG11 NG12 S18

NG20
NG15
NG10
PC23
380 ±5 bar 380 ±5 bar 380 ±5 bar 380 ±5 bar PC21 PC13 380 ±5 bar
PC24
PC12
a8 a7 a6 a5 a4 PC1 BB a3 a2 L2 a1
S10
P1
PR1
PR3
3bar
1bar
PR2
S T pi P2 PoP1 YK
WE1500227
Figure 36

5-7-44
Neutral
Boom, Arm Cylinder
Control pistons (S2 and S5) in lock position (no pump pressure
on the pilot-controlled check valve) and any load pressure from
the consumer. PL1
L IN
The load-holding pressure of the consumer (actuator) is held in
the PL chamber, and is reported to the PL1 chamber by the
piston (1) of the pilot cartridge. This means the same pressure is PL
available in the PL and PL1 chambers. The surface conditions
are selected so primary poppet (3) is held in a closed state by
the spring force (2). The oil flow is avoided by seat of the (4) of Spool Pilot Signal EX1400538
the main poppet (3).
Figure 37
Figure 38
Reference Reference
Number Number
1 Pistons of the Pilot Cartridge 3 Main (Primary) Poppet
2 Spring 4 Seat

5-7-45
Boom Up, Arm Crowd
Boom, Arm Cylinder
Pump pressure on the pilot-controlled check valve and any load
pressure from the consumer.
PL1
As soon as the pump pressure (PL) is greater than the load L
pressure (PL1) plus the spring force (2), the primary poppet (3)
of the pilot-controlled check valve (antidrift valve) opens, and the
required volume flow can flow to the consumer. This balances PL
out the pressure in the PL and PL1 chambers by the pistons of
the pilot cartridge (1).
Spool Pilot Signal EX1400539
Figure 39
Figure 40
Reference Reference
Number Number
1 Pistons of the Pilot Cartridge 3 Primary Poppet
2 Spring 4 Seat
Holding Valve Operation - Cylinder Released

Pilot Pressure
Pilot pressure is given. When the pilot pressure rises, the
position of lock valve is changed, making the fluid inside of
cylinder rod released through the spool holding valve operation.
Spools
Cylinder
Tank
EX1400235
Figure 41

5-7-46
Pilot-controlled Check Valve (Return Flow)
Boom, Arm Cylinder
The return pressure on the pilot-controlled check valve and
control of the pilot cartridge by pst.
When the piston of the pilot cartridge (1) is controlled by the pst PL1
pressure, the connection of the PL1 and PL chambers is L
separated, and the PL1 chamber to the drain connection L is
released. The main piston (3) can now be opened against the
spring (3) by the surface of the PL chamber with the pressure of PL
the return oil, and the return oil from the consumer can flow into
the tank by the control piston (S1 or S5). Spool Pilot Signal EX1400540
Figure 42
Figure 43
Reference Reference
Number Number
1 Pistons of the Pilot Cartridge 3 Primary Poppet
2 Spring 4 Seat

5-7-47
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

attachments on the ground.
2. Stop engine.
WE1400569
Figure 44

5-7-48
I
(Figure 45)
LOCK
WARNING OFF OFF
ON
ON

switch.
WE1400464
Figure 46

(Figure 47) OFF
ON
Figure 47 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 48

5-7-49
WARNING
doing any work.
14. Oil drain method
NOTE: Check the level on the oil level gauge before Return Filter Cover
draining the oil.
A. Remove cover on oil tank (bolt: 6 ea) and drain
hydraulic oil using oil pump. (Figure 50)
• Tool: 17 mm ( )
Figure 50 WE1500552
B. Drain hydraulic fluid using drain plug.

(without oil pump) (Figure 51)
• Tool: 27 mm ( )
C. Plug the filter cap to location of suction filter.
Item Part Number

Filter Cap 2188-1008
Figure 52 WE1500566

5-7-50
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 53
15. Open the engine cover and remove bolts and washers (1,
2
Figure 54) (4 ea) with cover (2). 1
• Tool: 19 mm ( )
• Cover weight: 15 kg (33.1 lb)
Figure 54 WE1500554
16. Disconnect the harness connector (2 ea).

1
Port Location
b1, BB Top Side
Figure 55 EX1404086

5-7-51
17. Remove hose 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.
L2 Pc2
a1 a2 a3 Pi AB S a4 a5 a6 a7
Bottom Side View

Figure 56 WE1500342

Port Name
a1 from Shuttle Valve "a1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
a3 from Shuttle Valve "b3" UNF 9/16"-16-2B 19 25.5 2.6 18.8
from Shuttle Valve "a5" UNF 11/16"-16-2B 22 38.2 3.9 28.2
a5
Connect with Shuttle Tee UNF 9/16"-16-2B 19 25.5 2.6 18.8
a7 Plug UNF 9/16" 19 25.5 2.6 18.8
AB from Shuttle Valve "AB" UNF 9/16"-16-2B 19 25.5 2.6 18.8
Pc2 from Shuttle Tee UNF 9/16"-16-2B 19 25.5 2.6 18.8
L2 to Tank (Connect with "L1") UNF 9/16"-16-2B 19 25.5 2.6 18.8
from Logic Valve "PA"
Pi UNF 9/16"-16-2B 19 25.5 2.6 18.8
(Connect with Shuttle Tee)
S to Swing Device "C" UNF 1 7/16"-12-2B 41 169.5 17.3 125.1

5-7-52
• Fitting
Size Torque
Port Name
a1, a2, a6 Adapter UNF 9/16"-18 UNF 11/16"-16 19 25.5 2.6 18.8
a3, a4, AB Adapter UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
UNF 11/16"-16,
a5 Tee UNF 9/16"-18 19 25.5 2.6 18.8
UNF 9/16"-18
Pc2 Adapter PF 1/4" UNF 9/16"-18 19 30.4 3.1 22.4
Adapter PF 1/4" UNF 9/16"-18 19 30.4 3.1 22.4
L2
Tee UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
Pi Tee UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
S Adapter M33 x 2 UNF 1 7/16"-12 41 140.1 14.3 103.4
a1, a2, a5, a6 O-ring S8040061 (1B B-06) S8030061 (1B F-06)
2180-1216D11
a3, a4, AB, Pi O-ring S8040061 (1B B-06)
(ID: 7.65, W: 1.78, 1B)
a7 O-ring S8040061 (1B B-06)
2180-1216D11
Pc2, L2 O-ring
(ID: 7.65, W: 1.78, 1B)
S O-ring S8030165 (4D F-16)

5-7-53
B1 B2 B3 B4 B5 B6
A1 A2 A3 L1 A4 A5 A6
Figure 57 Front Side View WE1500343

Port Name
A1 Arm Dump (to Arm cylinder Rod) SAE 1" 6,000 psi, D25 10 107.9 11 79.6
A2 Left Swing (to Swing Device "B") SAE 1" 6,000 psi, D25 10 107.9 11 79.6
Travel Motor "B" FWD
A3 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
(to Center Joint "13")
Dozer Up
A4 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
Boom Down
A5 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
(to Boom Cylinder Rod)
Bucket Dump
A6 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
(to Bucket Cylinder Rod)
Arm Crowd SAE 1 1/4" 6,000 psi,
B1 12 176.4 18 130.1
(to Arm cylinder Head) D32
Right Swing
B2 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
(to Swing Device "A")
Travel Motor "A" REV
B3 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
Dozer Down
B4 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
Boom Up SAE 1 1/4" 6,000 psi,
B5 12 176.4 18 130.1
(to Boom Cylinder Head) D32
Bucket Crowd
B6 SAE 1" 6,000 psi, D25 10 107.9 11 79.6
(to Bucket Cylinder Head)
L1 to Tank (Connect with "L2") UNF 9/16"-16-2B 19 25.5 2.6 18.8

5-7-54
• Fitting
Size Torque
Port Name
L1 Adapter PF 1/4" UNF 9/16"-18 19 30.4 3.1 22.4
A1, A2, A3,
DS2856003
A5, A6, B2, Ring Seal
(1", ID: 33.2, OD: 40.2, 1B)
B3, B4, B6
DS2856004
B1, B5 Ring Seal
(1 1/4", ID: 38, OD: 45, 1B)
2180-1216D11
L1 O-ring
(ID: 7.65, W: 1.78, 1B)

5-7-55
P2
K T P1
Figure 58
Rear Side View WE1500344
Torque
Port Name Plug/Flange Size (Hose)
(mm) N.m kg.m ft lb
T to Tank SAE 1 1/4" 3,000 psi, D32 8 63.7 6.5 47.0
K from Oil Cooler SAE 1 1/4" 3,000 psi, D32 8 63.7 6.5 47.0
P1 from Main Pump "A1" SAE 1 1/4" 6,000 psi, D32 12 176.4 18 130.1
P2 from Main Pump "A2" SAE 1 1/4" 6,000 psi, D32 12 176.4 18 130.1
• O-ring
Size
Port Name
A B
DS2856004
T, K, P1, P2 Ring Seal
(1 1/4", ID:38, OD:45, 1B)

5-7-56
L3 Pc1
b7 b6 b5 b4 Y BB Po b3 b2 b1
Top Side View
Figure 59 WE1500567

Port Name
from Shuttle Valve "b1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
b1
Pressure Sensor PF 1/4" 27 5.9 0.6 4.3
b2 from Shuttle Valve "b2" UNF 11/16"-16-2B 22 38.2 3.9 28.2
b3 from Shuttle Valve "a3" UNF 9/16"-16-2B 19 25.5 2.6 18.8
b4 from Shuttle Valve "b4" UNF 9/16"-16-2B 19 25.5 2.6 18.8
from Shuttle Valve "b5" UNF 11/16"-16-2B 22 38.2 3.9 28.2
b5
Connect with "BB" UNF 11/16"-16 21 38.2 3.9 28.2
b6 from Shuttl Valve "b6" UNF 11/16"-16-2B 22 38.2 3.9 28.2
b7 Plug UNF 9/16" 19 25.5 2.6 18.8
Connect with "b5" UNF 11/16"-16 21 38.2 3.9 28.2
BB
L3 to Tank UNF 9/16"-16-2B 19 25.5 2.6 18.8
Pc1 to Tank (Connect with "Po") UNF 9/16"-16-2B 19 25.5 2.6 18.8
Po Connect with "Pc1" UNF 9/16"-16-2B 19 25.5 2.6 18.8
Y Solenoid Valve "PL" UNF 9/16"-16-2B 19 25.5 2.6 18.8

5-7-57
• Fitting
Size Torque
Port Name
UNF 11/16"-16,
b1, BB Tee UNF 9/16"-18 19 25.5 2.6 18.8
PF 1/4"
b2 Adapter UNF 9/16"-18 UNF 11/16"-16 19 25.5 2.6 18.8
b3, b4 Adapter UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
b5 Tee UNF 9/16"-18 UNF 11/16"-16 19 25.5 2.6 18.8
b6 Elbow UNF 9/16"-18 UNF 11/16"-16 19 25.5 2.6 18.8
L3, Y Adapter PF 1/4" UNF 9/16"-18 19 30.4 3.1 22.4
Adapter PF 1/4" UNF 9/16"-18 19 30.4 3.1 22.4
Pc1
Tee UNF 9/16"-18 UNF 9/16"-18 19 25.5 2.6 18.8
Po Tee UNF 9/16"-18 UNF 9/16"-18 17 25.5 2.6 18.8
b1, b2, BB,
O-ring S8040061 (1B B-06) S8030061 (1B F-06)
b5, b6
2180-1216D11
b3, b4, Po O-ring S8040061 (1B B-06)
(ID:7.65, W:1.78, 1B)
b7 O-ring S8040061 (1B B-06)
2180-1216D11
L3, Pc1, Y O-ring
(ID:7.65, W:1.78, 1B)
18. Tie with rope to the eyebolts to lift it and remove mounting
bolts (3 ea) from bracket. (Figure 60)
• Tool: 24 mm ( )
• Control valve weight: about 203 kg (447.5 lb)
19. Lift the control valve by crane from machine slowly and
carefully.
IMPORTANT
WE1500346
connected to valve. Figure 60

5-7-58
INSTALLATION
WARNING
SERIOUS INJURY
NOTE: First, assemble the bolts (3 ea) of main control valve

mounting to main frame. (Figure 61)
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 attaching

piping and hoses. Unnecessary stress can cause spools to
bind and the control valve from functioning properly.
WE1500346
3. Tighten the assembling bolts alternately and evenly to the
Figure 61
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.
2. Start the engine and run at low idling for about 5 minutes.
3. Operate the joystick lever and actuate the hydraulic
cylinder 4 ~ 5 times very slowly, about 100 mm before the
end of stroke.
4. 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)

5-7-59
DISASSEMBLY
General Repair Instructions
General instructions
After the decommissioning, there is still oil in the control block.
Leaking hydraulic fluid can cause damage to the environment
and pollution of the groundwater.
1. Observe the information in the safety data sheet of the
hydraulic fluid and the vehicle/system manufacturer's
specifications.
Cleaning
1. Clean the control block from contamination and loose
foreign bodies.
2. Do not use cleaning agents that
• May attack plastics or change their properties
• May attack metals or react with them
• Can leave residues behind.
1. Suitable cleaning agents are plastic brushes and hydraulic
oil. Do not use metal brushes.
2. In case of contamination, clean bores using a brush tool
with plastic hair and hydraulic oil.
3. Do not clean the disassembled control block with a
pressure washer.
Housing and parts

1. You may only use original Doosan parts.
2. After disassembly, elastic seal elements must be
exchanged against new ones.
3. Housings and parts must be clean and undamaged.
4. Damaged housings and parts must no longer be used.
5. Any reprocessing of threads is not admissible.
6. Any reprocessing of bores is not admissible.
7. Protect the bores and threads against the deposition of
contamination.

5-7-60
Flange surfaces and sealing surfaces
1. Adhesion forces may act between the flange areas in the
disassembly.
2. Remove contamination using a whetstone and clean the
surface using an oil-soaked cleaning cloth.
3. Surfaces with punch marks or signs of wear in the sealing
surface must no longer be used.
4. Any reprocessing of the sealing surfaces is not admissible.
Bench vise
Protective brackets with hard rubber are to be used. Sealing and
flange surfaces must not be damaged.
Required tools
1. Oil-soaked cleaning cloth
2. Whetstone
3. You need only commercially available tools to mount the
control block.
Repair Instructions
Parts List Control Block
IMPORTANT
You can find the part numbers of the spare parts in the
specific spare part list according to the material number of
your control block.
Replace Load-holding Valve Spool (Item 130)

1. Required tools
• Hexagon wrench or socket wrench size 30
• Magnet gripper
• Torque wrench for 100 Nm with hexagon socket size 30

5-7-61
2. Load-holding valve consisting of:
• Poppet
• Pressure spring
• Plug screw
Figure 62
3. Removing load-holding valve

• Unscrew and remove plug screw with hexagon
wrench in counterclockwise direction.
• Remove pressure spring and poppet with magnet
gripper.
• Dispose the load-holding valve parts that have been
removed.
• Ensure that no contamination enters the bore.
Figure 63
4. Installing load-holding valve

• Check seals at the plug screw. The surfaces must be
clean and undamaged.
• Check the bore in the housing. If the bore is
damaged, the block must be replaced.
• Install load-holding valve by hand into the bore. Take
care, that spring has the right position inside the bore
of the poppet and the plug screw. Screw in plug
screw in clockwise direction.
• Tighten plug screw with torque wrench in clockwise
Figure 64
direction. Tightening torque MT = 100 Nm.
Replace Plug Screw (Item 132)

Follow the instructions according to See "Replace Load-holding
Valve Spool (Item 130)" on page-61.

5-7-62
Replace Throttle Check Valve (Item 135, 136) for Semi
Priority Boom Vs. Bucket and Swing Vs. Arm
1. Required tools
• Hexagon socket wrench size 24
• Magnet gripper
2. Throttle check consisting of
• Poppet
• Spring
• Plug screw
Figure 65
3. Removing throttle check valve

gripper.
• Dispose the throttle check valve parts that have been
removed.
Figure 66
4. Installing throttle check valve

• Check seal at the plug screw. The surfaces must be
• Install throttle check valve by hand into the bore.
Take care, that spring has the right position inside the
bore of the poppet and the plug screw. Screw in plug
screw in clockwise direction.
Figure 67

5-7-63
Replace Pilot Control Cartridge MHSL 5.5 (Item 210) for
Antidrift-valve Boom and Arm
1. Required tools
• Torque wrench for 100 Nm with hexagon wrench or
socket wrench size 27
2. Pilot control cartridge
Figure 68
3. Removing pilot control cartridge

• Unscrew and remove pilot control cartridge by turning
in counterclockwise direction.
• Dispose the pilot control cartridge that has been
removed.
Figure 69
4. Installing pilot control cartridge

• Check the seals at the pilot control cartridge. The
surfaces must be clean and undamaged.
• Install pilot control cartridge by hand into the bore.
• Tighten pilot control cartridge with torque wrench in
clockwise direction. Tightening torque MT = 100 Nm.
Figure 70

5-7-64
Replace Antidrift Valve (Item 140, 141)
1. Required tools
• Screw M6
• Tong
2. Removing antidrift valve
• Remove antidrift valve with screw M6 and tong by
turning in clockwise direction.
Figure 71
• Dispose the antidrift valve that has been removed.

Figure 72
3. Installing antidrift valve

• Check the seal at the antidrift valve. The surfaces
must be clean and undamaged.
• Install antidrift valve carefully by hand into the bore
without tilting.

5-7-65
Replace Secondary Pressure Relief Valve (Item 202, 208) /
Plug Screw (Item 200)
1. Required tools
• Hexagon wrench or socket wrench size 27 for item
200, 202 (hexagon socket size 30 for item 208)
socket wrench size 27 for item 200, 202 (120 Nm with
hexagon socket size 30 for item 208)
2. Removing secondary pressure relief valve
• Unscrew and remove pressure relief valve/plug
screw in counterclockwise direction.
• Dispose the pressure relief valve that has been
removed.
Figure 73
3. Installing secondary pressure relief valve
IMPORTANT
The pressure setting of the secondary valves can be
different on each axis. Ensure the correct installation
of the secondary valves to the valve axis.
• Check the seal at the thrust ring. The surfaces must

be clean and undamaged.
Figure 74
• Lubricate the pressure relief valve/plug screw and
screw it into the bore in clockwise direction.
• Tighten pressure relief valve/plug screw with torque
wrench.
Tightening torque MT = 100 Nm for item 200, 202.
Tightening torque MT = 120 Nm for item 208.
Figure 75

5-7-66
Replace Load-holding Valve Function Consisting of Poppet
(Item 205), Spring (Item 206) and Plug Screw (Item 207)
1. Required tools
• Magnet gripper
2. Removing load-holding valve
207
• Remove pressure relief valve (208) according to 206
Replace Antidrift Valve (Item 140, 141). 205
208
IMPORTANT
208
Pay attention that no parts fall into the bore of the
housing. 205
207 206
• Unscrew and remove plug screw (207) in FG021079
counterclockwise direction. Figure 76
• Remove spring (206) and poppet (205) with
magnet gripper.
205
T
207 206
FG021078
Figure 77
3. Installing load-holding valve
IMPORTANT
Pay attention that no parts fall into the bore of the
housing.
• Install poppet and spring by hand into the bore.
Take care, that spring has the right position
inside the bore of the poppet.
• Screw in plug screw in clockwise direction.
Tightening torque MT = 150 Nm.
• Install pressure relief valve (208) according to
Replace Antidrift Valve (Item 140, 141).

5-7-67
Replace Spool Boom Summation (Item 170, Similar With
Spool Arm Summation Item 171)
1. Required tools
2. Spool kit consisting of:
• Spool
• Spring retainer
• Pressure spring
• Spring retainer
Figure 78
3. Removing cover
• Unscrew and remove cylinder screw (158) on cover
(155) on side B with hexagon wrench in
counterclockwise direction. Take care, that cover
doesn't fall down.
• Remove cover and deposit it in a clean place.
• Protect cover and bore from contamination and
moisture.
Figure 79
4. Removing spool kit
• Remove pressure spring, spring retainer and spool
without tilting.
5. Installing spool kit
• Install pressure spring, spring retainer and spool by
hand into the bore.
• Install cover with hexagon wrench.
Figure 80

5-7-68
Replace Main Spool
1. Required tools
2. Removing cover
• Unscrew and remove cylinder screws (158) on cover
(155) on side A and B with hexagon wrench in
counterclockwise direction. Take care, that cover
doesn't fall down.
• Protect cover and bore from contamination and moisture.
Figure 81
3. Removing main spool

• Remove spring kit consisting of spring (152) and
spring retainer (151).
• Remove main spool without tilting Figure 82
4. Installing main spool
NOTE: Observe the installation position of the main
spool! The B-side of the main spool is marked
with a rill on the low end.
Figure 83
• Install main spool by hand into the bore without tilting.

• Install spring kit.
Figure 84

5-7-69
• Install cover (155) with hexagon wrench.
Figure 85
Replace Pilot Shuttle Valve (Item 163)

1. Required tools
• Screw tap 3 mm or 4 mm
• Magnet gripper
2. Removing pilot shuttle valve
• Screw in a screw tap into the pilot shuttle valve and
pull it out. According to mounting position use a
screw tap of 3 mm or 4 mm.
IMPORTANT
The pilot shuttle valve will be destroyed during
disassembly and must be replaced.
Take care to remove all parts of the pilot shuttle valve!

5-7-70
3. Installing pilot shuttle valve
• Install pilot shuttle valve by hand into the bore and
press in on block.
• Install cover (155) according to "Replace main spool"
on page -72.
IMPORTANT
Note mounting position for main spool!
• Mounting position for main spool:

Pilot shuttle valve direction to port!
A B
FG021081
Figure 86
Figure 87
• Mounting position for spool boom summation, spool

arm summation or cut-valve spool:
Pilot shuttle valve direction to housing!
A B
FG021082
Figure 88

5-7-71
Replace Cut Spool (Item 182)
1. Required tools
• Torque wrench for 10.4 Nm with hexagon wrench
hexagon socket size 5
2. Cut spool consisting of:
• Spool
• Spring
• Spring retainer
• Retaining Ring
Figure 89
3. Removing cover on axis PC2

• Unscrew and remove cylinder screws (187) on cover
(186) with hexagon wrench in counterclockwise
direction. Take care, that cover doesn't fall down.
• Protect cover and bore from contamination and moisture.
Figure 90
4. Remove cut spool

• Remove cut spool (182) carefully.
• Dispose the cut spool that has been removed.
Figure 91
5. Installing cut valve spool

• Install cut spool by hand without tilting.
• Install cover with torque wrench.
Tightening torque MT = 10,4 Nm.

5-7-72
Replace End Plate (Item 113) and Directional Valve
(Item 101)
1. Required tools
• Hexagon socket wrench size 10
• Torque wrench for 100 Nm with hexagon socket size
10
• Oily cloth
• Dressing stone
2. Removing end plate and directional valve
• Unscrew and remove cylinder screws (120) in
counterclockwise direction. Take care, that end plate
and the directional valve don't fall down.
• Remove end plate and the directional valve from the
monoblock.
NOTE: Flange faces may stick together. Gently
pry components apart to disassemble.
• Remove O-rings (111) from the ports.
• Clean all flange faces of the monoblock, the end
element and of the directional valve with the dressing
stone if contaminated and wipe it down with an oily
cloth. Ensure that no contamination enters the bore
during cleanup.
• The sealing faces on the flange face and on the
recess of a flange face, and the sealing elements,
must be clean, dry and free from damage. If the
directional valve is damaged, it must be replaced!

5-7-73
111
111
FG021080
Figure 92
3. Installing end plate and directional valve

• Ensure that all sealing faces and sealing elements
are clean, dry and free from damage.
• Install O-rings (111).
• Bring the directional valve and the end plate into line
with the tightening bores of the monoblock.
• Install cylinder screws (120) by hand and tighten
crosswise with torque wrench.

5-7-74
Replace Inlet Section (Item 220)
1. Required tools
• Oily cloth
• Dressing stone
2. Removing inlet section
• Remove cylinder screws (221) of the plate with
socket wrench in counterclockwise direction.
• Lift and remove plate (220). Protect bores in plate
and monoblock from contamination and moisture.
NOTE: Flange faces may stick together. Gently
pry components apart to disassemble.
Figure 93
• Remove O-rings (30, 31, 32) from the ports.

• Clean all flange faces of the monoblock and of the
plate with the dressing stone if contaminated and
wipe it down with an oily cloth. Ensure that no
contamination enters the bore during cleanup.
• The sealing faces on the flange face and on the
recess of a flange face, and the sealing elements,
must be clean, dry and free from damage. If the plate
is damaged, it must be replaced!
Figure 94
3. Installing inlet section

• Install the plate (220) to the monoblock and bring the
bores into line.
• Install cylinder screws (221) by hand and tighten
crosswise with torque wrench.
FG021138
Figure 95

5-7-75
Replace Pre-load Valves (Item 20 and 21) for Tank Line and
Cooler Back Pressure
1. Required tools
• Screw M6
2. Removing pre-load valve
• Unscrew and remove pre-load valve with screw M6
by turning in clockwise direction.
• Dispose the pre-load valve parts that have been
removed.
Figure 96
3. Installing pre-load valve

NOTE: There are two different types of pre-load valves:
Two-piece valve consisting of poppet and
spring kit One-piece valve.
IMPORTANT
Both pre-load valves (20, 21) have a different spring
force and should not be inverted! The pre-load valve for
cooler back pressure always has the softer spring.
Figure 97
• Check the seal at the pre-load valve. The surfaces

must be clean and undamaged.
• Two-piece type: Install the poppet by hand into the
bore and press in carefully. Then press the spring kit
by hand into the bore on block.
• One-piece type: Install pre-load valve by hand into
the bore and press in carefully.
Figure 98

5-7-76
Replace Primary Pressure Relief Valve (Item 222)
1. Required tools
2. Removing primary pressure relief valve
• Unscrew and remove pressure relief valve MHDBN
22 K2-3X/... in counterclockwise direction.
• Dispose the pressure relief valve that has been
removed.
3. Installing primary pressure relief valve
• Check the seal and the thrust ring. The surfaces must
be clean and undamaged.
damaged, the inlet section must be replaced.
• Lubricate the pressure relief valve and screw it into
the bore in clockwise direction.
• Tighten pressure relief valve with torque wrench.
Figure 99

5-7-77
Replace Check Valves for Primary Pressure Relief (Item 42)
1. Required tools
• Magnet gripper
2. Check valve consisting of:
• Poppet
• Pressure spring
• Plug screw
Figure 100
3. Removing check valve

gripper.
• Dispose the check valve parts that have been
removed.
Figure 101
4. Installing check valve

• Check the bore in the plate. If the bore is damaged,
the plate must be replaced.
• Install check valve by hand into the bore. Take care,
that spring has the right position inside the bore of the
poppet and the plug screw. Screw in plug screw in
clockwise direction.

5-7-78
Replace Straight Travel Valve
1. Required tools
• Hexagon socket wrench size 22 for item 13
• Hexagon socket wrench size 12 for item 9
2. Straight travel valve consisting of:
• Plug screw (13)
• Pressure spring (12)
• Spring retainer (11)
• Spool (10)
• Plug screw (9) Figure 102
3. Removing straight travel valve

• Unscrew and remove plug screw (13) on side A with
hexagon socket wrench in counterclockwise
direction.
• Unscrew and remove plug screw (9) on side B with
hexagon socket wrench in counterclockwise
direction.
• Remove pressure spring, spring retainer and spool
from the bore without tilting. Push from the opposite
side if necessary.
Figure 103
4. Installing straight travel valve
• Check the bore in the plate. If the bore is damaged,
the plate must be replaced.
• Install plug screw (9) on side B by hand into the bore.
• Tighten the plug screw with torque wrench in
• Install spool, spring retainer and pressure spring by
hand into the bore and side A. Figure 104
• Install plug screw (13) on side A by hand into the
bore.
• Tighten the plug screw with torque wrench in

5-7-79
REASSEMBLY
WARNING
HIGH-PRESSURE OIL HAZARD
• Make sure the relevant system component is not under
pressure before assembling the product or when
connecting and disconnecting plugs.
• Protect system components against unintended
switching on.
ELECTRICAL SHOCK HAZARD

• Switch off power supply to the relevant system
component before assembling the product or when
connecting and disconnecting plug-in connectors.
• Connect control block solenoids only if no voltage is
applied.
• Protect the system component against unintended
switching on.
• Always connect the ground connections of the control
block with the appropriate ground system in your
installation.
• Only use a power pack with electrical isolation.
• Always comply with the applicable laws and
regulations.
TRIPPING HAZARD
• Lay the cables and lines so that they cannot be
damaged and no one can trip over them.
ACCIDENTAL MOVEMENT OF MACHINE

Avoid injury caused by incorrect assembly of pin
assignment or cable connections.
• Make sure that all pipes and/or hoses are applied at
the correct control block connection.
• After the completion of final assembly, you must
check the correct assembly of the cable plugs to each
control block solenoid.
NOTE: Noncompliance with protection class IP67 and risk of

short circuit because of missing seals and caps.
Fluids and foreign materials may penetrate into the
control block and destroy it.
– Before assembling make sure that all seals and
plugs of the plug-in connections are tight.

5-7-80
NOTE: Damage caused by incorrect assembly!
When assembling hydraulic lines and hoses under
mechanical stress, they are exposed to additional
mechanical forces during operation, which reduces
the service life of the control block and the complete
machine.
– Assemble hydraulic lines and hoses without
mechanical stress.
NOTE: Wear and malfunctions caused by contaminated
pressure fluid
The cleanliness of the hydraulic fluid has a
considerable impact on the cleanliness and service
life of the hydraulic system as a whole. Any pollution/
contamination of the hydraulic fluid will result in wear
and malfunctions. In particular, foreign bodies (e.g.
welding beads or metal cuttings) in the hydraulic lines
may damage the control block.
– Always ensure absolute cleanliness
– Assemble the control block free from any
pollution.
– Make sure that all connections, hydraulic lines
and add-on units (e.g. measuring instruments)
are clean.
– Ensure that no pollutants are able to penetrate
when sealing the connections.
– Ensure that no detergents are able to penetrate
the hydraulic system.
– Do not use cleaning rags/cotton waste or linty
cloth for cleaning.
– Only use suitable and permitted sealing
material for the seals.
– Possible oil residues from the factory check
must be completely removed.
– Remove possible resinifications caused be
incorrect storage.
NOTE: Functional impairment caused by wrong plug
connections!
Only use the plug connections listed in the "Technical
data sheet" for electrical connection.
– Observe the assembly instructions of the
manufacturer of the plug connections!
– Before commissioning, you must check the
power supply whether the voltage complies with
the details on the "Installation drawing" and
whether the total of the solenoid currents to be
expected is lower than or equals the capacity of
the power supply.

5-7-81
– The plug connections may only be contacted
when deenergized. The assembly process must
not be repeated more than 10 times.
NOTE: Incorrect connection wiring!
The control block must only be connected by a
specialized electrician or under supervision of the
same. The lines used have to be suitable for
operating temperatures of 20 °C...+100 °C.
– De-energize the connection line before
installation.
– Avoid sharp bends in the connection line and
the stranded wires, to avoid short-circuits and
interruptions.
– Route the connection line(s) using strain relief.
The first attachment point must be located at a
distance to the cable entry of 15 cm at most.
– Use fine-wired conductors with pressed-on wire
end sleeves only.
Unpacking
Dispose of the packaging according to the applicable laws and
regulations.
Coating the Control Block

If the control block is to be painted before being assembled,
please observe the following:
1. Protect the hydraulic ports against paint contamination by
screwing-in plastic threaded plugs beforehand.
2. Protect fastening threads against paint by screwing in
bolts.
3. Mask the flange surfaces of the control blocks and the
connection and end plates carefully before painting so no
dirt or paint may enter.
4. Avoid paint being applied to the contacts of the electrical
connections and make sure not to cause any damage to
the connector.
5. If you remove plastic screw-in plugs after painting you
must make sure that no paint chips enter the control block.
Nameplates are protected against the application of paint using
a foil which can be removed after coating.

5-7-82
Installation Conditions
When installing the product always observe the ambient
conditions specified in the technical data.
Installation position
If not indicated otherwise in the technical documents, the control
blocks can be installed in any position.
Required Tools
For mounting the control block, you only need commercial tools
suitable for the fastenings specified on the installation drawing.
Assembling the Control Block
Fastening the control block

For fastening, the control block is provided with fastening bores
which can be seen on the "Installation drawing". Please see the
"Installation drawing" for the position tolerances of the fastening
bores at the machine. Select the tightening torque according to
the usual standard values for each bore size and screw
tensioning class. Too much tightening torque might cause the
jamming of the valve spool. If this is the case, you must reduce
the tightening torque accordingly.
Observe the adequate residual clamping force of the screws.
1. Observe the requirements for the contact surface specified
in the "Installation drawing".
2. Check the smoothness of the flange surface in the
machine (tolerance: 0.5 mm)
3. Tighten mounting screws applying the tightening torque
specified in the standard.
4. Always mount the control block at the provided mounting
points and only use screws having the property class
according to EN ISO 4762 or EN ISO 4014 as specified.

5-7-83
We recommend screwing with the following parameters:
Series Dimensions Property Class Tightening Torque (Nm) Screw-in Depth (mm)
M1-16 M8 8.8/10.9 27/40 1
M1-25 M10 8.8/10.9 54/79 10

M1-32 M12 8.8/10.9 93/37 1
M4-12 M10 8.8/10.9 41/60 12...15

M4-15 M10 8.8/10.9 54/79 10
M4-22 M16 8.8/10.9 230/338 1
M6-15 M10 8.8/10.9 54/79 10

M6-22 M12 8.8/10.9 93/137 12
M7-20 M12 8.8/10.9 93/137 12
M7-22 M16 8.8/10.9 230/338 16
M8-16 M16 8.8/10.9 230/338 16
M8-18 M16 8.8/10.9 230/338 16
M8-22 M16 8.8/10.9 230/338 16
M8-25 M16 8.8/10.9 230/338 16
M8-32 M20 8.8/10.9 464/661 20
M8-35 M16 8.8/10.9 230/338 1
M9-20 M16 8.8/10.9 230/338 16

M9-25 M16 8.8/10.9 230/338 16
MO-10 M10 8.8/10.9 54/79 1
MO-16 M8 8.8/10.9 27/40 1
MO-22 M10 8.8/10.9 54/79 1
MO-32 M12 8.8/10.9 93/137 1
MO-40 M16 8.8/10.9 230/338 1
MO-52 M20 8.8/10.9 464/661 20

SP-08 M8 8.8/10.9 25/30 10...14; 1
SM 12 M8
SX 10 M8
SX 12 M8
SX 14 M10
SX 14 NGE M10
1
Through-holes in the housing; the screw-in depth depends on
the material of the nut thread.
Mechanically Connecting the Control Block

Please see the "Installation drawing" for the connection of the
actuating elements including. tolerances. Select the tightening
torque according to the actuating elements.
The actuation must be free of transverse forces!
1. Make sure before commissioning that switch is at zero
position (spool in center position).

5-7-84
Hydraulically Connecting the Control Block
The connecting system and the tightening torque required for
the hydraulic connection are specified on the "Installation
drawing" and the "Technical data sheet". The connection must
be designed according to the appropriate standard. The
standards are available at the distribution organizations which
are commissioned with the distribution of the standards by the
standard committee.
1. Use the provided seal for each hydraulic connection.
Installing the Electrical Supply

De-energize the relevant part of the system.
IMPORTANT
Information on the correct pin assignment are available in
the "Quotation/installation drawing".

5-7-85
Before First Commissioning
1. Make sure that interfaces of the machine and the
installation conditions allow for the safe operation of the
control block. In case of doubt, contact to us.
2. Check the operating instructions for the machine to find out
in which machine the control block must be installed, and
make a visual inspection to check whether the
commissioning of the hydraulics might result in
uncontrolled and dangerous motions. If necessary,
observe the risk analysis/risk evaluation of the machine.
3. Take according precautions if risks are to be expected, e.g.
make sure that cylinder piston rod can be extended without
any risks.
4. Secure the load to be lifted additionally with lifting gear/
load bearing equipment.
5. Check whether the electrical control of the machine allows
for the manual switching of the control block solenoids
during commissioning. If manual switching is not possible
or only under difficult conditions, you must prepare an
external control for the internal functional test of the
hydraulic system.
6. Develop a program for the commissioning process and file
it in the technical documents as annex to the operating
instructions.
7. Divide the functional circuit diagram in sub-circuits which
can be commissioned one after the other.
8. Read the functional circuit diagram and clarify ambiguous
facts and specifications.
9. Determine in which spool position the control blocks must
be switched and how they must be adjusted.
10. Apply important mandatory signs, prohibition signs,
information signs and check whether the meaning of these
signs is explained in the operating instructions.
11. Observe the following order for commissioning:
• Pump circuit
• Parts of the control: e.g. depressurization and switch-
over, free circulation, pressure reduction, etc.
12. Ensure that pipes and/or hoses are connected to all ports
and/or that ports are closed using plug screws.
13. Ensure that cap nuts and flanges are tightened properly on
pipe fittings and flanges.
14. Switch pressure and flow valves, pump controllers, and
sensors such as pressure switches, limit switches and
temperature controllers to the switching positions and set
values specified in the process program.

5-7-86
Maintenance and Repair
WARNING
• Regularly check the safety devices for correct
functionality.
• Adequately secure the maintenance area before
starting maintenance work.
• Pay attention to cleanliness in order to avoid
malfunctions caused by dirt. Paint residues on sealing
surfaces must be removed before assembly. Make
sure that paint residues do not enter block openings.
• Operate the hydraulic functions in maintenance mode. 
If machine operation is required with protective covers
removed, do so with care. Switch off the hydraulic
functions and secure them against unintended
switching on.
• The user is not allowed to change the set values of
safety valves. New adjustments may only be
accomplished by authorized testing authorities.
• Wear protective goggles, protective gloves and safety
boots. Relieve hydraulic pressure in the system and
accumulators before performing maintenance.
• Let system sections and pressure lines which can be
opened cool down before starting commissioning
works.
• Slowly open segments which must still be
pressurized.
• Please observe that if there are check valves in the
pressure lines above the pumps, the hydraulic system
might still be pressurized after it has been
disconnected from the actual pressure supply. Move
all cylinders to the safe end position.
• Lower any load. Provide support devices if the load
cannot be lowered. Never conduct maintenance work
on raised components without using proper support
devices.
• Document date and type of maintenance performed.

5-7-87
WARNING
• Stop the engine and relieve any stored hydraulic
pressure.
• Support vertical cylinders mechanically against
sinking.
• Only new, structurally identical and tested
components, spare parts and lubricants in original
equipment quality are admitted for replacement/use.
• Make sure that all protective devices and functions
which could impair the safety shutdown system are
correctly installed and checked for functionality before
each re-commissioning.
• After the completion of all work, remove all tools and
devices used for maintenance from the machine.
Personal injuries caused by not functioning spare parts that
do not meet the technical requirements specified by
Doosan may cause personal injuries.
• Only use genuine spare parts from Doosan.
NOTE: Penetrating dirt and liquids will cause faults!

– Always ensure absolute cleanliness when working
on the control block.
– Cover all openings with the appropriate protective
equipment to prevent detergents from penetrating
the system.
– Check that all seals and plugs of the plug-in
connection are firmly Installed so no humidity
can penetrate the control block during cleaning.
– Dust accumulations on the control block have to
be removed at regular intervals.
NOTE: Damage to the surface from solvents and aggressive
cleaning agents!
Aggressive detergents can damage the seals on the
control block and let them age faster.
– Never use solvents or aggressive detergents.
– Only clean the control block using a damp,
lint-free cloth. Only use water to do this and, if
necessary, a mild detergent.

5-7-88
NOTE: Damage to the hydraulic system and seals!
The water pressure of a high-pressure cleaner can
damage the control block and seals of the hydraulic
power unit. The water displaces the oil from the
hydraulic system and seals.
– Do not use a high-pressure cleaner.
Definition
In accordance with DIN 31051: 2003-6 the term maintenance
means the combination of all technical and administrative
measures taken by management during the life cycle of an item
in order to maintain the functional condition or to return to the
same, so that item is able to meet the required function.
These measures can be classified into:
1. Maintenance (measures to delay the decrease of the
existing wear reserve).
2. Inspection (measures to determine and assess the actual
condition of an item, including the determination of the
cause of wear and the derivation of the required
consequences for a future use).
3. Repair (measures to return an item to a functional state,
except improvements).
4. Improvement (combination of all technical and
administrative measures and measures taken by the
management to increase the functional safety of an item,
without modifying the function required).
Inspection and Maintenance

The goal of inspection and maintenance is
1. to maintain the functionality of the system with its initial
parameters.
2. to ensure the permanent availability of the system.
3. to determine weak points.
4. to achieve the required service life of the system.
Basically we recommend to keep an inspection and
maintenance record where any system and site-specific works
and inspection and maintenance intervals are defined and
documented.
If the specified operating and ambient conditions are observed,
the control blocks are maintenance-free. Regular inspection and
maintenance work is therefore not required.
However, the following must be checked at least every three
years (from the manufacturer date of the control block):
1. The control block for leakage at the outside.
2. All screws and connections are firmly seated.

5-7-89
3. All connection lines for damages. If damage is visible,
replace the connection line.
IMPORTANT
Order information for seal kits is available in See "Spare
Parts" on page-92..
Pressure Fluids
The performance characteristics of pressure fluids deteriorate
with increased aging (chemical deterioration). Acids and resin
residues are formed which cause the bonding of mobile parts
inside the control block.
The following factors accelerate the aging process:
1. High temperatures
2. Air in the pressure fluid
3. Humidity
4. Water
5. Metallic catalysts
6. High operating pressure
7. Contamination
IMPORTANT
Observe the following general rule:
From a hydraulic fluid temperature of > 70 °C, aging
speed doubles with every 10 °C.
8. Further information on hydraulic fluids based on mineral oil

also applying for control blocks are available in our
technical data sheets.

5-7-90
Malfunction Caused by Contaminated Hydraulic Fluid
Contaminations of the hydraulic fluid not only result in increased
wear and reduced service life of the control block but also in
malfunctions. This could impair the safety and reliability of the
control block.
Therefore you should regularly perform the maintenance
measures specified in the operating instructions of the machine
and check cleanliness when working on the control block.
The following aspects might cause the contamination of the
hydraulic fluid:
1. Wear during the operation of the machine (metallic and
nonmetallic abrasion)
2. Leakages on the control block
3. Contamination during maintenance/repair
4. Use of contaminated (unfiltered) hydraulic fluid for
replacement.
Replenishing/Refilling
When replenishing/refilling your hydraulic system you must
make sure that you use admissible hydraulic fluid of the same
type and the same manufacturer.
In case of major contamination and/or premature aging of the
hydraulic fluid, the system including the tank must be cleaned
and rinsed before refilling. Before refilling, you must always filter
new hydraulic fluid according to the required cleanliness class
because it usually does not comply with the required cleanliness
class in its as-delivered state. Lines and hoses must be rinsed
before installation.
Use a filter aggregate when filling the hydraulic fluid tank. The
filter must be clean. Do not remove filter screens from the filler
neck or the filter insert of filters when filling the hydraulic fluid
tank.
IMPORTANT
The filter mesh must at least meet the required cleanliness
class of the entire system. If possible, it must even be finer.
The applied filter unit must meet the requirements about
functional safety and service life.
If possible, replenish the hydraulic fluid tank using a filling
coupling at the return filter.

5-7-91
Repair
IMPORTANT
Doosan offers a wide range of repair services for the control
block.
1. Only use genuine spare parts from Doosan for repairing

the Doosan.
2. The spare parts lists of the control blocks are
product-specific. Please indicate material and series
number of the control block and the material number of the
spare parts when ordering spare parts.
Instructions for Repair

For repair works, the control block may only be disassembled to
the extent described in the operating instructions.
Spare Parts
1. Order spare parts in writing. In urgent cases you can also
order by phone, but you are kindly requested to confirm
your order in writing (e.g. by fax).
2. Please send any enquiry to your nearest Doosan service
center or contact headquarters direct.
3. When ordering spare parts, please indicate the following
information from the product's nameplate:
• The material number of the control block.
4. Please indicate the following details from the spare parts list:
• Part number.
5. Additionally indicate:
• The desired number of spare parts.
• The desired type of dispatch (e.g. as parcel, freight,
air freight, by courier service, etc.).

5-7-92
TROUBLESHOOTING
Troubleshooting, Testing and Adjustment
How to Proceed for Troubleshooting

1. Always act systematically and targeted, even under
pressure of time. Random and imprudent disassembly and
readjustment of settings might result in the inability to
restore the original error cause.
2. First get a general idea of how the mobile control block
works in conjunction with the entire system.
3. Try to find out whether the mobile control block has worked
properly in conjunction with the entire system before the
troubles occurred first.
4. Try to determine any changes of the entire system in which
the mobile control block is integrated:
• Were there any changes to the mobile control block's
operating conditions or operating range?
• Were there any changes or repair works on the entire
system (machine/vehicle, electronics, control) or on
the mobile control block? If yes: which?
• Was the mobile control block or machine/vehicle
used as intended?
• How did the problem appear?
5. Try to get a clear idea of the error cause. Directly ask the
(machine) operator.

5-7-93
Malfunction Table
The control block is not susceptible to faults as long as the
specified conditions of use are complied with, in particular the
quality of the oil.
Problem Possible Cause Remedy

Pressure fluid escaping from the Control block housing leaking at Check seals, renew if necessary,
mobile control block the piston check tightening torques.
See "Installation Drawing" and
"Parts list"
Plug screws leaking Tighten plug screws, renew
sealing rings if necessary.
For O-ring seals:
Do not re-tighten the plug screw,
replace the seals and tighten the
plug screw with the specified torque
(see "Installation Drawing")
Control block housing leaking Remove control block and replace
it with a new one.
Connections leading to the Check seals, renew if necessary.
actuator leaking (Screw sockets, Check tightening torques,
screw connections) see "Installation Drawing"
Pressure fluid escaping from pipe or Pipe or hose lines damaged Renew pipe or hose lines
hose lines Pipe or hose lines have worked loose Tighten the screw connections and
fittings according to the assembly
instruction applicable to the fittings.
The corresponding assembly
instructions are available from the
manufacturer.
Pressure fluid leaking between the Seals in flange surface damaged Renew the seals, see "Installation
mobile control block modules Drawing"
Contamination entry upon Disassemble the control block,
assembly of the control block clean the flange surface,
see "Installation Drawing"
Mobile control block housing Renew damaged mobile control
leaking at flange surface block module.
Tightening torque of tie rods too low Check the tightening torques, see
"Installation Drawing"
Hydraulic function disturbed Air in the pressure fluid Vent hydraulic system.

5-7-94
Spool cannot Tie rods have been tightened with Loosen the nuts of the tie rods and
be mechanically too great a tightening torque tighten at the specified torque, see
displaced "Installation Drawing" of the
respective product.
Oil temperature too high and/or too Check cooler function, oil supply
great a temperature difference and pump pressure in neutral
between the pressure fluid and the position. Avoid temperature shock.
mobile control block, causing
blocking because of dissimilar heat
expansion of spool and mobile
control block
Contamination or foreign particles Visually inspect the connectors to
introduced during the assembly of the actuator, remove foreign
the connections leading to the particles with a magnet or
actuator are jamming the spool tweezers. In case of jammed
foreign particles, replace the control
block module with a new one.
Spool returns too slowly or not at all Spool jamming See "Spool cannot be
mechanically displaced" above in
the event of a malfunction.
Following a breakdown because of contamination, it is essential

to check the oil quality and if necessary to improve it by suitable
means, such as flushing or the additional building in of filters.

5-7-95
START-UP PROCEDURES
Commissioning
WARNING
Air enclosed in hydraulic systems can cause components
to vibrate during operation and cause unexpected
movements of the actuators:
• Depressurize the hydraulics before starting
commissioning and relieve accumulator pressure.
• Before commissioning you must make sure that
enclosed air is completely removed from the system.
This can be done by operating all machine functions at
low idle.
NOTE: Product damages resulting from a lack of pressure

fluid
If you commission the control block without or with
too little pressure fluid, the control block will be
immediately damaged or even destroyed.
– When commissioning or re-commissioning a
machine or system, you should ensure that
housing space, and the suction and work lines
of the control block are filled with pressure fluid
and that they remain filled with oil during
operation.

5-7-96
First Commissioning
1. Let the control block acclimate itself for several hours
before commissioning, otherwise water may condense in
the housing.
2. Make sure that all electrical and hydraulic connections are
either used or covered. Commission the control block only
if it is installed completely.
3. Avoid temperature shocks. Do not exceed temperature
differences of more than 20 °C between control block and
pressure fluid. Otherwise you risk jammed spools.
If temperatures are below-20 °C, the control block must be
warmed up.
Proceed as follows for the first commissioning of the control
block:
1. Completely fill the control block with permissible pressure
fluid.
2. Before commissioning, the housing of the control block
and, if available, the pre-control circuit must be completely
filled with pressure fluid and must be bled (see below).
3. Switch on hydraulic supply.
4. Activate the electrical supply.
5. Check electrical connections.
Before first or re-commissioning, have the electrical
connections checked for proper condition by a trained
electrician or under the direction and supervision of a
trained electrician.
IMPORTANT
Observe the operating instructions of the machine
where the control block is installed.
6. Bleed the hydraulic system.

Before the actual operation, you must switch the control
block several times under operating pressure in each
actuating direction and with reduced velocity. Thus, the
remaining air in the control block is pressed out.
Mechanical damage because of inadmissibly high
acceleration of the pressure fluid and the control block
spool is thus avoided and the control block's service life is
increased.

5-7-97
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do not
use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
7. Leakage test
Check whether during operation, hydraulic fluid leaks at
the control block and at the connections.
8. Perform a functional test ensuring that all controls function
as intended.
9. Commission control block.
IMPORTANT
Details for fine adjustment are available in the
operating instructions of each machine.
10. Check the operating temperature of the machine after

several hours of continuous operation. Too high operating
temperatures indicate errors which must be analyzed and
removed.
11. Have a pressure fluid sample analytically tested for the
required cleanliness class after first commissioning.
Replace the pressure fluid if the required cleanliness class
is not achieved. If the pressure fluid is not tested in the
laboratory after first commissioning, the following applies:
Replace the pressure fluid.
Re-commissioning
Proceed as follows to re-commission the control block:
1. Follow the instructions in See "First Commissioning" on
page-97.

5-7-98
Swing Device
Edition 1
DX210W-5 Swing Device

5-8-1
MEMO
Swing Device DX210W-5

5-8-2
Table of Contents
Swing Device
General ...........................................................5-8-5
Specification .............................................................. 5-8-5
Swing Motor ......................................................... 5-8-5
Swing Reduction Gear ......................................... 5-8-5
Pinion Gear .......................................................... 5-8-5
Parking Brake....................................................... 5-8-5
Overview ................................................................... 5-8-6
Parts List ................................................................... 5-8-8
Swing Motor ......................................................... 5-8-8
Swing Reduction Gear ....................................... 5-8-10
Swing Device...................................................... 5-8-12
Hydraulic Motor .................................................. 5-8-13
Valve Casing ...................................................... 5-8-14
Schematic of Operation of Reactionless Valve .. 5-8-18
Brake Part .......................................................... 5-8-19
Cautions for Operation ............................................ 5-8-21
Inspection ........................................................... 5-8-21
Direction of Rotation........................................... 5-8-21
External Load at the End of Shaft ...................... 5-8-22
Hydraulic Oil and Temperature Range............... 5-8-22
Filter ................................................................... 5-8-23
Installation and Piping ........................................ 5-8-23
Oil Filling and Air Ventilation .............................. 5-8-23
Instructions before Starting to Operate .............. 5-8-23
Removal .......................................................5-8-24
Installation ....................................................5-8-29
Completing work ...........................................5-8-30
Precaution ....................................................5-8-31
Tools for Disassembly and Assembly ..................... 5-8-31
Tightening Torque ................................................... 5-8-31

5-8-3
Section View .................................................5-8-34
Disassembly .................................................5-8-36
Swing Motor ............................................................ 5-8-36
Swing Reduction Gear ............................................ 5-8-41
Reassembly ..................................................5-8-45
Swing Motor ............................................................ 5-8-45
Swing Reduction Gear ............................................ 5-8-51
General Instructions ................................................ 5-8-59
Examination of Hydraulic Motor .............................. 5-8-59
Troubleshooting....................................................... 5-8-60
Maintenance Instructions..............................5-8-63
Replacement Standard of Worn Parts..................... 5-8-63
Standard of Sliding Surface Correction ................... 5-8-63

5-8-4
SAFETY INSTRUCTIONS
WARNING
machine. Read and understand the Operation and
or serious injury.
GENERAL
Specification
Swing Motor
Type Axial Piston

Displacement 128 cc/rev (0.004 ft3)
Crossover Relief Valve Setting 265 bar (270 kg/cm2, 3,840 psi) @201 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 6 bar (6 kg/cm2, 85 psi)

Time Delay 5 sec

5-8-5
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

5-8-6
SH
RED
PG
DB
265 bar
265 bar
C
PA PB
A B WE1400030
Figure 2

5-8-7
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

5-8-8
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

5-8-9
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

5-8-10
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

5-8-11
Swing Device
2 3
WE1400044
Figure 5
Reference Reference
Number Number
1 Socket Bolt 3 Air Breather Assembly
2 Level Gage Assembly

5-8-12
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=
2x
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

5-8-13
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.

5-8-14
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

5-8-15
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

5-8-16
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

5-8-17
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

5-8-18
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

5-8-19
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

5-8-20
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)

5-8-21
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.

5-8-22
Filter
Dust or metal particles in hydraulic oil accelerate wear of sliding
surfaces or can cause sticking. Install 10 m 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

1. Check if there is any loose joint or other trouble in the
pipeline. Figure 20
WE1401576
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.

5-8-23
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 21 and
lower the boom until the attachment is 10 cm above the
ground.
3. Lower dozer blade and outriggers to ground, if equipped.
4. Stop the engine. 10 cm
WE1401486
the machine from moving. Figure 21

5-8-24
I
(Figure 22)
LOCK
WARNING OFF OFF
ON
ON

switch.
WE1400464
Figure 23

(Figure 24)
OFF
ON
Figure 24 WE1500101

5-8-25
3
5 8
1 2
7 6
4
EX1401809
Figure 25
WARNING
doing any work.
Pulling the breather cap upward, the check valve (0.45 bar) WE1500550
opens, and the air is discharged to the atmosphere from Figure 26
16. Disconnect harness from the swing device.
WE1500253
Figure 27
How to disconnect the harness connector.

1
EX1402340
Figure 28

5-8-26
17. 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)
Sgr
PG
A
B SH
WE1500254
Figure 29

Torque
Port Name Plug/Flange Size (Hose)
(mm) N.m kg.m ft lb
A Main Port (from MCV "B2") UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
B Main Port (from MCV "A2") UNF 1 3/16"-12-2B 36 124.5 12.7 91.8
C Make-up Port (from MCV "S") UNF 1 7/16"-12-2B 41 169.5 17.3 125.1
DB Drain Port (Connect with Center Joint) UNF 13/16"-16-2B 24 55.9 5.7 41.2
Brake Release Port
PG UNF 9/16"-16-2B 19 25.5 2.6 18.8
(from Solenoid Valve "P2")
Brake Release Signal
UNF 9/16"-16-2B 19 25.5 2.6 18.8
SH (from Shuttle Valve)
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

5-8-27
• Fitting
Size Torque
Port Name
A B (C) (mm) (mm) N.m kg.m ft lb
A, B Elbow SAE 3/4", D20 UNF 1 3/16"-12 8 56.8 5.8 41.9
C Elbow PF 1" UNF 1 7/16"-12 41 215.6 22 159.1
DB Tee PF 1/2" UNF 13/16"-16 27 107.8 11 79.5
PG Elbow PF 1/4" UNF 9/16"-18 19 36.3 3.7 26.8
Tee PF 1/4" UNF 9/16"-18, PF 1/4" 19 36.3 3.7 26.8
SH
Reducer PF 1/4" PF 1/4" 19 39.2 4 28.9
Sgr Adapter PT 1/4" PF 1/4" 19 17.6 1.8 13.0
Adapter PT 1/2" PF 1/2" 27 44.1 4.5 32.5
Dr (RG)
Elbow PF 1/2" PF 1/2" 27 93.1 9.5 68.7
DS2856002
Ring Seal/
A, B (3/4", ID: 25.3, S8030125 (4D F-12)
O-ring
OD: 32.3, 1B)
C O-ring S8000291 (1B P29) S8030165 (4D F-16)
DB O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
PG O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)
2180-1216D11,
SH O-ring S8000115 (4D P11)
S8000115 (4D P11)
18. Install the eyebolts (M10 x 1.5 x DP18) (Figure 30).

19. Attach a nylon sling onto the eyebolt.
Figure 30 WE1500255
• Tool: 30 mm ( )
• Torque: 539 N.m (55 kg.m, 398 ft lb)
21. Remove plugs (2, Figure 31) (2 ea).
22. Install the back bolt to the plug position to ensure that
2
frame and swing device can be separated.
23. Hoist and remove swing device from the frame.
1
NOTE: When hoisting the swing device one part of
swing device will contact with the main frame. Figure 31 WE1500256
Hoist the swing device a little and push to the
front side while hoisting slowly.

5-8-28
24. 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 32
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.

5-8-29
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 33 WE1500257
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.

5-8-30
PRECAUTION
Tools for Disassembly and Assembly

Tables 1 and 2 and Figure 34 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 lock ring For ø62 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

5-8-31
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 34 Tools for Brake Piston Disassembly

5-8-32
5-8-33
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 35 WE1400048

5-8-34
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

5-8-35
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 36
4. Remove bolts (406) (3 ea) with brake valve (400).

• Tool: 10 mm ( )
301
400
406 WE1400016
Figure 37
5. Remove relief valve (107) from valve casing (101).

• Tool: 41 mm ( ) 101
107
FG022404
Figure 38

5-8-36
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 39
7. Remove swing reactionless valve assembly (105) from

valve casing (101).
105
101
WE1400017
Figure 40
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 41
9. Remove brake springs (310) from the brake piston (309).

310
309
FG022408
Figure 42

5-8-37
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 43
11. After placing the motor horizontally, take out cylinder block 301
(205) from casing (301).
201
205
WE1400019
Figure 44
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 45
206
208
209
205
WE1400021
Figure 46

5-8-38
13. Pull out friction plate (306) (2 ea) and separation plate
(305) (3 ea) from casing (301). 306
305
301
WE1400022
Figure 47
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 48
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 49

5-8-39
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 50
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 51
3) Take out valve plate (213) and O-ring (112) from the
valve casing (101).
213
112
101
WE1400024
Figure 52
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 53

5-8-40
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 54
3. Remove No. 1 sun gear (602) from No. 1 carrier 602

subassembly.
No. 1 Carrier
FG022430
Figure 55
4. Remove No. 1 carrier subassembly.

No. 1 Carrier
sub-assembly
FG022431
Figure 56

5-8-41
5. Remove No. 2 sun gear (702) from No. 2 carrier
subassembly. 702
FG022441
Figure 57
6. Remove bolt (509) in No. 2 carrier.

• Tool: 24 mm ( ) 509
FG022451
Figure 58
7. Remove No.2 carrier subassembly from ring gear.

No. 2 Carrier
Sub-assembly
FG022452
Figure 59
8. Remove bolt (802) in ring gear (1 ea).

802
• Tool: 6 mm ( )
WE1400025
Figure 60

5-8-42
9. Remove ring gear (801) from casing (501).
801
501
FG022454
Figure 61
10. Remove pins (512) from casing (501).

512
501
FG022455
Figure 62
11. Remove bolt (507) from casing (501).

501
507
FG022456
Figure 63
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 64

5-8-43
13. Remove bearing (504) from case (501). 504
501
WE1400026
Figure 65
14. Remove pinion shaft (502) from casing (501).
501
502
FG022462
Figure 66
15. Remove oil seal (505).

505
IMPORTANT
Do not reuse oil seal!
Disassembling is finished, check each component throughly.
FG022460
Figure 67

5-8-44
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 68
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 69

5-8-45
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 70
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 71
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 72

5-8-46
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 73
7. Place collar (208), thrust ball (206) to the cylinder block

(205).
206
208
205 FG022421
Figure 74
8. Assemble the retainer (207) with the piston sub assembly

(203) unit to the cylinder block (205). 206
208
209
205
WE1400021
Figure 75
207 203
205
WE1400020
Figure 76

5-8-47
9. Insert cylinder block (205) to driveshaft (201) by aligning
with the spline.
201
205
FG022410
Figure 77
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 78
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 79
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 80

5-8-48
13. Assemble brake springs (310) into brake piston (309).
310
Confirm the springs are fitted to the brake piston
completely.
309
FG022408
Figure 81
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 82
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 83
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 84

5-8-49
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 85
18. Install swing reactionless valve (105) to valve casing (101).

Confirm the spring in the swing reactionless valve (105).
105
101
WE1400017
Figure 86
19. Assemble relief valve (107) with O-ring to valve casing

(101).
101
• Tool: 41 mm ( )
107
FG022404
Figure 87
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 88

5-8-50
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 5-8-31.
1. Install the bearing cover (506) and the taper roller bearing
(503) on the pinion shaft (502).
503
506
502
FG022461
Figure 89
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 90

5-8-51
3. Tighten screws (507) to assemble cover (506).
506
• Torque: 29 N.m (3 kg.m, 21 ft lb)
507
FG022463
Figure 91
4. Mount a casing (501) on a suitable work table or jig.
501
FG022464
Figure 92
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 93
6. Install the taper roller bearing (504) with a using of tool.
504
501
FG022466
Figure 94

5-8-52
7. Assemble pins (512) with casing (501).
512
501
FG022455
Figure 95
8. Apply sealant evenly to ring gear assembly of casing.
FG022467
Figure 96
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 97
10. Tightening special bolts (802) with no Loctite applied.

802
• Tool: 6 mm ( )
WE1400025
Figure 98

5-8-53
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 99
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 100
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 101
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 102

5-8-54
15. Install No. 2 sun gear (702) in No. 2 carrier.
702
FG022441
Figure 103
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 104
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 105
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 106

5-8-55
19. Install No. 1 sun gear (602) in No. 1 carrier.
602
FG022473
Figure 107
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 108
21. Apply sealant evenly to ring gear assembly of motor.
FG022475
Figure 109
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 110

5-8-56
23. Apply Loctite to socket bolts (314) (16 ea).
314
FG022498
Figure 111
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 112
25. Install the level gauge pipe sealed with teflon tape with a
pipe wrench.
Level Gauge
Pipe
FG022500
Figure 113

5-8-57
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 114

5-8-58
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.

5-8-59
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.

5-8-60
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.

5-8-61
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

5-8-62
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 () 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 115
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.

5-8-63
5-8-64
Joystick Valve
(Work Lever)
Edition 1
DX210W-5 Joystick Valve (Work Lever)

5-9-1
MEMO
Joystick Valve (Work Lever) DX210W-5

5-9-2
Table of Contents
Joystick Valve (Work Lever)

General ...........................................................5-9-5
Specifications ............................................................ 5-9-5
Overview ................................................................... 5-9-6
Parts List ................................................................... 5-9-8
Tools and Torques .................................................. 5-9-11
Section View .................................................5-9-12
Removal .......................................................5-9-14
Installation ....................................................5-9-20
Completing work ...........................................5-9-21
Tools and Torques........................................5-9-22
Disassembly .................................................5-9-22
Reassembly ..................................................5-9-26

5-9-3
5-9-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specifications
Max. Primary Pressure 49 bar (50 kg/cm2, 711.1 psi)
Max. Back Pressure 2.9 bar (3 kg/cm2, 42.7 psi)
Rated Flow 20 L/min (5.3 U.S. gal)
Continuous Rated Current of Switch DC30 V x 6 A
Internal Leakage Oil Temperature 50 ±5°C (122 ±41°F)
Neutrality 30 ~ 150 cc
At Work (15 kg/cm2) 30 ~ 400 cc
Performance
Port 1, 3 Port 2, 4
40 40

Operating Torque (kg.cm)
28 1.5 28 1.5
Single Operating Torque Single Operating Torque
(17.6) (17.9)
14.6 3 14.6 3
6.5 1 6.5 1
4.5 2 4.5 2
Secondary Pressure Secondary Pressure
0 1 2 3 4 5 6.5 7 0 1 2 3 4 5 6 7.5 8
Push Rod Stroke (mm) Push Rod Stroke (mm)
0 3 5 10 15 17.5 19 0 3.1 5 10 15 20 21.5

Operating Angle Operating Angle 21
Figure 1 EX1400109

5-9-5
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.
P1
S2
P1
S3
S2
S1
S1
ingle
21.5 S
, 4)
(Port 2 S3
gle
19 Sin 25
, 3) Do
(Port 1 ubl
e
Rocker Switch (R1)

Forward
RH
Neutral
Reverse
Rear View (RH)
Front View (LH) Front View (RH)
P1 - Red P1 - Black R1 - Orange P1 - Red P1 - Black

R1 - Pink
P1 - Blue P1 - Blue
R1 - Brown R1 - Violet
S2 - Yellow S2 - Yellow S2 - Yellow S2 - Yellow
S3 - Green S3 - Green S1 - White S1 - White S3 - Green S3 - Green S1 - White S1 - White
4 4
1 P 1 P
T T
2 3 2 3
WE1400625
Figure 2

5-9-6
Port and Hydraulic Circuit
Switches
1. Push button switch
Switch 1 White White
Switch LH RH
Switch 2 Yellow Yellow
Breaker/Booster
S1 Horn Button Switch 3 Green Green
Button
Intelligent Floating EX1301712
One Touch Figure 3
S2 Boom Temporary
Deceleration Button
Reset Button
S3 Spare Button Spare Button
2. Proportional switch
4 V (Right) Red ( 5 V)
Switch LH RH
Blue
P1 Rotating Switch Shear Switch (Signal)
1 V (Left) Black (Ground)

EX1301713
Figure 4
3. Rocker switch (R1)

Violet 6 (Down)
Brown 2 Pink 4 (Center)
(Common)
Orange 1 (Up)
WE1400626
Figure 5
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 6

5-9-7
Parts List
Handle (Left)
SPOOL
Handle (Right)
SPOOL
EX1403268
Figure 7

5-9-8
Reference Reference
Number Number
1 Case 20 Boot
2 Plug 21 Joint Assembly
3 Bushing 22 Swash Plate
4 Spool 23 Nut
5 Shim 24 Nut
6 Spring Joystick (LH)
25
7 Spring Seat Joystick (RH)
8 Stopper 25-1 Push Button Switch
9 Spring 25-2 Thumb Switch
10 Stopper 26 Handle Bar
11 Spring 28 Bellows
12 Push Rod 29 Bushing
13 Spring 30 Washer
14 Spring Seat 33 Spool Kit 1, 3
15 Stopper 34 Spool Kit 2, 4
16 Plug 35 Plug Kit 1, 3
17 O-ring 36 Plug Kit 2, 4
18 Rod Seal 37 Handle Kit (RH)
19 Plate 38 Handle Kit (LH)

5-9-9
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 8
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 9

5-9-10
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 10
Tools and Torques
Reference Torque
Description Tool
Number Nm 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 ( )

5-9-11
SECTION VIEW
25-2
25-1
27
25
24 28
26
23
21
20
22 12
11
30
18
19
16
10 13
29 17
15
14 8
7
13
6
5
5
4 9
3
1
2 EX1403269
Figure 11

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

5-9-13
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1401483
Figure 12

5-9-14
(Figure 13) I
LOCK
WARNING OFF OFF
ON
ON
maintenance, always use extreme caution. Always
EX1500510
have one person in the cabin at all times. Never leave
the cabin with engine running. Figure 13

O
8. Apply the service brake with full stroke several time to
I
9. Turn key to "O" (OFF) position and remove from starter switch.
WE1400464
Figure 14

(Figure 15)
OFF
ON
Figure 15 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 16

5-9-15
WARNING
doing any work.
12. Loosen the oil tank air breather slowly to release the pressure
inside the hydraulic oil tank.
Pulling the breather cap upward, the check valve (0.45 bar)
WE1500550
opens, and the air is discharged to the atmosphere from Figure 17
13. Remove bolts (3 ea) and washers (3 ea) and remove arm
rest from bracket. (Right side)
Left side is same.
• Tool: 13 mm ( )
EX1301715
Figure 18
14. Remove screw with arm rest cover.

Left side is same.
• Tool: Phillips screwdriver
EX1301716
Figure 19
15. Remove rubber and screws, remove cover (1, Figure 20)
from stand upper cover, and disconnect the connector of
harness which connect with switches.
1
EX1301717
Figure 20 Stand RH

5-9-16
16. Remove socket bolt (1, Figure 21) with grip (2).
2
17. Remove screw (3) with cover (4) from stand upper cover,
and disconnect the connector of harness which connect
with switches. 3
• Tool: 4 mm ( ), phillips screwdriver
1
4
Figure 21 Stand LH WE1400628
18. Remove screws (Figure 22) (4 ea), remove upper cover (1,
1
Figure 22) from bracket, and disconnect the connector of
harness which connect with switches.
Left side is same.
EX1301719
Figure 22 Stand RH
EX1301720
Figure 23 Stand LH

5-9-17
19. Remove screws (4, Figure 24) (2 ea), socket bolts and
washers (3) (4 ea) of joystick valve (1).
20. Remove bracket (2, Figure 24) from control stand bracket. 1
21. Separate joystick valve from control stand.

Left side is same. 2
• Tool: 5 mm ( ), phillips screwdriver 3
4
EX1301721
Figure 24 Stand RH
1
2
3
4
EX1301722
Figure 25 Stand LH

5-9-18
22. Remove hoses and adapters from joystick valve.
NOTE: Attach identification tags to the removed hoses for reassembling.
After disconnecting hoses from joystick valve, plug them to prevent dirt or dust from entering.
4 4
P P
1 1
P
T T
2 3 2 3
2 1
Left Hand Right Hand

EX1403098
Figure 26

Port Name
1 to Joint Plate Assembly "A2" UNF 11/16"-16-2B 22 38.2 3.9 28.2
Left 3 to Joint Plate Assembly "B2" UNF 11/16"-16-2B 22 38.2 3.9 28.2
Hand 4 to Joint Plate Assembly "B1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
P from PT Block "P" UNF 11/16"-16-2B 22 38.2 3.9 28.2
T to PT Block "T" (Drain) UNF 11/16"-16-2B 22 38.2 3.9 28.2
1 to Joint Plate Assembly "B6" UNF 11/16"-16-2B 22 38.2 3.9 28.2
Right 3 to Joint Plate Assembly "A6" UNF 11/16"-16-2B 22 38.2 3.9 28.2
Hand 4 to Joint Plate Assembly "B5" UNF 11/16"-16-2B 22 38.2 3.9 28.2
• Fitting
Size Torque
Port Name
1, 2, 3, 4,
Adapter PF 3/8" UNF 11/16"-16 22 40.2 4.1 29.6
Left/Right P, T
Hand 1, 2, 3, 4, S8000145 S8030061
O-ring
P, T (4D P14) (1B F-06)

5-9-19
23. Remove joystick valve from control stand.
EX1403099
Figure 27
INSTALLATION
WARNING
SERIOUS INJURY

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

5-9-20
COMPLETING WORK
1. Start engine and set throttle at "LOW IDLE".
FG019382
Figure 28
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.
FG018384
Figure 29

5-9-21
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 30
2. Remove lever assembly from case (1).
FG000805
Figure 31

5-9-22
3. Remove hex nut (23) and swash plate (22) from case.
FG000806
Figure 32
4. Remove joint assembly (21) from case.
FG000807
Figure 33
5. Remove plate (19) from case (1).
FG000808
Figure 34
6. Remove plug kit assembly, stopper (10), and spring (11)

from case (1).
FG000809
Figure 35

5-9-23
FG000810
Figure 36
FG000811
Figure 37
7. Remove four spool kit assemblies from case (1).
FG000812
Figure 38
FG000813
Figure 39

5-9-24
8. The bushing (3) and plug cannot be removed from case
(1).
FG000814
Figure 40
FG000815
Figure 41
FG000816
Figure 42
FG000817
Figure 43

5-9-25
REASSEMBLY
1. Install four plugs (2) into case (1).
FG000815
Figure 44
FG000817
Figure 45
2. Install bushing (3) into case (1) using jig.
Figure 46 FG000814
FG000816
Figure 47

5-9-26
FG000818
Figure 48
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 49
FG000812
Figure 50
4. Install spring (9) into case (1).
FG000820
Figure 51

5-9-27
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
FG000821
Figure 52
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (2) into plug (16) in proper order.
FG000822
Figure 53
FG000810
Figure 54
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 55

5-9-28
FG000811
Figure 56
FG000823
Figure 57
8. Install plate (19) into case (1).
FG000808
Figure 58
9. Install joint assembly (21) into case (1).
FG000807
Figure 59

5-9-29
10. Install wash plate (22) and hex nut (23) into case (1).
FG000806
Figure 60
11. Insert bar and tighten it with a spanner to check balance of

joint assembly.
FG000824
Figure 61
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 62
13. Install lever assembly into case (1).
FG000805
Figure 63

5-9-30
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG000826
Figure 64
FG000827
Figure 65
15. Install lead wire terminal into connector terminal pressing

them together.
FG001097
Figure 66

5-9-31
16. Assemble connector assembly (30), and connect it to lead
wire terminal, and properly route wiring.
FG000828
Figure 67
FG000829
Figure 68

5-9-32
1Gear Pump
(Brake and Steering)
Edition 1
DX210W-5 Gear Pump (Brake and Steering)

5-10-1
MEMO
Gear Pump (Brake and Steering) DX210W-5

5-10-2
Table of Contents
Gear Pump (Brake and Steering)

Safety Instructions ........................................5-10-5
General .........................................................5-10-5
General Description................................................. 5-10-5
Specification ............................................................ 5-10-5
Overview ................................................................. 5-10-6
Location................................................................... 5-10-6
Parts List ................................................................. 5-10-7
Removal .......................................................5-10-8
Installation ..................................................5-10-12
Completing Work ........................................5-10-13
Single Gear Pump ......................................5-10-14
Disassembly .......................................................... 5-10-14
Reassembly........................................................... 5-10-16

5-10-3
5-10-4
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
Direction of Rotation
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)

5-10-5
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
Location
Gear Pump
(Steering and Brake) Main Pump
Figure 3 WE1500431

5-10-6
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 4
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

5-10-7
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1500294
Figure 5

5-10-8
I
(Figure 6)
LOCK
WARNING OFF OFF
ON
ON

switch.
WE1400464
Figure 7

(Figure 8)
OFF
ON
Figure 8 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 9

5-10-9
WARNING
doing any work.
13. Open the right side door.
WE1500281
Figure 11

5-10-10
14. Remove hoses and adapters from gear pump.
NOTE: Attach identification tags to the removed hoses
for reassembling.
Outlet (Steering)
After disconnecting hoses from gear pump, plug
them to prevent dirt or dust from entering.
Outlet (Brake)
gear pump.
Inlet
WE1500282
Figure 12

Port Name
Inlet from Main Suction Pipe SAE 1 1/4", D30.5 8 20.6 2.1 15.2
Outlet to Priority Valve "P" UNF 13/16"-16-2B 24 55.9 5.7 41.2
(Steering) Dummy UNF 13/16"-16-2B 24 55.9 5.7 41.2
Outlet
to Brake Filter "IN" UNF 13/16"-16-2B 24 55.9 5.7 41.2
(Brake)
• Fitting
Size Torque
Port Name
Outlet
Tee PF 1/2" UNF 13/16"-16 27 50.0 5.1 36.9
(Steering)
Outlet
Adapter PF 1/2" UNF 13/16"-16 27 50.0 5.1 36.9
(Brake)
DS2856004
Inlet Ring Seal
(1 1/4", ID:38, OD:45, 1B)
Outlet
(Steering, O-ring S8000185 (4D P18) S8030081 (1B F-08)
Brake)
15. Remove bolts (1, Figure 13) (2 ea) and washers with gear
pump (2) from main pump.
• Tool: 10 mm ( )
1
Figure 13 WE1400315

5-10-11
16. Remove gear pump from main pump.
• Pump weight: about 16 kg (35.3 lb)
WE1400316
Figure 14
INSTALLATION
WARNING
SERIOUS INJURY

5-10-12
COMPLETING WORK
FG019382
Figure 15
3. Slowly operate the steering wheel and brake pedal about

five times.
Figure 16 WE1400713
WE1400714
Figure 17

5-10-13
SINGLE GEAR PUMP
Disassembly
1. Clean exterior of pump.
FG001072
Figure 18
2. Remove clamp bolts.
FG001074
Figure 19
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 20

5-10-14
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 21
5. Remove retaining ring, if replacement is necessary.
FG000834
Figure 22
6. Remove shaft seal taking care not to damage surface of

shaft hole, if replacement is necessary.
FG000835
Figure 23
7. Pull drive gear up to facilitate removal of front plate.
FG001076
Figure 24

5-10-15
8. Remove driving gear and driven gear, keeping gears as
straight as possible.
FG001077
Figure 25
9. Remove rear plate and end cover.
FG001078
Figure 26
Reassembly
1. Clean all components with care.
FG001078
Figure 27
2. Using a suitable driver, install shaft seal in mounting

flange.
FG000839
Figure 28

5-10-16
3. Install retaining ring in groove.
FG000840
Figure 29
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 30
5. Install rear section body on rear cover.
FG001080
Figure 31
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 32

5-10-17
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 33
8. Install drive gear and driven gear.
FG001082
Figure 34
9. Insert pressure plate into body in proper direction.
FG001083
Figure 35
10. Locate mounting flange in right position.
FG001084
Figure 36

5-10-18
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 37
12. Check that pump rotates freely when driveshaft is turned

by hand. If not a pressure plate seal may be pinched.
FG000851
Figure 38

5-10-19
5-10-20
Brake System
Edition 1
DX210W-5 Brake System

5-11-1
MEMO
Brake System DX210W-5

5-11-2
Table of Contents
Brake System
General .........................................................5-11-6
Hydraulic Circuit ...................................................... 5-11-7

5-11-3
5-11-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-11-5
GENERAL
General Description
Oil from the gear pump, which is connected to the main pump,
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.
Gear Pump
Main Pump
Brake Pedal Valve
Brake Supply Brake Filter

Front Axle
Valve P1
BR1
BR2
P1
P2
B1 P2
A1 B2
A2 AC AB
6 7 Shuttle
Valve
Center Joint
Rear Axle
WE1500441
Figure 1

5-11-6
Hydraulic Circuit
1
4
3.5 bar 65 bar

2 x 0.75 L Low
30 bar Pressure
Warning
AB PSA PSD
AC
Release ACC A ACC B
Cruise BL1
C3 C4 C5
4.6 bar
T1 GP G1
BR1
P1 160 bar
10 P1
C6 C2
C1
6 103 bar Brake

Release 125 bar Supply
A2 A1 Cruise BL2 T Valve
4.6 bar
BR2 T2
B2 S1 B1
P2
3
5
65 ±5 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
WE1500111
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

5-11-7
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 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.

5-11-8
Brake Filter
Edition 1
DX210W-5 Brake Filter

5-12-1
MEMO
Brake Filter DX210W-5

5-12-2
Table of Contents
Brake Filter
General .........................................................5-12-5
Specification ............................................................ 5-12-5
Overview ................................................................. 5-12-6
Parts List ................................................................. 5-12-6

5-12-3
5-12-4
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 m
Element Replacement Interval 1,000 hr

5-12-5
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

5-12-6
Brake Supply Valve
Edition 1
DX210W-5 Brake Supply Valve

5-13-1
MEMO
Brake Supply Valve DX210W-5

5-13-2
Table of Contents
Brake Supply Valve

General .........................................................5-13-5
Specification ............................................................ 5-13-5
Overview ................................................................. 5-13-6
Parts List ................................................................. 5-13-7
Cautions for Disassembly and Reassembly ...5-13-10
Tools and Torque .......................................5-13-11
Removal .....................................................5-13-12
Installation ..................................................5-13-16
Completing Work ........................................5-13-17
Troubleshooting ..........................................5-13-18
How to Check Brake Pressure ...................5-13-19

5-13-3
5-13-4
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, 2,987 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)

5-13-5
Overview
3
2
4
WE1400685
Figure 1
No. Part Name Quantity Remark

1 Body 1
2 Logic Valve 1 C1
3 Relief Valve 1 C2
4 Check Valve 3 C3, C4, C5
5 Unloading Valve 1 C6
Port Name Size AB PSA PSD
P1 In (Brake Pump) AC
PF 1/2 ACC A ACC B
T Out (Tank) C4 C5
C3
ACC A Accumulator GP G1
160 bar
ACC B Accumulator P1
PF 3/8 C1 C6 C2
AB to Front Axle
AC to Rear Axle 103 bar
125 bar
T
PSD Pressure Switch PF 1/4
WE1400687
Figure 2

5-13-6
Parts List
3
2
4
WE1400685
Figure 3
Reference Reference
Number Number
1 Body 4 Check Valve
2 Logic Valve 5 Unloading Valve
3 Relief Valve

5-13-7
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.

5-13-8
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/cm 1,465 ±42 psi)
2, 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.

5-13-9
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.

5-13-10
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.
4
Disassembly
1
2
Assembly
WE1400686
Figure 4
Assembly Torque Assembling Tools

No. Part Name Screw Spec
N.m kg.m ft lb
1 Logic valve UNF 7/8-14" 49 5 36.2 Torque Wrench/32 mm Hex. Socket
2 Relief valve UNF 7/8-14" 49 5 36.2 Torque Wrench/1" Hex. Socket
3 Check Valve UNF 7/8-14" 49 5 36.2 Torque Wrench/1" Hex. Socket
4 Unloading Valve UNF 7/8-14" 49 5 36.2 Torque Wrench/32 mm Hex. Socket

5-13-11
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1401487
Figure 5

5-13-12
I
(Figure 6)
LOCK
WARNING OFF OFF
ON
ON
5. Operate the joystick levers and brake pedal several times

to release the remaining pressure in the hydraulic piping.
switch.
WE1400464
Figure 7
11. Turn battery disconnect switch to "OFF" position.

(Figure 8)
OFF
ON
Figure 8 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 9

5-13-13
WARNING
doing any work.
13. Open the left side door.
Figure 11 WE1500112
14. Disconnect the harness connector.
Figure 12 WE1500113

5-13-14
15. Remove hoses and adapters from brake supply valve.
T
NOTE: Attach identification tags to the removed hoses PSD
for reassembling. ACC A
After disconnecting hoses from brake supply

valve, plug them to prevent dirt or dust from
entering. P1
ACC B
brake supply valve.
AC AB
Figure 13 WE1500114

Port Name
T to Oil Cooler Pipe UNF 13/16"-16-2B 24 55.9 5.7 41.2
P1 from Brake Filter "OUT" UNF 13/16"-16-2B 24 55.9 5.7 41.2
AB to Brake Pedal Valve "P2" UNF 11/16"-16-2B 22 38.2 3.9 28.2
AC to Brake Pedal Valve "P1" UNF 11/16"-16-2B 22 38.2 3.9 28.2
ACC A to Accumulator (Rear Axle) PF 3/8" 32 44.1 4.5 32.5
ACC B to Accumulator (Front Axle) PF 3/8" 32 44.1 4.5 32.5
PSD Pressure Switch PF 1/4" 24 35.3 3.6 26.0
• Fitting
Size Torque
Port Name
T Adapter PF 1/2" UNF 13/16"-16 27 83.8 8.6 61.8
P1 Adapter PF 1/2" UNF 13/16"-16 27 83.8 8.6 61.8
AB Elbow PF 3/8" UNF 11/16"-16 22 44.1 4.5 32.5
AC Elbow PF 3/8" UNF 11/16"-16 22 44.1 4.5 32.5
T, P1 O-ring S8000185 (4D P18) S8030081 (1B F-08)
AB, AC O-ring S8000145 (4D P14) S8030061 (1B F-06)
ACC A,
O-ring S8000145 (4D P14)
ACC B

5-13-15
16. Remove bolts (1, Figure 14) (2 ea) and washers with brake
1
supply valve (2) from main frame.
• Tool: 17 mm ( )
Figure 14 WE1400719
17. Remove brake supply valve from main frame.

• Valve weight: about 4 kg (8.8 lb)
WE1400720
Figure 15
INSTALLATION
WARNING
SERIOUS INJURY

2. When installing the hose, be install the drain hose first.

5-13-16
COMPLETING WORK
FG019382
Figure 16
3. Slowly push brake pedal about five times without a load to

vent air from brake lines.
Figure 17 WE1400713

5-13-17
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."

5-13-18
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)

5-13-19
5-13-20
1Brake Pedal Valve
Edition 1
DX210W-5 Brake Pedal Valve

5-14-1
MEMO
Brake Pedal Valve DX210W-5

5-14-2
Table of Contents
Brake Pedal Valve

General .........................................................5-14-5
Specification ............................................................ 5-14-5
Overview ................................................................. 5-14-6
Section View .................................................5-14-9
Removal .....................................................5-14-10
Installation ..................................................5-14-15
Completing Work ........................................5-14-16
Disassembly ...............................................5-14-17
Reassembly ................................................5-14-17
Reassembly of the Lower Part .............................. 5-14-17
Reassembly of the Upper Part .............................. 5-14-19
Assembly of Pedal Plate ....................................... 5-14-22

5-14-3
5-14-4
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)

5-14-5
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

5-14-6
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

5-14-7
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

5-14-8
SECTION VIEW
T1
BL1
P1
BR1
T2
BL2
P2
BR2
WE1400368
Figure 6

5-14-9
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1401488
Figure 7

5-14-10
I
(Figure 8)
LOCK
WARNING OFF OFF
ON
ON
IMPORTANT
Operate the joystick levers and brake pedal valve
several times to release the remaining pressure in the
hydraulic piping.

6. Turn key to "O" (OFF) position and remove from starter
switch.
9. Attach a maintenance warning tag on controls. I
WE1400464
Figure 9

(Figure 10)
OFF
ON
Figure 10 WE1500101

5-14-11
3
5 8
1 2
7 6
4
EX1401809
Figure 11
WARNING
doing any work.
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
Never have wet hands when handling a window. Never
drop window or let it come into contact with other Figure 13 WE1400774
parts of machine.
Figure 14 WE1400742

5-14-12
• Tool: 19 mm ( )
1
2
• Under cover weight: 9 kg (20 lb)
WE1500563
16. Disconnect the harness connector (2 ea).
WE1400425
Figure 16
17. How to disconnect the harness connector.
WE1400426
Figure 17

5-14-13
18. 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 P1
BR1
valve, plug them to prevent dirt or dust from
entering.
BL2 T2
brake pedal valve.
BR2
P2
WE1400427
Figure 18 Bottom of Cabin

Port Name
T1 to Oil Tank UNF 11/16"-16-2B 22 38.2 3.9 28.2
T2 to Oil Tank UNF 11/16"-16-2B 22 38.2 3.9 28.2
P1 from Brake Supply Valve "AC" UNF 11/16"-16-2B 22 38.2 3.9 28.2
P2 from Brake Supply Valve "AB" UNF 11/16"-16-2B 22 38.2 3.9 28.2
BR1 to Shuttle Valve "A2" (Center Joint) UNF 11/16"-16-2B 22 38.2 3.9 28.2
BR2 to Shuttle Valve "A1" (Center Joint) UNF 11/16"-16-2B 22 38.2 3.9 28.2
• Fitting
Size Torque
Port Name
T1, T2,
Adapter PF 3/8" UNF 11/16"-16 22 30.8 3.14 22.7
P1, P2
BR1, BR2 Elbow PF 3/8" UNF 11/16"-16 22 30.8 3.14 22.7
BL1, BL2 Reducer PF 3/8" UNF 1/2"-20-2A 22 30.8 3.14 22.7
T1, T2,
S8000145 S8030061
P1, P2, O-ring
(4D P14) (1B F-06)
BR1, BR2
S8000145
BL1, BL2 O-ring
(4D P14)
* A: Opposite side of hose, B: Hose Side

5-14-14
19. Remove bolts (1, Figure 19) (4 ea) and washers with brake
pedal valve (2) from floor plate.
• Tool: 13 mm ( )
2
WE1400428
Figure 19
20. Remove brake pedal valve from floor plate.

• Valve weight: about 5 kg (11 lb)
WE1400429
Figure 20
INSTALLATION
WARNING
SERIOUS INJURY


5-14-15
COMPLETING WORK
FG019382
Figure 21
3. Slowly push brake pedal several times and wait for 5

minutes without a load to vent air from brake lines.
Figure 22 WE1400713

5-14-16
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

5-14-17
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

5-14-18
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

5-14-19
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

5-14-20
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

5-14-21
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

5-14-22
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

5-14-23
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

5-14-24
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

5-14-25
FG003675
Figure 46
FG003676
Figure 47
9. Install pedal angle adjustment bolt (10).
• Tool: 13 mm ( )
FG003677
Figure 48
FG003678
Figure 49

5-14-26
Accelerator Pedal Valve
Edition 1
DX210W-5 Accelerator Pedal Valve

5-15-1
MEMO
Accelerator Pedal Valve DX210W-5

5-15-2
Table of Contents
Accelerator Pedal Valve

General .........................................................5-15-5
Specification ............................................................ 5-15-5
Overview ................................................................. 5-15-6
Section View .................................................5-15-9
Removal .....................................................5-15-10
Installation ..................................................5-15-14
Completing Work ........................................5-15-15
Tools ...........................................................5-15-16
Disassembly ...............................................5-15-16
Assembly ....................................................5-15-18

5-15-3
5-15-4
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)
Weight 2 kg (4.4 lb)

5-15-5
Overview
P
T
A WE1400785
Figure 1
Hydraulic Circuit
Port Size
P, T, A PF 1/4
T
A
P
Figure 2 WE1400472

5-15-6
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).
12
T
A
8 P
T Port
P Port
3
A Port
WE1400786
Figure 3

5-15-7
2. Fine control
Moving the pedal 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 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.
12
T
5 A
P
T Port
P Port
3
A Port
WE1400787
Figure 4
3. Full control
Moving the pedal 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.
12
6
T
A
5 P
T Port
P Port
3
A Port
WE1400788
Figure 5

5-15-8
SECTION VIEW
II-13 II-10
II-9
II-12
II-11
I-6
I-7
I-5 2
I-4
I-3 1
EX1400789
Figure 6
Reference Reference
Number Number
1 Body 8 Spring
2 Plug II Plug Kit
I Spool Kit II-9 Plug
I-3 Spool II-10 Seal
I-4 Spring Seat II-11 O-ring
I-5 Spring II-12 Push Rod
I-6 Spring Seat II-13 Dust Seal
I-7 Stopper

5-15-9
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1401487
Figure 7

5-15-10
I
(Figure 8)
LOCK
WARNING OFF OFF
ON
ON

switch.
WE1400464
Figure 9

(Figure 10)
OFF
ON
Figure 10 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 11

5-15-11
WARNING
doing any work.
13. Stow the front upper window (1, Figure 13) in the cabin
ceiling.
1
14. Remove lower window (2) from cabin in direction of the
arrow.
WARNING
Never have wet hands when handling a window. Never
drop window or let it come into contact with other Figure 13 WE1400774
parts of machine.
Figure 14 WE1400742
• Tool: 19 mm ( )
1
2
• Under cover weight: 9 kg (20 lb)

5-15-12
Figure 16 WE1400794
18. Remove hoses and adapters from accelerator pedal valve.

NOTE: Attach identification tags to the removed hoses T
for reassembling.
After disconnecting hoses from accelerator
pedal valve, plug them to prevent dirt or dust
from entering.
Disconnect the hoses from the bottom to top of P
accelerator pedal valve.
A
Figure 17 Bottom of Cabin WE1400791

Port Name
A to Solenoid Valve "TS" UNF 9/16"-16-2B 19 25.5 2.6 18.8
P from Solenoid Valve "P3" UNF 9/16"-16-2B 19 25.5 2.6 18.8
T to P-T Block "T" UNF 9/16"-16-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
A Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
P, T Adapter PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
S8000115 2180-1216D11
A, P, T O-ring
(4D P11) (ID: 7.65, W: 1.78, 1B)

5-15-13
19. Remove bolts (1, Figure 18) (3 ea) and washers with
accelerator pedal valve (2) from floor plate.
• Tool: 5 mm ( )
1
2
Figure 18 WE1400792
20. Remove accelerator valve from floor plate.

Figure 19 WE1400793
INSTALLATION
WARNING
SERIOUS INJURY


5-15-14
COMPLETING WORK
FG019382
Figure 20
3. Slowly push accelerator pedal about five times without a

load to vent air from pilot lines.
Figure 21 WE1400795

5-15-15
TOOLS
Reference
Description Tool
Number
2 Plug 5 mm ( )
9 Plug 21 mm ( )
DISASSEMBLY
1. Remove bolts (49) (2 ea) and washers (54) (2 ea).
(Figure 22)
• Tool: 5 mm ( )
49, 54
WE1400790
Figure 22
2. Disassemble plug kit (ll) from the body (1).
FG007509
Figure 23
FG007510
Figure 24

5-15-16
3. Disassemble spool kit (l) from the body (1).
FG007511
Figure 25
4. Disassemble spring (8) from the body (1).
FG007512
Figure 26

5-15-17
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

5-15-18
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 bolts (49) (2 ea) and washers (54) (2 ea).

(Figure 34)
• Tool: 5 mm ( )
49, 54
WE1400790
Figure 34

5-15-19
5-15-20
1Accumulator
(Brake and Pilot)
Edition 1
DX210W-5 Accumulator (Brake and Pilot)

5-16-1
MEMO
Accumulator (Brake and Pilot) DX210W-5

5-16-2
Table of Contents
Accumulator
(Brake and Pilot)
General .........................................................5-16-6
Specifications .......................................................... 5-16-7

5-16-3
5-16-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-16-5
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

5-16-6
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)

5-16-7
5-16-8
Steering System
Edition 1
DX210W-5 Steering System

5-17-1
MEMO
Steering System DX210W-5

5-17-2
Table of Contents
Steering System
General .........................................................5-17-6

5-17-3
5-17-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-17-5
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
Steering Cylinder 9 9 Gear Pump

8
LS
L
R
T
P
Center Joint
Steering Valve
Main Pump
CF LS
EF
P
Tank Priority Valve
WE1500442
Figure 1

5-17-6
Hydraulic Circuit
Left Turn Right Turn 5

L 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
3 bar
2 CF EF
LS
P
WE1500443
6
Figure 2
Reference Reference
Number Number
1 Steering Valve 4 Gear Pump
2 Priority Valve 5 Front Axle
3 Center Joint 6 Main Pump

5-17-7
Theory of Operation
1. Neutral
L R
225 bar
CF
175 bar
LS
Priority Valve
LS Connected to Tank P T LS
T P
Neutral Position
WE1500444
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.

5-17-8
2. Right (left) turn
L R
225 bar
CF
175 bar
LS
Priority Valve
P P T LS
T
Steering Position
WE1500445
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.

5-17-9
5-17-10
Steering Valve
Edition 1
DX210W-5 Steering Valve

5-18-1
MEMO
Steering Valve DX210W-5

5-18-2
Table of Contents
Steering Valve
General .........................................................5-18-6
Specifications .......................................................... 5-18-8
Overview ................................................................. 5-18-9
Theory of Operation .............................................. 5-18-10
Gerotor Operation ................................................. 5-18-11
Relief Valve ........................................................... 5-18-11

5-18-3
5-18-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-18-5
GENERAL
General Description
This steering unit is a load sensing steering unit consisting of a
rotary valve, a changeover valve and two rotary meters.
The rotary meters are mechanically connected so the oil flow to
the steering cylinders is proportional to the angular movement of
the steering wheel.
When the pump pressure on the steering unit exceeds 7 bar
(7 kg/cm2, 101.5 psi) the oil flow from both rotary meters is
available for steering.
When the pump pressure is less than 4 bar (4 kg/cm2, 58 psi),
the oil flow for steering is available from only one of the rotary
meters.
This makes high manual steering pressure possible.
This steering unit gives the following facilities:
• Manual steering without emergency steering pump.
• Large displacement for working functions.
• Small displacement for driving on roads.
There is always a precise ratio between the metered oil quantity
and the angular movement of the steering wheel.
When the gear pump supplies sufficient oil flow to the steering
unit, operator can steer the vehicle with steering wheel.
However if the oil flow from the gear pump is too small, the
steering unit functions automatically in manual steering mode.
The steering system is sized so that manual steering only comes
into effect for short-lived manoeuvring of the vehicle in the event
of sudden gear pump pressure drop.
This is taken as the maximum steering wheel torque a driver of
average strength is able to exert.
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.

5-18-6
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)

Section (B)
Oil Control
WE1400590
Figure 1

5-18-7
Specifications
General
Type Load Sensing Non Reaction
Rated Displacement (EMR/NOR) 70 cc/rev (4.3 in3 /rev) / 320 cc/rev (20 in3 /rev)
Max. Pressure ON P - Port
175 ~ 185 bar (179 ~ 189 kg/cm², 2,538 ~ 2,683 psi)
(Relief Valve Setting)
Max. Pressure ON T - Port 20 bar (20 kg/cm², 290 psi)
Max. Pressure ON L, R - Port
225 ~ 245 bar (229 ~ 250 kg/cm², 3,263 ~ 3,553 psi)
(Shock Valve Setting)
Weight 6.3 kg (13.9 lb)
Operating Condition
Max. Pump Discharge Flow 22 L/min (5.8 U.S. gpm)
Max. Pump Pressure 200 bar (204 kg/cm², 2,900 psi)
Hydraulic Oil ISO VG 46 WR or SIMILAR
Hydraulic Oil Temperature -20 ~ 90°C (-4 ~ 194°F)

5-18-8
Overview
Spline
LS
L R
T P
WE1400591
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
Port and Hydraulic Circuit L R

225 bar
Port Name Size
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
Figure 3 WE1500446

5-18-9
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.

5-18-10
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

5-18-11
5-18-12
1Priority Valve
Edition 1
DX210W-5 Priority Valve

5-19-1
MEMO
Priority Valve DX210W-5

5-19-2
Table of Contents
Priority Valve
General .........................................................5-19-6
Overview ................................................................. 5-19-6
Removal .......................................................5-19-8
Installation ..................................................5-19-12
Completing Work ........................................5-19-13

5-19-3
5-19-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.

5-19-5
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

5-19-6
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

5-19-7
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1400569
Figure 4

5-19-8
I
(Figure 5)
LOCK
WARNING OFF OFF
ON
ON
5. Operate the joystick levers, pedals and steering wheel

several times to release the remaining pressure in the
hydraulic piping.
switch.
WE1400464
Figure 6

(Figure 7)
OFF
ON
Figure 7 WE1500101

5-19-9
3
5 8
1 2
7 6
4
EX1401809
Figure 8
WARNING
doing any work.
Figure 9 WE1500550
cover (2) on bottom of main frame. 2
• Tool: 19 mm ( )
1
WE1500119

5-19-10
14. Remove hoses and adapters from priority valve.
EF
for reassembling. P
After disconnecting hoses from priority valve,
plug them to prevent dirt or dust from entering.
CF
priority valve.
LS
WE1500120
Figure 11

Port Name
P from Steering Pump UNF 13/16"-16-2B 24 55.9 5.7 41.2
EF to Oil Cooler Pipe UNF 13/16"-16-2B 24 55.9 5.7 41.2
CF to Steering Valve "P" UNF 13/16"-16-2B 24 55.9 5.7 41.2
LS from Steering Valve "LS" UNF 9/16"-18-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
P, EF, CF Adapter PF 1/2" UNF 13/16"-16 27 83.8 8.6 61.8
LS Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
S8000185
P O-ring
(4D P18)
S8000185 S8030081
EF, CF O-ring
(4D P18) (1B F-08)
S8000115 2180-1216D11
LS O-ring
(4D P11) (ID:7.65, W:1.78, 1B)
15. Remove bolt (1, Figure 12) and washer with priority valve
(2) from bracket.
1
2
• Tool: 13 mm ( )
Figure 12 WE1401057

5-19-11
16. Remove priority valve from bracket.
WE1400412
Figure 13
INSTALLATION
WARNING
SERIOUS INJURY


5-19-12
COMPLETING WORK
FG019382
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.
WE1400714
Figure 15

5-19-13
5-19-14
1Dozer Joystick Valve
Edition 1
DX210W-5 Dozer Joystick Valve

5-20-1
MEMO
Dozer Joystick Valve DX210W-5

5-20-2
Table of Contents
Dozer Joystick Valve

General .........................................................5-20-5
Specifications .......................................................... 5-20-5
Overview ................................................................. 5-20-6
Parts List ................................................................. 5-20-8
Tools ...........................................................5-20-11
Removal .....................................................5-20-12
Installation ..................................................5-20-16
Completing work .........................................5-20-17
Disassembly ...............................................5-20-18
Reassembly ................................................5-20-21

5-20-3
5-20-4
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
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

5-20-5
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

5-20-6
Hydraulic Circuit
T P
1 2
FG007451
Figure 3

5-20-7
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

5-20-8
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

5-20-9
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

5-20-10
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 ( )

5-20-11
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

WE1401483
Figure 8

5-20-12
I
(Figure 9)
LOCK
WARNING OFF OFF
ON
ON
5. Operate the joystick levers, dozer lever and pedals several

times to release the remaining pressure in the hydraulic
piping.
O
8. Apply the service brake with full stroke several time to
I
9. Turn key to "O" (OFF) position and remove from starter
switch.
Figure 10 WE1400464

(Figure 11)
OFF
ON
Figure 11 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 12

5-20-13
WARNING
doing any work.
Figure 13 WE1500550
13. Remove bolts (3 ea) and washers (3 ea) and remove arm
rest from bracket.
• Tool: 13 mm ( )
Figure 14 Stand LH EX1403101
14. Remove screw with arm rest cover.

Figure 15 Stand LH EX1403102
15. Remove socket bolt (1, Figure 16) with grip (2).
2
16. Remove screw (3) with cover (4) from stand upper cover,
and disconnect the connector of harness which connect
with switches. 3
• Tool: 4 mm ( ), phillips screwdriver
1
4
WE1400628
Figure 16 Stand LH

5-20-14
17. Remove bolts and washers (1, Figure 17) (2 ea), separate
dozer lever (2) from stand bracket.
• Tool: 10 mm ( )
Figure 17 EX1403104
18. Remove hoses and adapters from dozer valve.

T
for reassembling.
After disconnecting hoses from dozer valve, plug
them to prevent dirt or dust from entering.
P
2
1
WE1401058
Figure 18

Port Name
1 to Joint Plate Ass'y "B4" UNF 9/16"-16-2B 19 25.5 2.6 18.8
2 to Joint Plate Ass'y "A4" UNF 9/16"-16-2B 19 25.5 2.6 18.8
• Fitting
Size Torque
Port Name
1, P, T Adapter PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
2 Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
S8000115 2180-1216D11
1, 2, P, T O-ring
(4D P11) (ID:7.65, W:1.78, 1B)

5-20-15
19. Remove dozer joystick valve from control stand.
EX1403106
Figure 19
INSTALLATION
WARNING
SERIOUS INJURY

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

5-20-16
COMPLETING WORK
FG019382
Figure 20
3. Slowly push and pull dozer lever as shown in Figure 21

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 21 EX1403107

5-20-17
DISASSEMBLY
1. Disassemble boot(22) and bushing(23) from the body(1).
Figure 22
2. Disassemble guide(16) and pin(17) from the cover(14).
FG003783
Figure 23
3. Disassemble cover(14) from the body(1).
FG003786-1
Figure 24
Figure 25

5-20-18
Figure 26
4. Disassemble plug kit (II) from the body (1).
FG003787
Figure 27
5. Disassemble spool kit (I) from the body (1).
FG003788
Figure 28
6. Disassemble spring (4) from the body (1).
FG003789
Figure 29

5-20-19
7. Disassemble plug (2) from the body (1).
Figure 30
Figure 31

5-20-20
REASSEMBLY
1. Assemble plug (2) in the body (1).
Figure 32
Figure 33
2. Assemble spring (4) in the body (1).
FG003789
Figure 34
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 35

5-20-21
4. Assemble spool kit (I) in the body (1).
FG003788
Figure 36
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 37
6. Assemble plug kit (II) in the body (1).
FG003787
Figure 38

5-20-22
7. Assemble cover(14) in the body(1) with wrench bolt.
Figure 39
Figure 40
8. Assemble wrench bolt(15) in the body(1) with torque

wrench.
FG003786-1
Figure 41
9. Assemble socket bolt(18) and nut(19) in the guide(16).
FG007458
Figure 42

5-20-23
10. Assemble guide(16) and lever(20) with spring pin(21).
FG003794
Figure 43
FG003794-1
Figure 44
11. Assemble guide(16) in the cover with pin(17).
FG003783
Figure 45
12. Adjust the clearance of lever(20) with wrench and spanner.
FG003795
Figure 46

5-20-24
13. Assemble boot(22) and busshing(23) in the body(1).
Figure 47
FG003781-1
Figure 48

5-20-25
5-20-26
1SolenoidValve
(4 Functions)
Edition 1
DX210W-5 Solenoid Valve (4 Functions)

5-21-1
MEMO
Solenoid Valve (4 Functions) DX210W-5

5-21-2
Table of Contents
Solenoid Valve 
(4 Functions)
General .........................................................5-21-5
Specification ............................................................ 5-21-5
Overview ................................................................. 5-21-6
Parts List ................................................................. 5-21-8
Tools and Torque .......................................5-21-11
Cautions for Disassembly and Reassembly..5-21-12

5-21-3
5-21-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This 4-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)
4. Supplies presssure to breaker (shear) operation.
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

5-21-5
Overview
C5
C4
C3
C2
C6
PB
HO
P3
CT
S
PS P2
P
IC
C7
CH
T
SD
WE1401104
Figure 1
Reference Reference
Number Number
C2 Ram Lock C4 Pilot Cut-off
C3 Inching Mode C5 Breaker (Shear)

5-21-6
SD CH IC PB PS HO
T
C7
C6
C1 C2 C3 C4 C5
P1
P2 P3 GTS
WE1401105
Figure 2
Port Name Size

P1 Pilot Filter
T Drain PF 1/2
PS Pilot Pressure
PB Accumulator
PF 3/8
P2 Transmission Control Valve
CH Ram Lock
IC Inching Mode (Low Travel)
PF 1/4
GTS Transmission Pressure Warning
HO Pilot Supply to Breaker (Shear)

5-21-7
Parts List
C5
C4
C3
C2
C5
C4
C3
C2
C6
PB
HO
P3
CT
S
1
PS P2
P
IC
C7
3
CH
T
SD
3
Figure 3
WE1401106
Reference Reference
Number Number
1 Body 3 Check Valve
2 Spool, Solenoid 4 Coil 24 V

5-21-8
Theory of Operation
Functions of 4 Solenoid Valve

This solenoid valve has functions as below:
1. Performs a ram lock.
2. Controls driving speed.
3. Cuts off pilot pressure.
4. Supplies pressure to breaker (shear) operation.
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
C2 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).
C3 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
C4 Cuts off pilot pressure. pump to the solenoid valve that supplies pilot pressure
and the remote control valve, to drive each device.
Used to supply pilot pressure to the option spool of main
C5 Operation of breaker.
control valve that supplies pressure to the breaker (shear).
Detailed Function and Application Descriptions by Solenoid Valve

1. C2 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 (C2) 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 (C2) 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. C3 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.

5-21-9
3. C4 cuts off pilot pressure.
(C4) transmits the pressure and oil supplied from the pilot
pump to solenoid valve that supplies pilot pressure 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.
4. C5 operation of breaker (Shear)
The (C5) 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.

5-21-10
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
C5
C4
C3
C2
C6
PB
HO
P3
CT
1
S
PS P2
P
IC
C7
CH
3 T
SD
Figure 4 3
WE1401107
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
3 Check Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket

5-21-11
AND REASSEMBLY
substances before disassembly and re-assembly.
specified in table of page 5-21-11 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.

5-21-12
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: 27.6  @ 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 (C4) 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, HO) 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, HO 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)

5-21-13
5-21-14
1SolenoidValve
(4 Functions)
Edition 1

5-22-1
MEMO

5-22-2
Table of Contents
Solenoid Valve 
(4 Functions)
General .........................................................5-22-5
Specification ............................................................ 5-22-5
Overview ................................................................. 5-22-6
Parts List ................................................................. 5-22-8
Tools and Torque .......................................5-22-11
Cautions for Disassembly and Reassembly..5-22-12

5-22-3
5-22-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
This 4-solenoid valve has functions as below.
1. Drives forward.
2. Drives backward.
3. Boosts main pressure.
4. 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

5-22-5
Overview
C4
C3
C2
C1
P3 TS
PL
P2 R
PB
R
PA
T P1
WE1401108
Figure 1
Reference Reference
Number Number
C1 Drive Forward C3 Main Pressure Boost
C2 Drive Backward C4 Cruise Control

5-22-6
P3
T
C1 C2 C3 C4 P2
P1
PAR PBR PL TS
WE1401109
Figure 2
Port Name Size

P1 Pilot Filter (Pilot Inlet)
PF 3/8
T Drain
P2 Swing Motor Parking Brake Release
P3 Pilot Pressure (Accelerator Valve)
PAR Drive Forward
PF 1/4
PBR Drive Backward
TS Cruise Control
PL Main Pressure Boost

5-22-7
Parts List
C4
C3
1
C2
C1
P3 TS
PL
P2
R
PB
R
PA
T P1
Figure 3 WE1401110
Reference Reference
Number Number
1 Body 3 Coil 24 V
2 Spool, Solenoid

5-22-8
Theory of Operation
Functions of 4 Solenoid Valve

This solenoid valve package has functions as below:
1. Boosts main pressure.
2. Drives forward.
3. Drives backward.
4. Controls cruise driving.
Application by Function of Each Solenoid Valve
No. Valve Function Application Remark

Driving forward or Used to drive vehicles forward or backward by
C1 and C2
backward operating the travel spool of the main control valve.
Used to increase set pressure of the main relief valve Pressure
C3 Main pressure boost
to boost excavation power temporarily. boost
C4 Cruise control Used to reduce driver fatigue in long-haul operations.
Detailed Functions and Application of Each Solenoid Valve

1. Control of driving forward or backward
The incoming pressure and oil flows from the pilot pump is
supplied via (C4) to the solenoid valve (C1 and C2) 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 (C1 and C2) 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 (C1) operates, while backward solenoid valve (C2)
operates when the vehicle runs backward.
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 350 bar
(357 kg/cm2, 5,076 psi) approx. to 370 bar (377 kg/cm2,
5,366 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 350 bar (357 kg/cm2,
5,076 psi) in the driving mode.

5-22-9
3. 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.

5-22-10
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
C3
C4
C2
C1
P3 TS
PL
P2 R
PB
R
PA
T P1
WE1401111
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
2-3 Solenoid Valve UNF7/8-14" 19.6 ±2.5 2 ±0.25 14.5 ±1.8
Hex. Socket

5-22-11
AND REASSEMBLY
substances before disassembly and re-assembly.
specified in table of page 5-22-11 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.

5-22-12
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: 26.7 @ 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 (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
PL, PBR, PAR, TS) and operate solenoid valve to checkpoints and
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

PL, PBR, PAR, TS PF1/4" O-ring boss Solenoid Valve "ON"
• Pilot pressure: 40 bar (40 kg/cm2, 580 psi)

5-22-13
5-22-14
Gear Pump
(Rotating)
Edition 1
DX210W-5 Gear Pump (Rotating)

5-23-1
MEMO
Gear Pump (Rotating) DX210W-5

5-23-2
Table of Contents
Gear Pump (Rotating)

General .........................................................5-23-5
Specification ............................................................ 5-23-5
Overview ................................................................. 5-23-6
Location................................................................... 5-23-6
Parts List ................................................................. 5-23-7
Single Gear Pump ........................................5-23-8
Disassembly ............................................................ 5-23-8
Reassembly........................................................... 5-23-10

5-23-3
5-23-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Direction of Rotation
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) 265 kg/cm2 (260 bar, 3,770 psi)
Max. Intermittent Pressure 286 kg/cm2 (280 bar, 4,061 psi)
Max. Peak Pressure 306 kg/cm2 (300 bar, 4,351 psi)
Weight 4.6 kg (10 lb)

5-23-5
Overview
Out
In
Figure 1 WE1500122

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
WE1500121
Figure 3

5-23-6
Parts List
13
1
11
5
17
4
16
14 10
9 15 3
8
18
12
WE1500123
Figure 4
Reference Reference
Number Number
1 Body 11 Seal
2 Cover; Front 12 Seal; Standard
3 Cover; Rear 13 Seal; Square Section
4 Plate; Thrust 14 Seal; Shaft
5 Shaft; Drive 15 Ring
6 Gear; Driven 16 Ring; Backup
7 Bolt; Socket 17 Key
8 Nut 18 Pin; Dowel
9 Washer * Seal Kit
10 Washer, Spring
*: 11, 12, 13, 14, 16

5-23-7
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

5-23-8
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

5-23-9
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

5-23-10
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

5-23-11
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

5-23-12
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

5-23-13
5-23-14
1One Spool Valve
(Rotating)
Edition 1
DX210W-5 One Spool Valve (Rotating)

5-24-1
MEMO
One Spool Valve (Rotating) DX210W-5

5-24-2
Table of Contents
One Spool Valve (Rotating)

General .........................................................5-24-5
Specification ............................................................ 5-24-5
Overview ................................................................. 5-24-6
Disassembly and Assembly..........................5-24-9
General Cautions .................................................... 5-24-9
Replacement of Spool ........................................... 5-24-10
Replacement of Main Relief Valve ........................ 5-24-12
Replacement of Overload Relief Valve ................. 5-24-13
Replacement of Sub-Block.................................... 5-24-15

5-24-3
MEMO

5-24-4
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)

5-24-5
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

5-24-6
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

5-24-7
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

5-24-8
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.

5-24-9
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

5-24-10
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

5-24-11
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

5-24-12
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.

5-24-13
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

5-24-14
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

5-24-15
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

5-24-16
1Lower Structure and
Chassis
Swing Bearing
Edition 1
DX210W-5 Swing Bearing

6-1-1
MEMO
Swing Bearing DX210W-5

6-1-2
Table of Contents
Swing Bearing
General ...........................................................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 WE1401490
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
DX210W-5 Front Axle

6-2-1
MEMO
Front Axle DX210W-5

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
DX210W-5 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

6-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Type Fully Floating Planetary Drive
Overall Reduction Ratio 16 : 1
Differential Oil Volume 9.6 L (2.5 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 17,000 kg (37,478 lb)
Axle Loading
Working 41,000 kg (90,389 lb)
Rated Pressure 175 bar (178 kg/cm2, 2,538 psi)
Steering
Relief Pressure 225 bar (229 kg/cm2, 3,263 psi)
DX210W-5 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

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.
DX210W-5 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 9.6 L (2.5 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

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).
DX210W-5 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.

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
DX210W-5 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

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
DX210W-5 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

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!
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 Front Axle

6-2-25
Input
1. Legend to Figure 60.
Reference
Description
Number
1 Input Pinion
2 Hex. Nut
3 Washer
4 Input Flange
5 Screen Sheet
6 Seal Ring
7 Taper Roller Bearing
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

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
DX210W-5 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

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
DX210W-5 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

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.
DX210W-5 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).

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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).

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
DX210W-5 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

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
DX210W-5 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).

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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.
DX210W-5 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.

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
DX210W-5 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.

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
DX210W-5 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

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
DX210W-5 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.

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.
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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.

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
DX210W-5 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

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
DX210W-5 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)

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)
DX210W-5 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.

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
DX210W-5 Front Axle

6-2-71
6-2-72
Rear Axle
Edition 1
DX210W-5 Rear Axle

6-3-1
MEMO
Rear Axle DX210W-5

6-3-2
Table of Contents
Rear Axle
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
DX210W-5 Rear Axle

6-3-3
6-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
Specification
Type Fully Floating Planetary Drive
Overall Reduction Ratio 16 : 1
Oil Volume 12 L (3.1 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)
DX210W-5 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

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.
DX210W-5 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 12 L (3.1 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

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
DX210W-5 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.

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.
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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.
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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

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
DX210W-5 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.

6-3-40
1Center Joint
Edition 1
DX210W-5 Center Joint

6-4-1
MEMO
Center Joint DX210W-5

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 ....................................................6-4-17
Completing Work ..........................................6-4-17
Disassembly .................................................6-4-18
Reassembly ..................................................6-4-21

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
18 15
1
2
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 all the attachments to ground. (Figure 3)
3. Stop engine.
WE1401484
Figure 3

6-4-8
(Figure 4) I
LOCK
WARNING OFF OFF
ON
ON
have one person in the cabin at all times. Never leave EX1500510
Figure 4

11. Turn key to "O" (OFF) position and remove from starter switch. I
WE1400464
Figure 5
13. Turn battery disconnect switch to "OFF" position. (Figure 6)

OFF
ON
Figure 6 WE1500101

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
(0.45 bar) opens, and the air is discharged to the Figure 8 WE1500550
atmosphere from the top of the hydraulic oil tank.
15. Remove bolts (1, Figure 9) (16 ea) from propeller shaft.
1
• Tool: 14 mm ( )
2
16. Remove bolts and washers (2) (6 ea) with center propeller 3
shaft includes bracket (3).
• Tool: 24 mm ( )
1
• Center shaft weight with bracket: about 45 kg (99.2 lb)
WE1400648
Figure 9 Bottom of Chassis Frame
17. Loosen 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
18. Remove hoses and adapters (Figure 11) from center joint.
Disconnect the hoses from the bottom to top of center joint.
FR 2
RE
ON AR 4
T
3
5
12 6
10 7
8
11
9
15
1
14
13
WE1500582
Figure 11 Hub of Center Joint
• Hoses and plugs parts

Port Name
1 from Travel Motor "T2" (Drain) UNF 13/16"-16-2B 24 55.9 5.7 41.2
2 to Travel Motor "X1/G" UNF 9/16"-16-2B 19 25.5 2.6 18.8
3 to Chocking Valve "Pi" UNF 9/16"-16-2B 19 25.5 2.6 18.8
4 to Transmission (High) "B" UNF 11/16"-16-2B 22 38.2 3.9 28.2
5 to Transmission (Low) "K" UNF 11/16"-16-2B 22 38.2 3.9 28.2
6 to Front Axle Hub UNF 11/16"-16-2B 22 38.2 3.9 28.2
7 to Rear Axle Hub UNF 11/16"-16-2B 22 38.2 3.9 28.2
8 to Steer Cylinder "Right" UNF 11/16"-16-2B 21 38.2 3.9 28.2
9 to Steer Cylinder "Left" UNF 11/16"-16-2B 21 38.2 3.9 28.2
to Dozer Cylinder "Rod" UNF 13/16"-16-2B 24 55.9 5.7 41.2
10
to Outrigger Cylinder "Rod" UNF 13/16"-16-2B 24 55.9 5.7 41.2
11 to Solenoid Valve (for FR/RE) "A" UNF 13/16"-16-2B 24 55.9 5.7 41.2
to Chocking Valve "Y" (Make-up) UNF 9/16"-16-2B 19 25.5 2.6 18.8
12
to Travel Motor "S" (Make-up) UNF 1 7/16"-12-2B 41 169.5 17.3 125.1
13 to Travel Motor "B" SAE 1", D25 10 97.0 9.9 71.6
14 to Travel Motor "A" SAE 1", D25 10 97.0 9.9 71.6
15 from Solenoid Valve (for FR/RE) "T" UNF 9/16"-16-2B 19 25.5 2.6 18.8

6-4-11
• Fitting
Size Torque
Port Name
1 Elbow PF 1/2" UNF 13/16"-16 27 83.8 8.6 61.8
2, 3 Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
4, 5 Elbow PF 3/8" UNF 11/16"-16 22 44.1 4.5 32.5
6, 7 Adapter PF 3/8" UNF 11/16"-16 22 44.1 4.5 32.5
8, 9 Adapter PF 1/2" UNF 11/16"-16 27 83.8 8.6 61.8
Adapter PF 1/2" UNF 13/16"-16 27 83.8 8.6 61.8
10
Tee UNF 13/16"-16 UNF 13/16"-16 24 55.9 5.7 41.2
11 Adapter PF 1/2" UNF 13/16"-16 27 83.8 8.6 61.8
Tee PF 3/4" PF 1/4", UNF 1 7/16"-12 32 158.8 16.2 117.1
12
Adapter PF 1/4" UNF 9/16"-18 19 39.2 4 28.9
15 Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
1 O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
2, 3 O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)
4, 5, 6, 7 O-ring S8000145 (4D P14) S8030061 (1B F-06)
8, 9 O-ring S8000185 (4D P18) S8030061 (1B F-06)
10, 11 O-ring S8000185 (4D P18) S8030081 (1B F-08)
S8030165 (4D F-16),
12 O-ring S8000235 (4D P22.4) S8000115 (4D P11),
2180-1216D11
DS2856003
13, 14 Ring Seal
(1", ID: 33.2, OD: 40.2, 1B)
2180-1216D11
15 O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)

6-4-12
WE1500583
Figure 12
20. Remove bolts (1, Figure 13) (2 ea) with plate (2).
• Tool: 24 mm ( )
Figure 13 WE1500584

6-4-13
21. Remove hoses and adapters (Figure 14) from center joint.
Disconnect the hoses from the bottom to top of center joint.
Rear Front
11
6
15
3
12
1
8
10
4
14 7 13
5 2
9
Figure 14 Spindle of Center Joint WE1500585
• Hoses and plugs parts

Port Name
1 Drain (to Swing Device "DB") UNF 13/16"-16-2B 24 55.9 5.7 41.2
2 from Solenoid Valve (for Lower) "IC" UNF 9/16"-16-2B 19 25.5 2.6 18.8
3 from Solenoid Valve (for Lower) "CH" UNF 9/16"-16-2B 19 25.5 2.6 18.8
4 from Solenoid Valve (for TM) "B" UNF 11/16"-16-2B 22 38.2 3.9 28.2
5 from Solenoid Valve (for TM) "K" UNF 11/16"-16-2B 22 38.2 3.9 28.2
6 from Shuttle Valve "A2" (Brake Pedal) UNF 11/16"-16-2B 22 38.2 3.9 28.2
7 from Shuttle Valve "A1" (Brake Pedal) UNF 11/16"-16-2B 22 38.2 3.9 28.2
8 from Steering Valve "R" UNF 13/16"-16-2B 24 55.9 5.7 41.2
9 from Steering Valve "L" UNF 13/16"-16-2B 24 55.9 5.7 41.2
10 from Control Valve "A4" UNF 1 3/16"-16-2B 36 124.5 12.7 91.8
11 from Control Valve "B4" UNF 1 3/16"-16-2B 36 124.5 12.7 91.8
Connect with Swing Device "C" UNF 1 7/16"-12-2B 41 169.5 17.3 125.1
12
from Control Valve "S" UNF 1 7/16"-12-2B 41 169.5 17.3 125.1
13 from Control Valve "A3" SAE 1", D25 10 97.0 9.9 71.6
14 from Control Valve "B3" SAE 1", D25 10 97.0 9.9 71.6
15 to Oil Tank UNF 9/16"-16-2B 19 25.5 2.6 18.8

6-4-14
• Fitting
Size Torque
Port Name
1 Adapter PF 1/2" UNF 13/16"-16 27 84.3 8.6 62.2
2 Adapter PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
3 Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
4 Elbow PF 3/8" UNF 11/16"-16 22 44.1 4.5 32.5
5, 6, 7 Adapter PF 3/8" UNF 11/16"-16 22 44.1 4.5 32.5
8 Elbow PF 1/2" UNF 13/16"-16 27 84.3 8.6 62.2
9 Adapter PF 1/2" UNF 13/16"-16 27 84.3 8.6 62.2
10, 11 Adapter PF 1/2" UNF 1 3/16"-12 36 84.3 8.6 62.2
Adapter PF 3/4" UNF 1 7/16"-12 41 158.8 16.2 117.1
12
Tee UNF 1 7/16"-12 UNF 1 7/16"-12 41 169.5 17.3 125.1
15 Elbow PF 1/4" UNF 9/16"-18 19 35.3 3.6 26.0
1 O-ring S8000185 (4D P18) S8030081 (1B F-08)
2180-1216D11
2, 3 O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)
4, 5, 6, 7 O-ring S8000145 (4D P14) S8030061 (1B F-06)
8, 9 O-ring S8000185 (4D P18) S8030081 (1B F-08)
10, 11 O-ring S8000185 (4D P18) S8030125 (4D F-12)
12 O-ring S8000235 (4D P22.4) S8030165 (4D F-16)
DS2856003
13, 14 Ring Seal
(1", ID: 33.2, OD: 40.2, 1B)
2180-1216D11
15 O-ring S8000115 (4D P11)
(ID: 7.65, W: 1.78, 1B)
22. Remove nuts (4 ea) from chassis frame (Figure 15).
WE1400405
Figure 15

6-4-15
23. Install the bolts (M12 x 1.75 DP 15, 2 ea) to center joint
(13, 14 port), and tie the rope to the bolts to lift it.
24. Remove center joint mounting bolts (1, Figure 16) (4 ea)
from chassis frame.
Figure 16 WE1500586
25. Remove center joint from the frame slowly and carefully.
• Center joint weight: about 90 kg (198 lb)
IMPORTANT
connected to center joint.
WE1400654
Figure 17

6-4-16
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

6-4-17
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 18 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 19

6-4-18
3. Disassembling the retainer ring.
Insert an appropriate jig into the retainer ring holes, widen
the ring and remove it.
FG003769
Figure 20
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 21
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 22
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 23

6-4-19
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 24
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 25

6-4-20
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.

6-4-21
6-4-22
1Travel Motor
Edition 1
DX210W-5 Travel Motor

6-5-1
MEMO
Travel Motor DX210W-5

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 ....................................................6-5-37

6-5-3
Completing Work ..........................................6-5-37
Section View .................................................6-5-38
General Repair Guidelines ...........................6-5-39
Seal Kits and Sub-assemblies ......................6-5-40
Replace Seal Nut .................................................... 6-5-42
Disassembly .................................................6-5-43
Sealing the Drive Shaft............................................ 6-5-43
Seal of the Control Parts ......................................... 6-5-44
Seal of the Relief Valve/Counter-balance Valve ..... 6-5-47
Counterbalance Valve ........................................ 6-5-48
Brake Release Valve (Pos.4) ............................. 6-5-49
Shuttle Valve (Pos.3).......................................... 6-5-49
Disassembly 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 390 bar (397 kg/cm2, 5,656.0 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 253 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) 390 bar (397 kg/cm2, 5,656.0 psi)
271 rpm (3.2 km/h)
1st Speed (Inching)
(X1: 30 bar over, Vg max.: Swivel Angle Max.)
2nd Speed (Low-speed) 699 rpm (8.3 km/h) (X1: 0 bar)
Speed
3rd Speed (High-speed) 3,402 rpm (33.9 km/h) (X1: 0 bar)
• Inching, 1 Speed Traveling - 1 Speed (Low) Solenoid Valve Operation
• 2 Speed Traveling - 2 Speed (High) Solenoid Valve Operation

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)
• 0 bar (214 kg/cm , 3,046 psi)
Setting Pressure: 210 -+30 2
210
64 85 q (cc)
WE1400284
Figure 30

6-5-31
REMOVAL
WARNING
immediately.
WARNING
workplace.
IMPORTANT
disposal.

3. Stop engine.
WE1401484
Figure 31

6-5-32
(Figure 32) I
WARNING
LOCK
OFF OFF
ON
ON

WE1400464
Figure 33
13. Turn battery disconnect switch to "OFF" position. (Figure

34)
OFF
ON
Figure 34 WE1500101

3
5 8
1 2
7 6
4
EX1401809
Figure 35

6-5-33
WARNING
doing any work.
Pulling the air breather cap upward, the check valve
WE1500550
(0.45 bar) opens, and the air is discharged to the Figure 36
atmosphere from the top of the hydraulic oil tank.
15. Remove nuts (1, Figure 37) (16 ea) with rear propeller
shaft (2).
1
• Tool: 14 mm ( ) 1

• Rear propeller shaft weight: about 18 kg (39.7 lb)
WE1500568
16. Remove hoses and adapters (Figure 38) from travel motor.
Disconnect the hoses from the bottom to top of travel motor.
X1 S B
A
T2 WE1500569
X2
Figure 38

6-5-34

Port Name
A from Center Joint "14" SAE 1 1/4", D30 12 176.5 18 130.2
B from Center Joint "13" SAE 1 1/4", D30 12 176.5 18 130.2
from Center Joint "12"
S UNF 1 7/16"-12-2B 41 169.5 17.3 125.1
(make-up)
X1 from Center Joint "2" UNF 9/16"-16-2B 19 25.5 2.6 18.8
X2 from Transmission UNF 9/16"-16-2B 19 25.5 2.6 18.8
G from Center Joint "2" UNF 9/16"-18-2B 19 25.5 2.6 18.8
to Center Joint "1"
T2 UNF 13/16"-16-2B 24 55.9 5.7 41.2
(Drain)
• Fitting
Size Torque
Port Name
S Adapter M27 x 2.0 UNF 1 7/16"-12 41 90.2 9.2 66.5
X1 Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
X2
Elbow UNF 9/16"-18 UNF 9/16"-18 17 25.5 2.6 18.8
G Adapter M14 x 1.5 UNF 9/16"-18 19 30.4 3.1 22.4
T2 Adapter M26 x 1.5 UNF 13/16"-16 30 70.0 7.1 51.6
DS2856004
A, B Ring Seal
(1 1/4", ID:38, OD:45, 1B)
S O-ring S8030165 (4D F-16)
DS2851078 2180-1216D11
X2 O-ring
(ID:11.3, W:2.2, 1B) (ID:7.65, W:1.78, 1B)
T2 O-ring S8030081 (1B F-08)
17. Support travel motor using like or similar picture.

• Travel motor weight: about 86 kg (190 lb)
NOTE: When support it, be careful do not to damage
the relief valve on travel motor.
WE1500570
Figure 39

6-5-35
18. Remove bolts (1, Figure 40) (4 ea), and separate travel
motor (2) from transmission (3).
• Tool: 14 mm ( )
2 3
1
WE1500571
Figure 40
19. Remove travel motor slowly and carefully.

• Travel motor weight: about 86 kg (190 lb)
WE1500572
Figure 41

6-5-36
INSTALLATION
WARNING
SERIOUS INJURY
NOTE: When mounting travel motor to transmission, intall O-

ring (Part No.: 2.180-00443) 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.
WE1500573
Figure 42
COMPLETING WORK

6-5-37
SECTION VIEW
X2
U MB X1 M2 M3
G ext
MA G T
U
M2
M3
MB MA
G
X1
WE1400306
Figure 43

6-5-38
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

6-5-39
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

6-5-40
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

6-5-41
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

6-5-42
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

6-5-43
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

6-5-44
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

6-5-45
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

6-5-46
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

6-5-47
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
Disassembly 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
DX210W-5 Driveshaft
6-6-1
MEMO
Driveshaft DX210W-5
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) ........................6-6-10
Installation (Center Driveshaft) .....................6-6-12
Removal (Rear Driveshaft) ...........................6-6-13
Installation (Rear Driveshaft) ........................6-6-15
DX210W-5 Driveshaft
6-6-3
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
DX210W-5 Driveshaft
6-6-5
Overview
Chassis Frame
1 2 3
Front Axle Rear Axle
Figure 1 Transmission
WE1500447
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
6-6-6
REMOVAL (FRONT DRIVESHAFT)
3. Stop engine.
WE1401484
Figure 4

(Figure 5) I
WARNING
LOCK
OFF OFF
ON
ON

WE1400464
Figure 6
13. Turn battery disconnect switch to "OFF" position. (Figure 7)

OFF
ON
WE1500101
Figure 7
DX210W-5 Driveshaft
6-6-7
3
5 8
1 2
7 6
4
Figure 8 EX1401809
14. Remove bolts and nuts (Figure 9) (8 ea) from front axle.
• Tool: 14 mm ( )
Front Axle
WE1400237
15. Remove bolts and nuts (Figure 10) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
WE1401101
16. Remove front propeller shaft slowly and carefully.

• Propeller shaft weight: about 18 kg (39.7 lb)
WE1500564
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).
WE1500565
DX210W-5 Driveshaft
6-6-9
REMOVAL (CENTER DRIVESHAFT)
3. Stop engine.
WE1401484
Figure 13

(Figure 14) I
WARNING
LOCK
OFF OFF
ON
ON

WE1400464
Figure 15

(Figure 16)
OFF
ON
WE1500101
Figure 16
6-6-10
3
5 8
1 2
7 6
4
Figure 17 EX1401809
14. Remove bolts and washers (1, Figure 18) (4 ea) with cover
(2) from bracket. FRONT
• Tool: 19 mm ( )
• Cover weight: 8 kg (17.6 lb)
WE1401153
15. Remove bolts and nuts (Figure 19) (16 ea) from propeller
shaft. FRONT
• Tool: 14 mm ( )
WE1401154
16. Remove bolts and washers (1, Figure 20) (4 ea) from
bracket. 1
FRONT
• Tool: 24 mm ( )
2
17. Remove center propeller shaft (2, Figure 20) slowly and
carefully.
WE1401155
DX210W-5 Driveshaft
6-6-11
INSTALLATION 
(CENTER DRIVESHAFT)
FRONT

normally.
When assembling, make the same direction of grease nipples
as shown in Figure 21.
After assembling, pour grease to grease nipple of bearing
WE1401156
(Figure 21). Figure 21 Bottom of Chassis Frame
6-6-12
REMOVAL (REAR DRIVESHAFT)
3. Stop engine.
WE1401484
Figure 22

(Figure 23) I
WARNING
LOCK
OFF OFF
ON
ON

WE1400464
Figure 24
13. Turn battery disconnect switch to "OFF" position. 

(Figure 25)
OFF
ON
WE1500101
Figure 25
DX210W-5 Driveshaft
6-6-13
3
5 8
1 2
7 6
4
Figure 26 EX1401809
14. Remove nuts (Figure 27) (8 ea) from transmission.
• Tool: 14 mm ( )
Transmission
Figure 27 WE1400245
15. Remove bolts and nuts (Figure 28) (8 ea) from center
propeller shaft.
• Tool: 14 mm ( )
WE1401157
16. Remove rear propeller shaft slowly and carefully.

WE1401158
6-6-14
INSTALLATION 
(REAR DRIVESHAFT)
normally.
After assembling, pour grease to grease nipple of universal joint
(Figure 30).
WE1401159
DX210W-5 Driveshaft
6-6-15
6-6-16
1Transmission
Edition 1
DX210W-5 Transmission
6-7-1
MEMO
Transmission DX210W-5
6-7-2
Table of Contents
Transmission
General ...........................................................6-7-5
Specification .............................................................. 6-7-6
Overview ................................................................... 6-7-6
Hydraulic Circuit ........................................................ 6-7-7
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.
• Tightening torque (M8/10.9)

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
DX210W-5 Boom and Arm

7-1-1
MEMO
Boom and Arm DX210W-5

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 G
WE1500448
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
WE1500449
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.
Never rotate the upper structure once the counterweight or
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 1,334 kg (2,941 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
DX210W-5 Bucket
7-2-1
MEMO
Bucket DX210W-5
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
DX210W-5 Bucket
7-2-3
Bucket DX210W-5
7-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
DX210W-5 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 DX210W-5
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
1
EX1404394
Figure 5
3. Remove the bucket pin (1, Figure 6).

• Bucket pin weight: about 20 kg (44 lb)
1
EX1404395
Figure 6
DX210W-5 Bucket
7-2-7
4. Separate the arm from the bucket and remove the O-ring
(1, Figure 7).
EX1404396
Figure 7
Installation
NOTE: Assemble double nut like Figure 9.
EX1404397
Figure 8
1 ~ 2 mm
EX1404398
Figure 9
Bucket DX210W-5
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.
DX210W-5 Bucket
7-2-9
Bucket DX210W-5
7-2-10
Cylinders
Edition 1
DX210W-5 Cylinders
7-3-1
MEMO
Cylinders DX210W-5
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
DX210W-5 Cylinders
7-3-3
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.
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 ø100 ø80
Stroke (mm) 1,240 1,450 1,060 1,045 748 1,538 1,060
Closed Length (mm) 1,805 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
DX210W-5 Cylinders
7-3-5
Parts List
The following parts list is for complete parts list information.
Boom Cylinder (LH)
32
28
30
31
28
29
36
26
1 35
27
34
24
23
A
A 33
32 24
28 17
22
21
22
31 19
18 B
19
20
16
14
25 13
15
7
6
5
8
3
9
10
B
11
4
12
WE1500450
Figure 2
7-3-6
Reference Reference
Number Number
1 Tube Assembly, Cylinder 20 Ring; Dust
2 Bush 21 O-ring
3 Rod Assembly, Cylinder 22 Ring; Backup
4 Bush 23 Nut, Piston
5 Cover, Rod 24 Screw; Set
6 DD-bush 25 Bolt; Socket
7 Ring; Retaining 26 Clamp, Pipe
8 Buffer Seal 27 Band, Pipe
9 U-packing 28 Washer; Spring
10 Ring; Backup 29 Bolt
11 Wiper; Dust 30 Pipe Assembly
12 Ring; Retaining 31 O-ring
13 O-ring 32 Bolt; Socket M10 x 1.5 x 40
14 Ring; Backup 33 Pipe Assembly
15 O-ring 34 Clamp, Pipe
16 Ring, Cushion 35 Washer; Spring
17 Piston 36 Bolt
18 Seal; Slipper * Seal Kit
19 Ring; Wear
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210W-5 Cylinders
7-3-7
Boom Cylinder (RH)
32
28
30
36
31
35 29
34
28 2
26
27
1
24
A 23
A
24
33
32
17
28 22
21
22
19
18 B
31 19
20
16
14
25 13
15
7
6
5
8
3
9
10
B
11 4
12
WE1500451
Figure 3
7-3-8
Reference Reference
Number Number
1 Tube Assembly, Cylinder 20 Ring; Dust
2 Bush 21 O-ring
4 Bush 23 Nut, Piston
7 Ring; Retaining 26 Clamp, Pipe
8 Buffer Seal 27 Band, Pipe
10 Ring; Backup 29 Bolt
11 Wiper; Dust 30 Pipe Assembly
12 Ring; Retaining 31 O-ring
13 O-ring 32 Bolt; Socket M10 x 1.5 x 40
16 Ring, Cushion 35 Washer; Spring
17 Piston 36 Bolt
18 Seal; Slipper * Seal Kit
19 Ring; Wear
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210W-5 Cylinders
7-3-9
Arm Cylinder
44
43
42
34 2
38
29
30
36
31
41 37 32
40 35
33
25
24
23
1 A
39
A 24
25
17
20
19
18
19
20
22
21 B
22
16
28 14
13
7 15
6
8
5
9
10
3
B 11
12
WE1500504
Figure 4
7-3-10
Reference Reference
Number Number
1 Tube Assembly, Cylinder 23 Nut, Piston
2 Bush 24 Ball, Steel
3 Rod, Cylinder 25 Screw, Set
4 Bush 28 Bolt; Socket
5 Cover, Rod 29 Valve; Check
6 DD-bush 30 Spring
7 Ring; Retaining 31 Support; Spring
8 Seal; Buffer 32 O-ring
9 U-packing 33 Plug
10 Ring, Backup 34 Band Assembly, Pipe
11 Wiper; Dust 35 Band, Pipe
12 Ring; Retaining 36 Washer; Spring
13 O-ring 37 Bolt; Hex
15 O-ring 39 O-ring
16 Ring; Cushion 40 Washer; Spring
17 Piston 41 Bolt; Socket
18 Seal; Slipper 42 Clamp, Pipe
19 Ring; Wear 43 Washer, Spring
20 Ring; Dust 44 Bolt
21 O-ring * Seal Kit; Arm
22 Ring; Backup
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210W-5 Cylinders
7-3-11
Bucket Cylinder
37
36
35
26
34
30
28 33
32 32
29
33
27 23 24
31
1
30
24
17
20
19
18
19
20
22
21
25 22
16
14
13
15
7
6
8 5
9
10
11
12
3
WE1500452
Figure 5
7-3-12
Reference Reference
Number Number
1 Tube Assembly 20 Ring; Dust
2 Bush 21 O-ring
4 Bushing, Carburizing 23 Nut, Piston
7 Ring; Retaining 26 Band Assembly, Pipe
8 Seal; Buffer 27 Band, Pipe
10 Ring; Backup 29 Bolt; Hex
11 Wiper; Dust 30 O-ring
12 Ring; Retaining 31 Pipe Assembly
13 O-ring 32 Bolt; Socket
14 Ring; Backup 33 Washer; Spring
15 O-ring 34 Pipe Assembly
16 Ring; Cushion 35 Clamp, Pipe
17 Piston 36 Washer, Spring
18 Seal; Slipper 37 Bolt
19 Ring; Wear * Seal Kit, Bucket
*: 8, 9, 10, 11, 13, 14, 15, 18, 19, 20, 21, 22
DX210W-5 Cylinders
7-3-13
Arti Boom Cylinder
33 29
33
32 28
31 32
31 27
26
30
29 2
28
26
24
22 23
23
24
16
18
17
18
5 19
21
20
25 21
14
13
15
7
6
8
9
10
11
12
WE1500453
Figure 6
7-3-14
Reference Reference
Number Number
1 Tube Assembly, Cylinder 18 Ring; Wear
2 Bushing 19 Dust Ring
3 Rod Assembly, Cylinder 20 O-ring
4 Bushing 21 Ring; Backup
5 Cover, Rod 22 Nut, Piston
6 Bushing, Du 23 Ball, Steel
7 Ring; Retaining 24 Screw, Set
8 Seal; Buffer 25 Bolt; Socket M20 x 2.5 x 65
9 Packing; U 26 O-ring
10 Backup Ring 27 Pipe Assembly
11 Wiper; Dust 28 Washer; Spring
12 Ring; Retaining 29 Bolt; Socket M10 x 1.5 x 40
13 O-ring 30 Pipe Assembly
14 Ring; Backup 31 Clamp, Pipe
15 O-ring 32 Washer; Spring
16 Piston 33 Bolt M12 x 1.75 x 55
17 Piston Seal * Seal Kit
*: 8, 9, 10, 11, 13, 14, 15, 17, 18, 19, 20, 21
DX210W-5 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 D2
4
(P: Pressure, = 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 (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 (D2)
4
Q2 = S x (D2-R2)
4
Q1 > Q2 FG001459
Figure 9
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
DX210W-5 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.
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)
DX210W-5 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)
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)
DX210W-5 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)
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)
DX210W-5 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)
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.)
DX210W-5 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
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
DX210W-5 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
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
DX210W-5 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
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
DX210W-5 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
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
DX210W-5 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
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.
DX210W-5 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.
7-3-36
1Hydraulic System
1Hydraulic
System
Edition 1
DX210W-5 Hydraulic System

8-1-1
MEMO
Hydraulic System DX210W-5

8-1-2
Table of Contents
Hydraulic System
General Description ........................................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
Safety Cutoff Valve Operation ......................8-1-10
Power Up Valve Operation ...........................8-1-11
Swing Brake Release Operation ..................8-1-12
Travel Forward and Backward Operation .....8-1-14
Steering Operation .......................................8-1-15
Boom Up Operation ......................................8-1-16
Boom Down Operation .................................8-1-18
Arm Dump Operation....................................8-1-20
Arm Crowd Operation ...................................8-1-22
Bucket Dump Operation ...............................8-1-24
Bucket Crowd Operation ..............................8-1-26
Combined Travel and Swing Operation........8-1-28

8-1-3
8-1-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
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 left side of the control valve. Output from the idle side
pump is transmitted to the right 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 left half of the hydraulic control valve, supplied by the
drive side pump in the pump, operates spools for dozer/
outrigger, boom, bucket and option 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 right half of the hydraulic control valve, fed by the idle
side pump in the pump, operates spools for arm, swing and
travel 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
OPT. PEDAL
MAIN CIRCUIT
OPT. PEDAL
63 (ARTI. BOOM) 17 DOZER ARM/SWING 15Dump BOOM/BUCKET 16 Down 62 (PE3C)
UP
2
DOWN
1 2
RH RETURN CIRCUIT
P1T_SH P1P_SH
26 (L) 2 (R)
1 3
Crowd
1
Dump
3
2
A3 1.5 bar
T P SUCTION CIRCUIT
PT_SH 1 2 4
Crowd
4
Up
1
LH 53
Pi_CV 1 T P 2
DOWN 1 P T 2
UP 4 P 2 1 T 3 1 P 3 2 T 4 1 T P 2
PROPORTIONAL
59 A
5 P1 T VALVE
C7
T PI_SH XAo2
(DN)
XBo2
(UP)
T-BLOCK A
T
3.5 bar
11
B(#57) A(#57)
P2 R3
2
BUCKET
P
TRAVEL
C1
DOZER
SD R1
BOOM
P3
13
SWING
ARM
PAR PBR 2x0.75 L

(#07) (#07) 30 bar
C2 CH
19 B4
1.1.14
A4 B3
1.1.13
A3 B1
1.1.11
A1 B2
1.1.10
A2 B6 A6 A5 B5 B7 A7
8
C3
1.1.15 1.1.12 1.1.6 1.1.2
T P1 GP ACC'A
IC PT 1.1.5 1.1.4 M2 PRESS. SENSOR P1(#67)
GTS
4 18
1.1.16
C6 1.1.7 C7 A2 490 Bar Rear
1.1.17
26 bar PB to P2(#20) T BLOCK T AB Axle

TRANS 0.75 L 1.1.8
M
10 bar 1.1.9 Y3 P A
MISSION C4 to P(#64) (Front)
PS PSA
PRESSURE 1.1.18 Vgmax X1 MODULATION VALVE C1
WARNING PI 66 ENGINE
DL06P
Vgmin
P3 P2 P1
Travel
C5
HO b4 a4 b3 a3
P11
P1 b1 AB a1 b2 SB a2 P2 P21 b6 a6 a5 b5BB b7 a7 GEAR 7
A7(#19) XBd XAd XAt XBt
(DN) (UP) (FWD) (REV)
XBa XAa XBs
(CR) (DU) (R)
XAs
(L)
XBo1 XAo1
XBk XAk XAb XBb (OPEN) (CLOSE)
PUMP
M3 TS M 6 C3
(CR) (DU) (DN) (UP) C6
C4 103 bar
X3 125 bar
Vgmax
Vgmin
T C3 Y(#20)
PL C4
A X1 P
B(HIGH)
REV 160 bar
P (Rear) C2 A3(#19)
K(LOW)
Y3 PBR C5
C2 PSD
FWD BRAKE
60 AI/SB
XAb(#20)
1
M
A1
to P1(#20) C1
PAR
B3(#19)
T SUPPLY
M1 PRESS. SENSOR T VALVE 65 bar
R2 S 490 Bar
to #65 P G1 ACC'B AC LOW
12 PRESSURE
WARNING
25 13 Front
2x0.75 L Axle
30 bar
0.5 bar
P
57 B7(#19) 27 29 14
SWING MOTOR SH
28
A B 24 BR1 P1
2(#62) LH-HI RH-HI 1(#62) 1.5 bar
(CLOSE) (OPEN) 4.6 bar T1
PG 10u
DB TANK
T BL1
CRUISE
from JOYSTICK(R) PPC

20 C 177u
RELEASE
BR2 P2
A1
30
380±5 bar
Shear Select operating 201 PA PB 4.6 bar T2

B1 265 bar
209 CRUISE
BL2
65±5 bar RELEASE BRAKE VALVE
b1 a1 AUTO RAM 80 bar
BUCKET XBa
23 Arm L2
XAa
A (RH) B (LH)
OPERATE
56 55 207
T2 T1 T2 T1 74 A2 Rear
Axle
Front
Axle
R.H A T 58 P XBs
B2
a2
XAs
74 P b2 Swing Left
Turn L
Right
R Turn
A3
a3 206 Lo : 350±5 bar
31 225+20
0 bar
L.H B3 CENTER
BB XAt Hi : 370±5 bar 3 3
1 1
1 1 3 3 1 1 3 3 1 3 1
JOINT
A T XBt
b3
Travel 1bar K 35 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
34
Y
PL(#07)
55 204
21
PC2 203 P1 from A1(#01) 70 71
ONE WAY BOOM
21 P0 GP
B(HIGH)
from C/V A7 L1
202 203 P2
from A2(#01)
K(LOW) 3
55 56 L.H 205 pi
5K
CHOCK
T A
Dozer/ 3bar T
AB
Outrigger
B A
52 52 XBd
b4
A4 PC1
XAd
S
G
X(IC)
C2 C2 a4 U T1 MB GEXT
R.H E E DOZER GP
B4 J B Pi BL 175+10
0 bar
GP
M (FWD)
XBb
b5 Boom a5 XAb
c(#69)
qmax 36 STEER
69 L3
33
S
9
380±5 bar
CYLINDER
B A A5 a5(#19) qmin Y BR
Pi1 Pi1 201 A
B5 P T LS
T T 208 CHOCK
MA (REV) 3 bar
V2 V2 T2 M3
LOCK VALVE M2 TRAVEL MOTOR
b6 a6
XBk XAk X2
Bucket GP (TU) 32 CF EF
380±5 bar
C XAb
A6
B6
201 REAR AXLE
BRAKE
FRONT AXLE
BRAKE
71
(#20)
C
T1 T2 P1
7-10 bar LS
b7 a7
XBo1 P
XAb 54 Option
XAo1
C
10
380±5 bar
(#19) A7 Ø0.5
0.5
QUICK COUPLER ROTATING A
201
B7
B6(#20) Ø0.5
0.5
C/V XBa ARM 67 P2 68 64
a A B T
61 V2 T Pil E
XBo2
b8 a8
XAo2
T 275 bar P BLOCK
from #66
Ø0.4 B P T Ø0.5
0.5
Arti Boom (gear pump)
73
380±5 bar
V2 T Pil E A8 A2 (#01)
A B
C2 201 P1 A P A
B8
Ø1.0 245 bar 78 bar
C2 T
65 T
72
51 LOCK VALVE from JOYSTICK(L) PPC
b 98 bar
ARTI. BOOM
22
WE1500454
Figure 1

8-1-8
Reference Reference
Number Number
1 Main Pump 36 Chocking Valve
2 Pilot Filter 51 Lock Valve (for Arti. Boom)
3 Chocking Cylinder 52 Lock Valve (for Boom)
4 Accumulator (for Pilot) Proportional Valve
53
(for Opt. Flow Control)
5 4-solenoid Valve
54 Slow Return Valve (for Arti. Boom)
6 Solenoid Valve (for TM)
55 Proportional Valve (for Opt.)
7 4-solenoid Valve
56 Stop Valve
8 Steering & Brake Pump
57 Proportional Valve (for PE3C)
9 Steering Unit
58 Breaker Filter
10 Priority Valve
59 1-solenoid Valve (for Opt.Pedal)
11 Brake Filter
1-solenoid Valve
12 Brake Supply Valve 60
(for Opt. Two Pump)
13 Accumulator (for Brake) 61 Arti. Boom Cylinder
14 Brake Pedal 62 Pedal Valve (for Opt)
15 Joystick Valve (L) 63 Pedal Valve (for Arti. Boom)
16 Joystick Valve (R) 64 Rotating Valve
17 Joystick Valve (Dozer) 65 Proportional Valve (for PERO)
18 Accelerator Pedal Valve 66 Rotating Pump
19 Shuttle Valve 67 Quick Coupler Valve
20 Main Control Valve 68 Quick Coupler
21 Boom Cylinder 69 Boom Floating Valve
22 Arm Cylinder 70 Dozer Cylinder
23 Bucket Cylinder 71 Outrigger Cylinder
24 Swing Device 72 2-solenoid Valve (for FR-OR.)
25 PT Block 73 1-solenoid Valve (for RE-DZ.)
26 Logic Valve 74 Switch Valve (for Clamshell)
27 Oil Cooler 201 Overload Relief Valve
28 Return Filter 202 Arm Summation Valve
29 Air Breather 203 Bypass Cut Valve
30 Hydraulic Tank 204 Boom Summation Valve
31 Center Joint 205 Travel Priority Spool
32 Travel Motor 206 Main Relief Valve
207 Arm Brake Valve
33 Transmission
208 Boom Holding Valve
34 Front Axle
209 Arm Holding Valve
35 Rear Axle

8-1-9
SAFETY CUTOFF VALVE OPERATION
Oil from the hydraulic tank (30) fills accumulator (4) first after passing through pilot pump and pilot filter (2) and is
supplied to the solenoid package valve (5).
If an electric signal is inputted to safety cutoff valve installed to the solenoid package valve (5), the oil sent to main
control valve (20), accelerator pedal valve (18) and joystick valve (15, 16) 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.
T
A
P
A3
1.5 bar
18
20
380±5 bar
A1
B1
201 2
209 R3
R1
b1 a1
Arm
L2
207
8
A2 M2 PRESS. SENSOR P1(#67)
B2 A2 490 Bar
b2 a2
Swing M
Y3
to P(#64) (Front)
A3 Vgmax
ENGINE Vgmin X1
B3 a3 206 Lo : 350±5 bar 66 DL06P
b3 BB Hi : 370±5 bar
1bar K GEAR
Travel PUMP
Y M3
203 204 P1
X3
PC2 Vgmax
P0 Vgmin
L1
202 P2 X1
203
205 (Rear)
pi Y3
Dozer/ 3bar
AB T
Outrigger S M
b4
A4
PC1
a4 1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
B4
Boom a5
b5
380±5 bar
L3
A5 201 Dump
ARM/SWING 15 BOOM/BUCKET 16 Down
B5
208 (L) 2 (R) 2
Crowd Dump
1 3 1 3
b6 a6 4 4
Bucket Crowd Up
380±5 bar
A6 4 P 2 1 T 3 1P 3 2 T 4
B6
201 P1 T
C7
P2
C1 SD
SD
b7 a7
P3
Option
380±5 bar
A7 CH
B7 201 C2 25
C3 IC
GTS
C6
b8 a8 PB 4
Arti Boom
380±5 bar
0.75 L
A8 PS 10 bar
B8 201 C4
0.5 bar
Safety Cut-off
29
C5 HO
28
5
10u
TANK
177u
30
WE1500189
Figure 2

8-1-10
POWER UP VALVE OPERATION
Pilot oil that passes through solenoid package valve (7) inside is supplied to main relief valve (Y) port of main
control valve (20) the following the signal of power up button of RH joystick (16).
Once the oil is supplied to (Y) port of main control valve (20), the setting pressure of main relief valve (206) is
changed from 350 to 370 bar, increasing power of actuator.
16
20
380±5 bar
A1 201
B1
209
b1 a1
Arm
L2
207
A2
B2 P3 P2 P1
b2 a2
Swing
TS
Lo : 350±5 bar A3 1.5 bar
A3 Hi : 370±5 bar
B3 a3 C4
206
b3 BB
Travel 1bar K C3
PL
Y
2
204 C2 PBR
203 P1 R3
PC2
P0 R1
C1 PAR
L1
P2 T
202 203 7
205
pi
8
Dozer/ 3bar
AB T M2 PRESS. SENSOR P1(#67)
Outrigger S 490 Bar
A2
b4 PC1
A4 a4 M
B4 Y3
to P(#64) (Front)
Vgmax
Boom a5 X1
b5 66 ENGINE Vgmin
DL06P
380±5 bar
L3
A5 201 GEAR
B5
208 PUMP
M3
P1 T X3
b6 a6
Vgmax
Bucket C7
380±5 bar
Vgmin
A6 P2
B6
201
C1 SD
SD X1
P3
Y3 (Rear)
a7 C2 CH
b7
M
Option
380±5 bar
A7
B7 201 GTS
C3 IC 1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
C6 PB 4
0.75 L
10 bar 0.5 bar
b8 a8 C4 PS
Arti Boom 29
380±5 bar
A8
B8 201 28
C5 HO
5
10u
TANK
177u
30
WE1500228
Figure 3

8-1-11
SWING BRAKE RELEASE OPERATION
Oil that passed through solenoid package valve (5) inside moves swing spool of main control valve (20) the
following the operation of joystick valve (15).
Following operation of the joystick valve (15), the oil is transferred to shuttle valve (19) (A2) or (B2) port. And the
oil is delivered to the port (SH) of swing device (24) through (Pl) port of shuttle valve (19).
Then oil is supplied to swing device's (24) (PG) port connected to solenoid valve (7) (P2) port and swing parking
brake is released.
ARM/SWING
15 Dump
(L) 2 (R)
1 3 1.5 bar
A3
5 P1 T
4 P 2 1 T 3
4
Crowd
C7
P2
P3
C1 SD 2
SWING
ARM
R3
CH
C2
19 B4 1.1.14
A4 B3 A3
1.1.13
B1
1.1.11
A1 B2
1.1.10
A2 B6 A6 A5 B5 B7 A7 R1
IC 1.1.15 1.1.12 1.1.6 1.1.2
GTS
C3
C6 4 PT 1.1.16
1.1.5 1.1.4
1.1.7
8
1.1.17 C7
PB 0.75 L 1.1.8
10 bar 1.1.9 M2 PRESS. SENSOR P1(#67)

C4 A2 490 Bar
Safety Cut-off
PS 1.1.18 to P2(#20)
PI M
Y3
C5 to P(#64) (Front)
HO
b4 a4 b3 a3 P11 P1 b1 AB a1 b2 SB a2 P2 P21 b6 a6 a5 b5BB b7 a7 Vgmax
66 ENGINE
DL06P
Vgmin X1
GEAR
PUMP
M3
X3
Vgmax
25 Vgmin
X1
Y3 (Rear)
M
20 1 A1
M1 PRESS. SENSOR
380±5 bar
A1 R2 S 490 Bar
B1 201
209
a1
b1 XAa
Arm L2
207
0.5 bar
A2
B2
a2 27 29
XAs
b2 Swing
A3
B3 a3
XAt
28 10u
TANK
b3 BB
1bar K 177u
Travel
Y Lo : 350±5 bar
30
206 Hi : 370±5 bar
203 204 P1
PC2
P0
L1
202 P2
203
from A2(#01)
205
pi
Dozer/ 3bar
AB Outrigger T SWING MOTOR SH
S
b4 PC1
A4 a4 24
B4
PG
Boom
b5 a5
380±5 bar
L3
A5 DB
B5 201
208
C
b6 a6 PA P3 P2 P1
PB
Bucket
7
380±5 bar
265 bar
A6
B6 201
TS
C4
b7 a7 A (RH) B (LH)
Option
380±5 bar
A7 C3 Y(#20)
B7 201 PL
REV
C2 A3(#19)
PBR
b8 a8 FWD
C1 B3(#19)
Arti Boom
380±5 bar
PAR
A8 T
B8 201
WE1500485
Figure 4

8-1-12
Pressure Relief & Swing Load Pressure Relief &
A2 B2
Input Pilot
a2 Pressure
b2
T T
Swing Right WE1500180
Figure 5

8-1-13
TRAVEL FORWARD AND BACKWARD OPERATION
When pressing the forward (backward) switch of right joystick, an electric signal is applied to the (C1 (C2))
solenoid of the solenoid valve (7) to switch the (C1 (C2)) solenoid spool.
And oil is transferred to shuttle valve (19), (A3) or (B3) port, so it is delivered to the port (a3 (b3)) of the main
control valve (20). 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
19 B4 1.1.14
A4 B3
1.1.13
A3 B1
1.1.11
A1 B2
1.1.10
A2 B6 A6 A5 B5 B7 A7
1.5 bar
1.1.15 1.1.12 1.1.6 1.1.2
PT 1.1.16
1.1.5 1.1.4
1.1.7 R3 Forward
1.1.17
C7
1.1.9
1.1.8 R1
2 Neutral
Backward
1.1.18
PI 8
M2 PRESS. SENSOR P1(#67)
b4 a4 b3 a3 P1 b1 AB a1 b2 SB a2 P2 a5 b5BB b7 a7
P11 P21 b6 a6 A2 490 Bar
to P2(#20)
M
Y3
to P(#64) (Front)
Vgmax
66 ENGINE Vgmin X1 Joystick RH
20 GEAR
DL06P
380±5 bar
A1 PUMP
201 P3 P2 P1
B1
209
M3 7
X3
TS
Vgmax
b1 a1 Vgmin
Arm C4
L2 X1
207
(Rear) C3 PL
Y3
A2
B2 M
A1 C2
b2
Swing
a2
1 M1 PRESS. SENSOR
490 Bar
PBR (REV)
R2 S
C1 PAR (FWD)
T
A3
a3 206 Lo : 350±5 bar
B3 Hi : 370±5 bar 0.5 bar
b3 BB
Travel 1bar K
27 29
Y
203 204 P1
PC2
P0 10u
L1
28 TANK
202 203 P2
177u
205
Dozer/ 3bar
pi 30
T
AB Outrigger S
b4 PC1
A4 a4
B4 31
3 3 1 1 3 3 1 1 3 3 1 3 1 CENTER
1 1
b5
Boom
a5 35 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
JOINT
34
380±5 bar
L3
A5
B5 201
208 70 71
GP
B(HIGH)
b6
Bucket
a6 K(LOW) 3
380±5 bar
5K
A6
B6
201 CHOCK
X(IC)
G
b7 a7 U T1 MB GEXT
DOZER J Pi BL GP
Option B
380±5 bar
GP
A7 M (FWD)
B7 201 qmax
S 36 STEER
CYLINDER
33 qmin Y BR
A
(REV) CHOCK
b8 a8 MA
T2 M3
Arti Boom M2
380±5 bar
TRAVEL MOTOR
A8 X2
B8 201 GP (TU) 32
REAR AXLE
BRAKE
FRONT AXLE
BRAKE
71
WE1500230
Figure 6

8-1-14
STEERING OPERATION
Hydraulic oil delivered from the gear pump (8), which is connected to the PTO (Power Take-Off) of the main pump
(1), is transferred to the port (P) of priority valve (10) which then delivers the oil to the port (CF).
Then, this oil is supplied to the port (P) of the steering unit (9) to build up pressure in the steering unit (9).
This hydraulic oil in the steering unit (9) 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 (31) to be delivered to the steering
cylinder of the front axle (34) in order to complete the steering operation.
If load is generated during the steering operation, the spool in the priority valve (10) is switched to open the port
(EF). Then, oil led into the steering unit (9) is returned to the tank to protect the steering system circuit. (Load
sensing function)
A3
R3
8
M2 PRESS. SENSOR
490 Bar
A2 Left Right
M Turn L R Turn
to P(#64) Y3 (Front) 225+20
0 bar
Vgmax
ENGINE X1
66 DL06P
Vgmin
GEAR
PUMP
M3
X3
Vgmax
Vgmin
X1
Y3 (Rear)
M
to P1(#20)
A1
1 M1 PRESS. SENSOR
490 Bar 175+10
0 bar
R2 S
0.5 bar
29 9
P T LS
28 10u
TANK CF EF
177u
30 7-10 bar LS
P
10
35 3 3 1 1 3 3 1 1 3 3 1 3 1 CENTER 34
31 8 8
1 1
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
70 71
GP
B(HIGH)
K(LOW) 3
5K
CHOCK
X(IC)
G
U T1 MB GEXT
DOZER J B Pi BL GP
GP
M (FWD)
qmax
S 36 STEER
CYLINDER
33 qmin Y BR
A
(REV) CHOCK
MA
T2 M3
M2 TRAVEL MOTOR
X2
GP (TU) 32
REAR AXLE
BRAKE
FRONT AXLE 71
BRAKE
Figure 7
WE1500486

8-1-15
BOOM UP OPERATION
17 DOZER
DOWN
ARM/SWING 15 Dump
BOOM/BUCKET 16 Down
1 2
(L) 2 (R) Crowd Dump
1.5 bar
1 3 1 3
2 4 4
UP 4 P 2 Crowd Up
1 P T 2 1 T 3 1 P 3 2 T 4
2
A3
BUCKET
TRAVEL
DOZER
BOOM
SWING
ARM
PAR PBR
(#07)
5 19 B4
(#07)
A4 B3 A3 B1 A1 B2 A2 B6 A6 A5 B5 B7 A7
P1 T 1.1.14
1.1.15
1.1.13 1.1.11
1.1.12
1.1.10
1.1.6 1.1.2
C7 1.1.5 1.1.4 R3
P2 PT 1.1.16
1.1.7
1.1.17 C7 R1
C1 1.1.8
P3 1.1.9
C2 CH 1.1.18
8
PI M2 PRESS. SENSOR
IC A2 490 Bar
C3
GTS
C6 4 b4
XBd XAd XAt XBt
a4 b3 a3
P11
P1 b1 AB a1
XBa XAa XBs
b2 SB
XAs
a2 P2 P21 b6 a6 a5
UP
b5BBb7 a7
25 M
PB (DN) (UP) (FWD) (REV) (CR) (DU) (R) (L) XBk XAk XAb Y3 (Front)
0.75 L (CR) (DU) (DN) to P(#64)
10 bar Vgmax
C4
PS Safety Cut-off 66 ENGINE
DL06P
Vgmin X1
GEAR
C5 HO 20 PUMP
M3
380±5 bar
A1
B1
201 X3
209 Vgmax
Vgmin
b1 a1
Arm X1
L2
207 (Rear)
Y3
A2 M
B2
b2 a2
1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
Swing
A3
B3 a3 206 Lo : 350±5 bar
21 BOOM
21 b3 BB
1bar
Hi : 370±5 bar
Travel K
Y
203 204 P1
PC2
P0
52 52 L1
P2 0.5 bar
C2 C2 202 203
E E
205 pi
29
Dozer/ 3bar T
AB Outrigger S
b4 PC1
Pi1
Pi1
T T
A4
B4
a4
28 10u
TANK
V2 V2 Boom
LOCK VALVE b5 a5 XAb 177u
L3
c(#69)
30
380±5 bar
A5
69 B A B5
208
201
b6 a6
Bucket
380±5 bar
A6
B6 201
C XAb
(#20)
T1 T2 P1 b7 a7
Option
380±5 bar
A7
XAb B7 201
(#19)
b8 a8
Arti Boom
380±5 bar
A8
201
B8
WE1500232
Figure 8
Once the joystick (16) is moved for boom-up operation, its inner
pilot pressure is applied to the (B5) port of the shuttle valve (19)
to send the oil to both the (b5) and (BB) ports of the main control
valve (20).
The oil flowed in through the (b5) port switches the boom spool,
and the oil though the (BB) port switches the summation valve
(204).
So oil from 2 pumps goes to boom cylinder through passage
described above. (Once the boom summation valve (204)
shifted, oil from (P1) and (P2) together goes into boom cylinders)
WE1500133
Boom spool and boom summation valve (204) are switched to a Figure 9
location, proportional to the input pilot pressure.

8-1-16
Port Relief
Anti-cavitation Valve Load Check Valve Anti-drift Valve
Boom Spool
Input Pilot Pressure
Boom Cylinder Boom Summation Valve
Boom Summation Valve

Travel Spool
Arm Spool
Boom Holding Valve
Boom Spool
Pilot Pressure
(Signal)
P2 P1
WE1500238
Figure 10

8-1-17
BOOM DOWN OPERATION
17 DOZER
DOWN
ARM/SWING 15 Dump
BOOM/BUCKET 16 Down
1 2
1.5 bar
1 3 1 3
2 4 4
UP 4 P 2 Crowd Up
1 P T 2 1 T 3 1 P 3 2 T 4
2
A3
BUCKET
TRAVEL
DOZER
BOOM
SWING
ARM
PAR PBR
(#07)
5 19 B4
(#07)
A4 B3 A3 B1 A1 B2 A2 B6 A6 A5 B5 B7 A7
P1 T 1.1.14
1.1.15
1.1.13 1.1.11
1.1.12
1.1.10
1.1.6 1.1.2
C7 1.1.5 1.1.4 R3
P2 PT 1.1.16
1.1.7
1.1.17 C7 R1
C1 1.1.8
P3 1.1.9
C2 CH 1.1.18
8
PI M2 PRESS. SENSOR
IC A2 490 Bar
C3
GTS
C6 4 b4
XBd XAd XAt XBt
a4 b3 a3
P11
P1 b1 AB a1
XBa XAa XBs
b2 SB
XAs
a2 P2 P21 b6 a6 a5 b5BB b7 a7
25 M
Down
PB (DN) (UP) (FWD) (REV) (CR) (DU) (R) (L) XBk XAk XBb Y3 (Front)
0.75 L (CR) (DU) (UP) to P(#64)
10 bar Vgmax
C4
DL06P
Vgmin X1
GEAR
C5 HO 20 PUMP
M3
380±5 bar
A1
B1
201 X3
209 Vgmax
Vgmin
b1 a1
Arm X1
L2
207 (Rear)
Y3
A2 M
B2
b2 a2
1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
Swing
Lo : 350±5 bar
A3 Hi : 370±5 bar
B3 a3 206
21 BOOM
21 b3 BB
1bar
Travel K
Y
203 204
PC2 P1
P0
52 52 L1
P2 0.5 bar
C2 C2 202 203
E E
205 pi
29
Dozer/ 3bar T
AB Outrigger S
b4 PC1
Pi1
Pi1
T T
A4
B4
a4
28 10u
TANK
V2 V2
LOCK VALVE
Boom 177u
b5 a5
L3
30
380±5 bar
A5
69 B A B5 208
201
b6 a6
Bucket
380±5 bar
A6
B6 201
T1 T2 P1 b7 a7
Option
380±5 bar
A7
B7 201
b8 a8
Arti Boom
380±5 bar
A8
201
B8
WE1500233
Figure 11
Once the joystick (16) is moved for boom-down operation, its

inner pilot pressure is applied to the (A5) port of the shuttle valve
(19) to send the oil to the a5 port of the main control valve (20).
The oil flowed in through the (a5) port switches the boom spool,
and it will be boom down.
And then 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.
WE1500134
Figure 12

8-1-18
Load Check Valve Anti-drift Valve
Port Relief
Anti-cavitation Valve
Input Pilot
Pressure
Regeneration Unit Inside

Insid
Boom Cylinder
Boom
Regeneration
Boom Spool
Boom Holding Valve
Pilot Pressure
(Signal)
Tank P2
WE1500239
Figure 13

8-1-19
ARM DUMP OPERATION
17 DOZER DOWN
ARM/SWING 15Dump BOOM/BUCKET 16 Down
1 2
1 3 1 3 1.5 bar
2 4 4
UP 4 P Crowd Up
1 P T 2 2 1 T 3 1 P 3 2 T 4
2
A3
BUCKET
TRAVEL
DOZER
BOOM
SWING
ARM
PAR PBR
(#07) (#07)
5 P1 T
19 B4 1.1.14
A4 B3
1.1.13
A3 B1
1.1.11
A1 B2
1.1.10
A2 B6 A6 A5 B5 B7 A7
1.1.15 1.1.12 1.1.6 1.1.2
C7 1.1.4
P2 PT 1.1.16
1.1.5
1.1.7
R3
1.1.17 C7 R1
C1 1.1.8
P3 1.1.9
C2 CH
PI
1.1.18
8
IC M2 PRESS. SENSOR
C3 b4 a4 b3 a3 P1 b1 AB a1 b2 SB a2 P2 P21 b6 a5 b5BB b7 a7 490 Bar
a6 A2
GTS
C6
4 P11
25 to P2(#20)
Dump
XBd XAd XAt XBt XBa XBs XAs XBo1 XAo1 M

PB (DN) (UP) (FWD) (REV) (CR) (R) (L) XBk XAk XAb XBb (OPEN) (CLOSE)
0.75 L Y3
10 bar (CR) (DU) (DN) (UP) to P(#64) (Front)
C4 Vgmax
PS Safety Cut-off
66 ENGINE
DL06P
Vgmin X1
C5 GEAR
HO PUMP
20 M3
A1
380±5 bar
X3
201 Vgmax
C/V XBa B1 Vgmin
ARM 209
V2 T Pil E b1 a1 X1
Arm
L2 Y3 (Rear)
207
C2 M
A2
B2 1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
b2 a2
Swing
LOCK VALVE
22 A3
B3 a3 206 Lo : 350±5 bar
Hi : 370±5 bar
b3 BB
Travel 1bar K
203 204 P1
PC2
P0
L1
202 203 P2
205 pi
0.5 bar
Dozer/ 3bar T
AB
b4
Outrigger
PC1
S 27 29
A4 a4
B4
b5
L3
Boom
a5 28 10u
TANK
380±5 bar
A5
B5 201 177u
208
30
b6 a6
Bucket
380±5 bar
A6
B6
201
b7 a7
Option
380±5 bar
A7
B7 201
b8 a8
Arti Boom
380±5 bar
A8
B8 201
WE1500234
Figure 14
Once the joystick (15) is moved for arm dump operation, its
(19) to send the oil to both the a1 and (AB) ports of the main
control valve (20).
The oil flowed in through the (a1) port switches the arm spool,
and the oil though the (AB) port switches the arm summation
valve (202).
As a result, high-pressure is exerted on arm cylinder rod area
and pushes the cylinder to "dump" direction.
Flowrate from cylinder head returns to tank. WE1500135
Figure 15

8-1-20
Regeneration Unit
Input Pilot Arm Summation Valve

Pressure
Arm Spool
Pilot Pressure
“AB”
Arm Cylinder
Arm Summation
Valve
Pilot Pressure
Spools
Spools
(Arm Dump)
P2 P1 Tank
WE1500240
Figure 16

8-1-21
ARM CROWD OPERATION
17 DOZER DOWN
ARM/SWING 15Dump BOOM/BUCKET 16 Down
1 2
1 3 1 3 1.5 bar
2 4 4
UP 4 P Crowd Up
1 P T 2 2 1 T 3 1 P 3 2 T 4
2
A3
BUCKET
TRAVEL
DOZER
BOOM
SWING
ARM
PAR PBR
(#07) (#07)
5 P1 T
19 B4 1.1.14
A4 B3
1.1.13
A3 B1
1.1.11
A1 B2
1.1.10
A2 B6 A6 A5 B5 B7 A7
1.1.15 1.1.12 1.1.6 1.1.2
C7 1.1.4
P2 PT 1.1.16
1.1.5
1.1.7
R3
1.1.17 C7 R1
C1 1.1.8
P3 1.1.9
C2 CH
PI
1.1.18
8
IC M2 PRESS. SENSOR
C3 b4 a4 b3 a3 P1 b1ABa1 b2 SB a2 P2 P21 b6 a5 b5BB b7 a7 490 Bar
a6 A2
GTS
C6
4 P11
25 to P2(#20)
Crowd
XBd XAd XAt XBt XBs XAs XBo1 XAo1 M

PB (DN) (UP) (FWD) (REV) (R) (L) XBk XAk XAb XBb (OPEN) (CLOSE)
0.75 L Y3
10 bar (CR) (DU) (DN) (UP) to P(#64) (Front)
C4 Vgmax
PS Safety Cut-off
66 ENGINE
DL06P
Vgmin X1
C5 GEAR
HO PUMP
20 M3
A1
380±5 bar
X3
201 Vgmax
B1 Vgmin
209
V2 T Pil E b1 X1
ARM a1
Arm
L2 Y3 (Rear)
207
C2 M
A2
B2 1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
b2 a2
Swing
LOCK VALVE
22 A3
B3 a3 206 Lo : 350±5 bar
Hi : 370±5 bar
b3 BB
Travel 1bar K
203 204 P1
PC2
P0
L1
202 203 P2
205 pi
0.5 bar
Dozer/ 3bar T
AB
b4
Outrigger
PC1
S 27 29
A4 a4
B4
b5
L3
Boom
a5 28 10u
TANK
380±5 bar
A5
B5 201 177u
208
30
b6 a6
Bucket
380±5 bar
A6
B6
201
b7 a7
Option
380±5 bar
A7
B7 201
b8 a8
Arti Boom
380±5 bar
A8
B8 201
WE1500235
Figure 17
Once the joystick (15) is moved for arm crowd operation, its
inner pilot pressure is applied to the (B1) port of the shuttle valve
(19) to send the oil to both the b1 and (AB) ports of the main
control valve (20).
The oil flowed in through the (b1) port switches the arm spool,
and the oil though the (AB) port switches the arm summation
valve (202).
High-pressure oil from arm cylinder rod chamber goes to head
chamber through a check valve located in arm spool. (Return oil
line is restricted by arm regeneration function.)
WE1500136
Figure 18

8-1-22
Arm Summation Valve
Input Pilot
Pressure
Regeneration Unit
Arm Holding Valve
Pilot Pressure (Arm Crowd)
Arm
Regeneration
Arm Summation
Valve
Spools
Arm Cylinder
Spools
Arm Spool
Arm Holding
Valve
P2 P1 Tank
WE1500241
Figure 19

8-1-23
BUCKET DUMP OPERATION
17 DOZER
DOWN
ARM/SWING 15 Dump
BOOM/BUCKET 16 Down
1 2
1.5 bar
1 3 1 3
2 4 4
UP 4 P 2 Crowd Up
1 P T 2 1 T 3 1 P 3 2 T 4
2
A3
BUCKET
TRAVEL
DOZER
BOOM
SWING
ARM
PAR PBR
(#07)
5 19 B4
(#07)
A4 B3 A3 B1 A1 B2 A2 B6 A6 A5 B5 B7 A7
P1 T 1.1.14
1.1.15
1.1.13 1.1.11
1.1.12
1.1.10
1.1.6 1.1.2
C7 1.1.5 1.1.4 R3
P2 PT 1.1.16
1.1.7
1.1.17 C7 R1
C1 1.1.8
P3 1.1.9
C2 CH 1.1.18
8
PI M2 PRESS. SENSOR
IC A2 490 Bar
C3
GTS
C6 4 b4 a4 b3 a3
P11
P1 b1 AB a1 b2 SB a2 P2 P21 b6 a6 a5 b5
BB
b7 a7
25 M
Dump
XBd XAd XAt XBt XBa XAa XBs XAs XBk
PB (DN) (UP) (FWD) (REV) (CR) (DU) (R) (L) (CR) Y3 (Front)
0.75 L to P(#64)
10 bar Vgmax
C4
DL06P
Vgmin X1
GEAR
C5 HO 20 PUMP
M3
380±5 bar
A1
B1
201 X3
209 Vgmax
Vgmin
b1 a1
Arm X1
L2
207 (Rear)
Y3
A2 M
B2
b2 a2
1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
Swing
A3
B3 a3 206 Lo : 350±5 bar
Hi : 370±5 bar
b3 BB
Travel 1bar
K
Y
203 204 P1
PC2
P0
L1 0.5 bar
P2
202 203
205 pi
29
Dozer/ 3bar T
AB Outrigger S
b4 PC1
A4
B4
a4
28 10u
TANK
Boom
BUCKET b5 a5 XAb 177u
23 L3
c(#69)
30
380±5 bar
A5
201
T2 T1 T2 T1 74 B5 208
b6 a6
P P Bucket
74
380±5 bar
A6
201
B6
b7 a7
Option
380±5 bar
A7
B7 201
b8 a8
Arti Boom
380±5 bar
A8
201
B8
WE1500236
Figure 20
Once the joystick (16) is moved for bucket dump operation, its
(19) to send the oil to the (a6) port of the main control valve (20).
The oil flowed in through the (a6) port switches the bucket spool,
and it will be bucket dump.
Oil from one pump goes to bucket cylinder rod through passage
described above.
Oil from bucket cylinder head returns to tank reservoir through
bucket spool.
WE1500137
Figure 21

8-1-24
Port Relief Bucket Load Port Relief
Input Pilot
Pressure
Bucket Spool
Spools
Bucket Cylinder
Pilot Pressure
(Bucket Dump)
Tank P2
WE1500242
Figure 22

8-1-25
BUCKET CROWD OPERATION
17 DOZER
DOWN
ARM/SWING 15 Dump
BOOM/BUCKET 16 Down
1 2
1.5 bar
1 3 1 3
2 4 4
UP 4 P 2 Crowd Up
1 P T 2 1 T 3 1 P 3 2 T 4
2
A3
BUCKET
TRAVEL
DOZER
BOOM
SWING
ARM
PAR PBR
(#07)
5 19 B4
(#07)
A4 B3 A3 B1 A1 B2 A2 B6 A6 A5 B5 B7 A7
P1 T 1.1.14
1.1.15
1.1.13 1.1.11
1.1.12
1.1.10
1.1.6 1.1.2
C7 1.1.5 1.1.4 R3
P2 PT 1.1.16
1.1.7
1.1.17 C7 R1
C1 1.1.8
P3 1.1.9
C2 CH 1.1.18
8
PI M2 PRESS. SENSOR
IC A2 490 Bar
C3
GTS
C6 4 b4 a4 b3 a3
P11
P1 b1 AB a1 b2 SB a2 P2 P21 b6 a6 a5 b5
BB
b7 a7
25 M
Crowd
XBd XAd XAt XBt XBa XAa XBs XAs
PB (DN) (UP) (FWD) (REV) (CR) (DU) (R) (L) Y3 (Front)
0.75 L to P(#64)
10 bar Vgmax
C4
DL06P
Vgmin X1
GEAR
C5 HO 20 PUMP
M3
380±5 bar
A1
B1
201 X3
209 Vgmax
Vgmin
b1 a1
Arm X1
L2
207 (Rear)
Y3
A2 M
B2
b2 a2
1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
Swing
A3
B3 a3 206 Lo : 350±5 bar
Hi : 370±5 bar
b3 BB
Travel 1bar
K
Y
203 204 P1
PC2
P0
L1 0.5 bar
P2
202 203
205 pi
29
Dozer/ 3bar T
AB Outrigger S
b4 PC1
A4
B4
a4
28 10u
TANK
Boom
BUCKET b5 a5 XAb 177u
23 L3
c(#69)
30
380±5 bar
A5
201
T2 T1 T2 T1 74 B5 208
b6
a6
P P
Bucket
74
380±5 bar
A6
201
B6
b7 a7
Option
380±5 bar
A7
B7 201
b8 a8
Arti Boom
380±5 bar
A8
201
B8
WE1500237
Figure 23
Once the joystick (16) is moved for bucket crowd operation, its
inner pilot pressure is applied to the (B6) port of the shuttle valve
(19) to send the oil to the (b6) port of the main control valve (20).
The oil flowed in through the (b6) port switches the bucket spool,
and it will be bucket crowd.
Oil from one pump goes to bucket cylinder head through
passage described above.
Oil from bucket cylinder rod returns to tank reservoir through
bucket spool.
WE1500138
Figure 24

8-1-26
Port Relief Bucket Load Port Relief
Input Pilot
Pressure
Pilot Pressure
(Bucket Crowd)
Spools
Bucket Cylinder
Bucket Spool Tank P2

WE1500243
Figure 25

8-1-27
COMBINED TRAVEL AND SWING OPERATION
The travel and swing spools are so arranged that they use the oil from the same pump (P1).
So operating travel and swing simultaneously with the oil distribution from one source would slow down their
motion unless it could be prevented.
To prevent slowing down, a pilot signal is sent to the (Pi) port to switch the travel priority spool so that travel and
swing use the flow from the P1 and P2 pump respectively.
The travel signal inputted to the shuttle valve (19) opens the spool (2601) of the logic valve (26) through the (PT)
port.
Then, passing through the opened spool (2601), the pilot swing signal inputted to the shuttle valve (19) is applied
to the (Pi) port to switch the travel priority spool (205).
ARM/SWING
Dump
1.5 bar
(L) 2 (R)
1 3 A3
P1T_SH P1P_SH
26 15 4 P 2 1 T 3
4
Crowd
PT_SH
Pi_CV
2
SWING
ARM
PAR PBR R3
2601
T PI_SH 19 B4
1.1.14
(#07)
A4 B3
1.1.13
(#07)
A3 B1
1.1.11
A1 B2
1.1.10
A2 B6 A6
1.1.6
A5 B5 B7 A7
R1
1.1.15 1.1.12 1.1.2
PT
8
1.1.5 1.1.4
1.1.16
1.1.7
1.1.17 C7
5 P1 T 1.1.9
1.1.8
M2 PRESS. SENSOR
A2 490 Bar
C7
P2 1.1.18 M
PI Y3
C1 SD to P(#64) (Front)
P3 P2 P1
P3
C2 CH
b4 a4 b3 a3 P11 P1 b1 AB a1 b2 SB a2 P2 P21 b6 a6 a5 b5BB b7 a7 66 ENGINE
DL06P
Vgmax
Vgmin
X1
7
TS
GEAR
PUMP C4
C3 IC
GTS M3
C6
PB 0.75 L
4 X3 C3 PL
Vgmax
C4
PS
10 bar
25 Vgmin
C2
REV
PBR
X1
FWD
(Rear) C1
C5 Y3 PAR
HO T
M
1 R2 S
A1
M1 PRESS. SENSOR
490 Bar
SWING MOTOR SH
20 24
380±5 bar
A1
B1 201
209 PG
b1 a1 DB 0.5 bar
Arm
207
L2
C
27 29
A2
PA PB
B2 265 bar
10u
b2
Swing
a2
Lo : 350±5 bar
28 TANK
A3 Hi : 370±5 bar 177u
B3 a3 206 A (RH) B (LH)

b3
Travel
BB
1bar K 30
Y
203 204 P1
PC2
P0 from A1(#01)
L1 205
202 203
P2
pi from A2(#01)
Dozer/ 3bar T
AB Outrigger S
b4 PC1
A4 a4
B4
Boom a5
b5
380±5 bar
L3
A5
B5
208
201
31
CENTER 3 3 1 1 3 3 1 1 3 3 1 3 1
X (IC) 1 1
JOINT 8 8 2 2 8 8 4 4 8 8 2 4 4
b6 a6 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2
Bucket
380±5 bar
A6 G
B6 201 MB GEXT
U T1
B
b7 a7 (FWD)
Option
380±5 bar
qmax
A7
B7 201 S
qmin
A
b8 a8
(REV)
Arti Boom T2
380±5 bar
MA
A8 M3
B8 201
M2 TRAVEL MOTOR
X2
(TU)
32
WE1500487
Figure 26

8-1-28
1Hydraulic
System Testing
and Adjustment
Edition 1
DX210W-5 Hydraulic System Testing and Adjustment

8-2-1
MEMO
Hydraulic System Testing and Adjustment DX210W-5

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 - (Power plus mode without SPC)
• at 1,600 rpm with no load.
• at 1,680 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,900 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.
• Posicon, positive control pressure.
• Main relief pressure (drive side and idle side pump)
• Swing pressure.
• Port relief pressure (individual control functions; boom, arm
and bucket)
• Power boost circuit.
• Standard performance tests; cylinder speed, hydraulic
motor (travel and swing) speed, cylinder oil tightness
"permissible drift" test.
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

8-2-6
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 23 ±1.5 bar
on Speed Control Dial (40 ±5 kg/cm2, 569 ±71 psi) (23 ±1.5 kg/cm2, 334 ±21 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 Condition Current Pressure

2,000 SPC off
Travel 230 mA ±30 2.1 bar (2.1 kg/cm2, 30 psi)
1,700 SPC on
1,700 SPC off 250 mA ±30
Midrange value corresponding to
Power Plus 2.6 bar (2.7 kg/cm2, 37 psi)
engine rpm for both current and
1,600 SPC on hydraulic pressure readings.
1,600 SPC off
Power 275 mA ±30 3.4 bar (3.5 kg/cm2, 50 psi)
1,500 SPC on
1,500 SPC off
Standard 275 mA ±30 3.4 bar (3.5 kg/cm2, 50 psi)
1,400 SPC on
1,400 SPC off
Economic 300 mA ±30 4.7 bar (4.8 kg/cm2, 68 psi)
1,300 SPC on

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 350 bar
(357 kg/cm2, 5,076 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 350 bar (357 kg/cm2, 5,076 psi), but less than 370 bar
(377 kg/cm2, 5,366 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)
350 ±5 bar 40 ±10 bar
Power Mode Cylinder Stall
(357 ±5 kg/cm2, 5,076 ±73 psi) (40 ±10 kg/cm2, 290 ±145 psi)
Power Mode W/ 370 ±10 bar
Cylinder Stall
Pressure Up (377 ±10 kg/cm2, 5,366 ±145 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" lever. 
Record values at all specified pressures.
• Rear pump test – operate "Dozer Up" 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/cm 2, 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)
350 bar (357 kg/cm2, 5,076 psi)
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 and 270 bar
(3,771 psi and 3,916 psi), with both swing locks
engaged. With swing locks released, during full
acceleration and deceleration, pressure should
approach 265 bar (270 kg/cm2, 3,840 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 6 bar (6 kg/cm2, 85 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
DX210W-5 Electrical System

9-1-1
MEMO
Electrical System DX210W-5

9-1-2
Table of Contents
Electrical System
Introduction .....................................................9-1-7
Electrical Supply System ................................9-1-8
Engine Starting Circuit ..................................9-1-10
Start Operation ........................................................ 9-1-10
After Start ................................................................ 9-1-12
Engine Preheating System ...........................9-1-14
Engine Stop ..................................................9-1-16
Charging System ..........................................9-1-18
Monitoring System ........................................9-1-19
Display Monitor........................................................ 9-1-20
Functional Check..................................................... 9-1-20
Monitoring System Schematic................................. 9-1-22
Operation ......................................................9-1-24
Instruments.............................................................. 9-1-24
Warning and Indicator Lights ........................9-1-26
Indication of Warning Lights .................................... 9-1-26
Indication of Multifunction Gauge ............................ 9-1-30
Initial Operation ............................................9-1-31
Graphic Information Area Display.................9-1-32
Overview ................................................................. 9-1-32
Main Menus for the Graphic Display Area............... 9-1-32
Menu Selector Buttons ............................................ 9-1-32
User Menu ....................................................9-1-33
User Menu - Access and Escape Methods ............. 9-1-33
Special Menu ................................................9-1-71
Entering/Accessing and Exiting/Escaping Menus ..... 9-1-71
Special Menu Selections ......................................... 9-1-72
Failure Code .................................................9-1-88
Failure Code at Machine ......................................... 9-1-88

9-1-3
Failure Code at Engine Side ................................... 9-1-90
FMIs (Failure Mode Identifier) ............................... 9-1-122
Electronic Hydraulic Control System 
(EPOS) .......................................................9-1-124
Control System Schematic .................................... 9-1-124
Power Plus Mode Control ...........................9-1-126
Operation............................................................... 9-1-128
Power Mode Control - Circuit Diagram .......9-1-130
Smart Power Control (SPC)........................9-1-131
Operation............................................................... 9-1-131
Engine Control System ...............................9-1-134
Engine Control Dial ............................................... 9-1-135
Acceleration Pedal ................................................ 9-1-136
Engine Control Circuit Diagram ............................. 9-1-138
Automatic Deceleration Control 
(Auto Idle Control) ......................................9-1-140
Engine Overheat Protection System ..........9-1-142
Power Boost Mode .....................................9-1-146
Operation............................................................... 9-1-146
Power Boost Control - Circuit Diagram ................. 9-1-148
cruise control ..............................................9-1-150
Operation............................................................... 9-1-150
Cruise Control Circuit ............................................ 9-1-152
Self-diagnostic Function .............................9-1-154
EPOS Controller.................................................... 9-1-154
Air Conditioner System ...............................9-1-156
Outline ................................................................... 9-1-156
Internal and External Filters .................................. 9-1-157
Air-Conditioning System Layout ............................ 9-1-159
Air Conditioner/Heater Circuit Diagram ................. 9-1-160
Air Conditioner/Heater Unit ................................... 9-1-161
Ambient Air Temperature Sensor.......................... 9-1-166
Sun Sensor............................................................ 9-1-167

9-1-4
Control Panel......................................................... 9-1-167
Compressor........................................................... 9-1-175
Receiver Dryer ...................................................... 9-1-175
Refrigerant Troubleshooting .......................9-1-176
Refrigerant System Repairs .......................9-1-178
Refrigerant Safe Handling Procedures.................. 9-1-178
Repair and Replacement Procedure ..................... 9-1-179
Refrigerant Recovery ............................................ 9-1-181
Vacuuming Refrigerant System............................. 9-1-181
Leakage Check ..................................................... 9-1-183
Refrigerant Charging ............................................. 9-1-183
Inspecting System For Leakage............................ 9-1-185
Wiper System .............................................9-1-186
Wiper Circuit.......................................................... 9-1-186
Wiper Operation .................................................... 9-1-187
Lighting System ..........................................9-1-190
Lighting System Circuit Diagram ........................... 9-1-190
Type ...................................................................... 9-1-191
Operation............................................................... 9-1-191
Overload Warning Device...........................9-1-192
Overload Warning Device Circuit Diagram............ 9-1-192
Audio Controller ..........................................9-1-193
Audio Controller Circuit Diagram........................... 9-1-193
Ram lock device .........................................9-1-194
Ram Lock Control Circuit ...................................... 9-1-194

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 electrical
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.
Electrical 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 and fuse box.
The negative terminal of the battery is grounded to the machine
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1)  circuit breaker 1 (3)  fuse box (6).
1. Terminal "5" of stereo.
2. Terminal "B" of starter switch.
3. Hour meter.
4. Engine controller.
5. Terminal "2" of fuel pump auto shutoff controller. (Optional)
6. Terminal "6" of wiper motor.
7. Terminal "13" of wiper controller.
8. Terminal "CN7-5, CN7-6" of instrument panel controller.
9. Terminal "CN9-6" of air conditioner panel.
10. Cabin light
11. TMS
When the starter switch (5) is in the "ON" or "START" positions,
the current flows from the battery (1)  circuit breaker 1 (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 3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
1
STARTER SWITCH CONNECTION P(R) B(B+) R(I)
PST TML B BR R2 C ACC

OFF
SG
ACC
ON
7
START R
F
E
E ALTERNATOR
8B
WE1400660
Figure 1 Electric Power Circuit Diagram
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Circuit Breaker 1 7 Alternator
4 Circuit Breaker 2 8 Diode

9-1-9
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to "START" position, the "S"
and "E" terminals of the starter controller (7) are connected. Now
the contacts in the starter relay 1 (8) are closed by the current
flow from the battery (1)  circuit breaker 1 (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
 "86" terminal of starter relay 1 (8) - "85" terminal  "S"
terminal of starter controller (7) - "E" terminal  ground.
When the contact point "30" and "87" of starter relay 1 (8) are
connected, the pinion gear of the starter (9) is pushed forward
and contacts 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)  "B" terminal of the starter (9). 
The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated, the
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.
If the security system is locked, current flows from
battery (1)  circuit breaker 1 (3)  fuse box (6) 
"B" terminal of starter switch (5)  "BR" terminal of 3 4 5 6 7 8 9 : ; <
starter switch (5)  "86" terminal of starter relay 2 (12) Enter Owner Password
 "85" terminal of starter relay 2 (12)  "2-115"
terminal of EPOS (13) ground. 
This current flow causes the coil in starter relay 2 (12) EX1301416
to be activated, opening contacts at "87a" terminal. Figure 2
This prevents starter relay 1 (8) from functioning.

9-1-10
7 87a 9
N S 30 S
P 87
B E
85 86
87a 8
30
87 A
85 86 ACC
C
B 5
R2 BR
12
3
2-115
6
4
B A
1-69
BR
13 E
11
2

OFF SG - + - +
ACC 10 12V 150AH 12V 150AH
ON R 1
F
START E
E ALTERNATOR
8B
WE1400661
Figure 3 Starter Circuit (1) - While Starting
Reference Reference
Number Number
1 Battery 8 Starter Relay 1
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 "P" 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 "P" 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.

9-1-12
7 87a 9
N S 30 S
P 87
B E
85 86
87a 8
30
87 A
85 86 ACC
C
B 5
R2 BR
12
3
2-115
6
4
B A
1-69
BR
13 E
11
2

OFF SG - + - +
ACC 10 12V 150AH 12V 150AH
ON R 1
F
START E
E ALTERNATOR
8B
WE1400661
Figure 4 Operation of Start Circuit (2) - Immediately After Start
Reference Reference
Number Number
1 Battery 8 Starter Relay 1
2 Battery Relay 9 Starter
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 EPOS Controller
7 Starter Controller

9-1-13
ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of the engine.
When the starter switch (5) is turned "ON," the current flows
from the battery (1)  circuit breaker 1 (3)  fuse box (6) 
"B" terminal of starter switch (5)  "BR" terminal of starter
switch (5)  "1-69" terminal of engine controller (12), causing
current to flow though "1-74" terminal of engine controller (12) 
"C and D" terminals of preheat relay (7)  "1-83" terminals of
engine controller (12)  ground.
This current flow causes the coil in preheat relay (7) to be
activated, closing contacts.
When the contacts of the preheat relay (7) are closed, the
heating coils of the air heating device (8) are heated by current
flowing from the battery (1)  battery relay (2)  preheat relay
fuse (13)  preheat relay (7)  air heater (8)  ground.
The duration of the heating cycle depends on the temperature of
engine coolant. The preheat indicator light in the instrument
panel (9) will turn "ON" during preheating cycle.
The preheat relay (7) is controlled by the engine controller (12)
and operates only at temperatures of 10°C (50°F) and below.
The longer the preheating period, the lower the temperature of
coolant is.

9-1-14
3
9 4
CN7-5, 6 2
ACC C B A
CN6-12, 13
B 5
R2 BR
BR E
10
CN1-39, 40, 21
CN1-69
- + - +
12V 150AH 12V 150AH
11 1
C B
- +
200A
13
STARTER SWITCH CONNECTION
1-46, 47, 10
7 TML
1-69 PST B BR R2 C ACC
(1) (2)
1-74 OFF
D H
1-83
+
8 -
ACC
ON
START
12
WE1400663
Figure 5 Engine Preheat Circuit
Reference Reference
Number Number
1 Battery 8 Air Heater
2 Battery Relay 9 Preheat Indicator Light
4 Circuit Breaker 2 11 EPOS Controller
5 Starter Switch 12 Engine Controller
6 Fuse Box 13 Preheat Relay Fuse
7 Preheat Relay

9-1-15
ENGINE STOP
When starter switch (5) is turned "ON" the engine controller (8)
is activated. The engine controller monitors and controls the
engine including the injector solenoid (9). It controls the fuel
deliver rate and the injection timing for each cylinder.
NOTE: There is an individual injector solenoid (9) for each of
cylinders. Only one solenoid is shown in Figure 7.
When starter switch (5) is turned "OFF," the engine controller
stops suppling power to the injector solenoid (9). This stops fuel
from being injected into the engine cylinder, thus stopping the
engine.
If the engine cannot be shut down using the starter switch (5), an
emergency stop switch (10) is provided to stop engine. To
activate the emergency stop switch, move it to "I"
(EMERGENCY STOP) position.
The emergency stop switch (10) is in its "O" (OFF) position I
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until engine stops. When
released it will automatically move back to "O" (OFF) position.
O
EX1403563
Figure 6 Engine Emergency Stop Switch

9-1-16

OFF
ACC
ON
START
8
6
3
ACC C
10 B 5
1
1-11 2 3
R2
BR
4 2
B A
1-74
1-69 BR
E
7
9
- + - +
12V 150AH 12V 150AH
1
WE1400664
Figure 7 Engine Stop Circuit
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Circuit Breaker 1 8 Engine Controller
4 Circuit Breaker 2 9 Injector Solenoid
5 Starter Switch 10 Engine Emergency Stop Switch

9-1-17
CHARGING SYSTEM
When the starter switch (5) is turned to "ON" position, an initial
excitation current flows to the field coil of the alternator (7)
through the battery relay (2) and circuit breaker 2 (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 "R (I)" 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 electrical system.
ACC C
B 5
R2
BR 3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
P(R) B(B+) R(I)
1
OFF SG
7
ACC
R
ON F
E
START
E ALTERNATOR
8B
WE1400675
Figure 8 Charging Circuit
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box

9-1-18
MONITORING SYSTEM
1
2 5 7
4
AM
H H 8 3 9
17
C
E
E F
F
C 10
TRIP
/h rpm ECO
Min Max 16
s
SPC
USB
11
6
21
12
18
20 15
14
22
19 13
WE1400676
Figure 9
Reference Reference
Number Number
1 Instrument Panel 12 Air Cleaner Indicator
2 Battery 13 Engine Controller Unit
3 Light Switch 14 Parking Brake Sensor
4 Return Filter Switch 15 Brake Oil Pressure Switch
5 Pilot Filter Switch 16 Travel Speed Select Switch
6 EPOS Controller 17 Parking Brake Switch
7 Alternator 18 Steering Console
8 Warning Buzzer 19 FNR Select Switch
Pump Discharge Pressure 20 Left Side Combination Switch
9
Sensor 21 Ram Lock Switch
10 Oil Temperature Sensor 22 Jog Switch Control Panel
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.

9-1-19
Display Monitor
10
9 8
AM 12
1
H H
3 4
E F
2 C E F C
TRIP 5
rpm ECO
7 /h Min Max
s
SPC
USB 13
15 14 16
6
11
EX1300990
Figure 10
Reference Reference
Number Number
1 Fuel Gauge 9 Display Warning Symbols
2 DEF (AdBlue) Level Gauge 10 Warning Light
Engine Coolant Temperature 11 Function Buttons
3
Gauge 12 Mode Selector Buttons
Hydraulic Oil Temperature 13 Selector Function Display
4
Gauge
14 Jog Switch
Multifunction Gauge and Graphic
5 Camera Mode Selector/
Information Area 15
ESC Button
6 ECO Gauge
16 Multimedia Selector Button
7 Trip Meter
8 Digital Clock
Functional Check
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 (2)
seconds.
During this functional check, a LOGO will appear on the
multifunction gauge in the graphic information area (3 and 4,
Figure 10).

9-1-20
9-1-21
Monitoring System Schematic
1 2
CN6-1
22
CN7-5
CN7-6
3
3 2
CN6-4
33
LAMP SWITCH 4
1
2 CN7-4
3 CN7-3 20
4
19
1
2
3
4 17
34
1 1-69
21
18
2 1-34
3
5 1-10
4
1-10
6
2-85 10 PEDAL BRAEKER
CN6-12 1-39 PRESSURE SW 1 (OPT)
CN6-13 1-40
1-21
2-103 11 PEDAL BRAEKER
PRESSURE SW 2 (OPT)
1-23
1-50
12
32 1-24
INDICATOR
1-43
23 1-37
1-49 13
1-46
PILOT FILTER SW
1-47
7 1-48 14
1-10 RETURN FILTER SW
1-36 2-92 15 BRAKE OIL

PRESS SW
12
8
16 1-28
1-2
9
36 24 1-19
PARKING BRAKE
1-13
25 35 1-11
SENSOR
CN17-2 26
CN17-1 27
28
29
(RAM LOCK) 1-72
(BEAM) 1-53
30 (TRAVEL SELECT) 1-62
31 (PARKING) 1-74
WE1400677
Figure 11

9-1-22
Reference Reference
Number Number
1 Instrument Panel 18 Battery
2 Pilot Buzzer 19 Battery Relay
3 Light Switch 20 Circuit Breaker 1
4 Starter Switch 21 Circuit Breaker 2
5 Front Pump Pressure Sensor 22 Fuse Box
6 Rear Pump Pressure Sensor 23 Check Connector
7 Fuel Sensor 24 Blink Unit
8 Hydraulic Oil Temp. Sensor 25 Steering Console
9 Parking Brake Sensor 26, 27 Turn Signal Switch
10 Pedal Breaker Pressure Sensor 1 28 High Beam
11 Pedal Breaker Pressure Sensor 2 29 Ram Lock Switch
12 Air Cleaner Indicator 30 Travel Switch
13 Pilot Filter Switch 31 Parking Switch
14 Return Filter Switch 32 Engine Controller
15 Brake Oil Pressure Switch 33 Rear and Side View Camera (Opt)
16 Alternator 34 Rear View Camera
17 EPOS Controller

9-1-23
OPERATION
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
17% (46°C)
97% 100% 33% (59°C)
81% 50% (72°C)

H
65%
65% (90°C)
Coolant ECU-CAN
81% (96°C)
Temperature 50% Communication
95% (103°C) (Tropical Zone Mode)
33% C 97 % (106°C)
17% EX1300991 98 % (107°C) (Warning Start)
100 % (110°C)
White
1/10 LCD (Red Zone) Blinking 

CN1-37 over 5K ohms
Fuel Level
1/10 CN1-10
Red
FULL  under 525 ohms
Full
E F
EX1301123
17% (46°C)
100% 97% 33% (59°C)
81% 50% (72°C)

H
65% 65% (85°C)
Hydraulic Oil CN1-36
81% (91°C)
Temperature 50% CN1-28
95% (97°C) (Tropical Zone Mode)
C 33% 97% (98°C)

17%
EX1300992 98% (99°C) (Warning Start)
100% (101°C)

9-1-24
Sensor Specification
Function Display
Input Terminal Input Specification
5%  Min.
DEF (AdBlue) ECU-CAN
20%  Red Zone
Level Gauge E F Communication
100%  Max.
EX1300993
ECU-CAN
Tachometer rpm Communication
EX1301378
ECO symbol: The instant workload

- Green: Normal operation
- Amber: Idling operation
Green/Amber/Red/Gray
- Red: Heavy loading operation
EPOS-CAN - Gray: ECO symbol off
ECO Gauge ECO
ECO Communication
Min Max ECO gauge: The average fuel
efficiency for 1 minute
Green Amber Red
- Green: Fuel efficiency is good
EX1300994
- Amber: Fuel efficiency is normal
- Red: Fuel efficiency is not good
Amount of fuel use ( ℓ)

TRIP
EPOS-CAN Operating hours (hr)
Trip Meter
Communication Average fuel efficiency ( ℓ/hr)
/h
Daily average fuel efficiency ( ℓ/hr)
EX1300995
V = F/0.04421 x ((T x I)  r) (km/h)

F = Frequency of T/M speed sensor
(Hz)
Speed Meter km/h 1-68 T = Number of transmission output
gear
r = Radius of tire
I = Axle ratio
FG022323

9-1-25
WARNING AND INDICATOR LIGHTS
Indication of Warning Lights

Input
Description Symbol Operation Remarks
Terminal
This symbol appears
in case of no charge
[voltage of engine
controller engine Normally, it lights
running terminal is when starting engine
Charge 1-2
below or overcharge] and is out after engine
[voltage of engine starts.
controller engine
HAOA610L
running terminal is
above 33 (V)].
After starting engine,

This symbol appears
ECU-CAN if engine oil pressure
Engine Oil when engine oil
Communic is insufficient after 8
Pressure pressure is below the
ation seconds, a warning
reference.
buzzer will sound.
HAOA620L
ECU-CAN This symbol appears

Engine
CHECK Communic in case of fault in
Check
ation engine system.
FG000045
This symbol appears

ECU-CAN when engine coolant
Coolant
Communic temperature sensor
Temperature
ation resistant is above
about 112°C.
HAOD350L
Preheating period
depends on coolant
This symbol appears temperature.
Preheating 2-101
during preheating.
20 sec preheating at
5°C.
HAOA639L

9-1-26
Input
Terminal
- Lights up when the
parking brake
switch is placed in
Parking 1-19 the park position.
Brake
Indicator
Light
P 1-13
1-11
- Lights up when
parking brake
pressure decrease
BCS0790L
below 26.0 kg/m2
(377 psi)
The WIF sensor

voltage is under
Water CN1-28
1.5 ±0.5 V, because
Separator CN1-38
moisture is detected
in fuel.
FG013744
Europe:
20%: Light on
10%: Flashes every
2 seconds
ECU-CAN
DEF 0.5 seconds
Communic
(AdBlue) Low America:
ation
20%: Light on 
FG019175 2 seconds
0.5 second
Alarm notifying
abnormal operation
at the post
ECU-CAN processing side of
SCR Fault Communic the SCR system.
ation Check the ECU
malfunction from the
FG019176 current malfunction
information.
ECU-CAN This symbol appears

Engine Stop STOP Communic in case of fault in the
ation engine system.
FG019003

9-1-27
Input
Terminal
The warning buzzer

This symbol appears sounds
Quick
CN1-77 when quick coupler is simultaneously when
Coupler
operated. quick coupler is
operated.
EX1301541
EPOS-CAN This symbol appears

Vehicle
Communic when a breakdown
Check
ation occurs to the vehicle.
EX1301542
This symbol appears

EPOS-CAN
Vehicle when there is an
Communic
STOP irregularity in the
ation
vehicle.
EX1301543
When hydraulic oil

Hydraulic Oil CN1-36
temperature is above
Temperature CN1-28
about 98°C.
FG000056
Fuel CN1-37 When fuel is almost

Exhausted CN1-10 exhausted.
FG000057
When air cleaner is

Air Cleaner CN1-50
clogged.
FG000053

9-1-28
Input
Terminal
When return filter

pressure is above
Return Filter CN1-48
about 1.50 bar
(21 psi)
FG000054
When pilot filter

Pilot Filter CN1-49 pressure is above
about 1 bar (14 psi)
FG000055
Warning buzzer also

It flashes in case of
starts when boom
2.68 V and above and
pressure sensor
Overload CN1-32 lights continuously in
output voltage is
Warning CN1-10 case of 2.77 V and
about 2.68 V while
above (and warning
overload warning
buzzer also starts).
FG000253 switch is "ON".
This symbol appears

Work Light CN1-74 when work light turns
"ON" (24 V applied).
HB4O2003

9-1-29
Indication of Multifunction Gauge
Input
Terminal
This symbol appears

Intelligent
when the Intelligent
Floating CN1-54
floating boom switch
Boom
is operated.
EX1301578
If the Voltage step-up

This symbol appears
switch is operated or
when the voltage
Voltage step- the lift mode is
CN1-81 step-up switch is
up selected, the voltage
operated or the lift
step-up solenoid
mode is selected.
valve is operated.
FG000554
Jog Switch
This symbol appears
Excavation CAN
when the excavation
mode Communic
mode is selected.
ation
EX1301579
Jog Switch
This symbol appears
CAN
Lift Mode when the lift mode is
LIFT Communic
ation
selected.
EX1301580
Jog Switch
This symbol appears
Breaker CAN
when the breaker
Mode Communic
mode is selected.
ation
EX1301581
Jog Switch
Breaker This symbol appears It appears only for the
CAN
Mode when the breaker vehicle with PE3C
Communic
(Option) mode is selected. option.
ation
EX1301582

9-1-30
Jog Switch
This symbol appears
Two-Way CAN
when the two-way
Mode Communic
mode is selected.
ation
EX1301583
Jog Switch
Two-Way This symbol appears It appears only for the
CAN
Mode when the two-way vehicle with PE3C
Communic
(Option) mode is selected. option.
ation
EX1301584
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 "CN7-2" is applied Saving Mode is enable, the power mode is standard
Initial
battery voltage (starter switch) mode or economy mode.
Operation
shifts from "OFF" to "ON" • Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, fuel level,
hydraulic oil temperature, engine speed, DEF
(AdBlue) level, trip meter.
• Clock: Current time display.
NOTE: Refer to method for setting clock in operation manual

for setting time.

9-1-31
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 jog switch.
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
3
SPC
S USB
2 1
EX1300996
Figure 12
Selector Buttons Graphic Display Area

1. Jog Switch 3. Letter Information Display Department
2. Escape Button
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. Jog Switch (1 on Figure 12): Move cursor and set menu.
2. Escape Button (ESC, 2 on Figure 12): Move a screen to
previous menu or main menu.

9-1-32
USER MENU
User Menu - Access and Escape Methods
Access Method
1. On the normal display screen, click on the jog switch to
access the user menu screen.
2. Proceed to the user menu using the menu/esc button on
the front of the dashboard.
3. Select the user menu from the launch menu.
PM PM
User Menu
H H
E F
C E F C Vehicle GP
TRIP Vehicle State Configuration Entertainment Configuration
/h rpm ECO
Min Max
SPC SPC
S USB S USB
<Normal Indication Monitor> <Main Menu Monitor>

EX1301029
Figure 13
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
Turn the jog switch and move the cursor to see a reversed User Menu
display on the desired menu. Then, click on the jog switch to
select the menu.
Vehicle State  Vehicle Configuration  Entertainment 
GP Configuration
Vehicle GP
Vehicle State Configuration Entertainment Configuration
Press the ESC button to return to the previous screen.
SPC
S USB
WARNING Figure 14
EX1301030

Do not use vehicle state menu when traveling or operating.

9-1-33
1. Vehicle State
PM
This is used to check the current vehicle state, filter/oil Vehicle State
information, vehicle information, etc.
Monitoring
Turn the jog switch and move the cursor to see a reversed
Filter/Oil Information
display on the desired menu. Then, click on the jog switch
to select the menu. Vehicle Information
Fuel Efficiency Data

Monitoring  Filter/Oil Information  Vehicle
Information  Fuel Efficiency Data SPC
S USB
Press the ESC button to return to the previous screen. EX1402166

Figure 15
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, click on the jog switch 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 16
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, click on the jog switch to display Filter/Oil Information
the filter/oil information. Vehicle Information
Fuel Efficiency Data
SPC
S USB
EX1402167
Figure 17

9-1-34
Reset Method/Replacement Period Change Method
Move the cursor over the filter/oil item you wish to Fuel Filter
change using the jog switch or the and buttons TIME: 40hr
REMAIN: 1960hr
CHANGE: 2000hr
2 %
on the front of the dashboard and click the jog switch Air Cleaner
or press the 'Enter' button on the front of the TIME: 0 hr
REMAIN: 2000hr
CHANGE: 2000hr
0 %
dashboard. A window for resetting/changing the filter/ Engine Oil Filter

oil time will pop-up.  TIME: 0 hr
REMAIN: 100hr
CHANGE: 100hr
0 %
To reset the use time, move the cursor over 'clear' Return Filter
and click the jog switch or press the 'Enter' button on TIME: 41 hr
REMAIN: 1359hr
CHANGE: 1400hr
2 %
the front of the dashboard.

EX1301406
Turn the jog switch to locate it at YES. Then, click on Figure 18
the jog switch to reset the operation hour.
Turn the jog switch to locate it at NO. Then, click on
the jog switch to allow the pop-up window to
disappear without resetting the operation hour. TIME: 40hr
Fuel Filter
CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
TIME: 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 19
– 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 20
Fuel Filter
TIME: 40hr CHANGE: 2000hr
REMAIN: 1960hr 2 %
Air Cleaner
Fuel Filter
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 21

9-1-35
To change the filter/oil exchange period, move the
cursor over 'change' in the window for resetting/
changing the filter/oil time and click the jog switch or TIME: 40hr
Fuel Filter
CHANGE: 2000hr
press the 'Enter' 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 %
click the jog switch or press the 'Enter' button on the Engine Oil Filter
front of the dashboard and the exchange time will TIME: 0 hr \HV QR
CHANGE: 100hr
REMAIN: 100hr 0 %
start flashing. Return Filter
Next, change the exchange period using the jog REMAIN: 1359hr 2 %
switch or the and buttons on the front of the EX1301410

dashboard. Figure 22
Then, turn the jog switch counterclockwise to reduce
the period. Turn clockwise to extend the period.
With the replacement period change being
completed, click on the jog switch to create a pop-up
window to select the period change.
Turn the jog switch to locate it at YES. Then, click on
the jog switch to change the replacement period.
Turn the jog switch to locate it at NO. Then, click on
the jog switch 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 2,000 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 23

9-1-36
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 jog switch to allow the H Caution H
pop-up window to disappear.
Return Filter
F
E period starts!
Replacement
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1301047
Figure 24
If the filter/oil replacement period is exceeded, this

pop-up window will be created. Press the ESC button PM
or the jog switch to allow the pop-up window to H Caution H

disappear.
Return Filter
WARNING TRIP
C E
F
E period is exceeded!
Replacement
F C
/h rpm ECO
Min Max
AVOID DEATH OR SERIOUS INJURY SPC
S USB
Do not use vehicle state menu when traveling or EX1301048

operating.
Figure 25
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, click the jog switch to access the Filter/Oil Information
vehicle information screen. Vehicle Information
Click the ESC button to return to the previous screen. Fuel Efficiency Data
SPC
S USB
EX1402168
Figure 26
Vehicle Information
Engine
Attachment Option Not Available
Vehicle Number 001001
EX1301411
Figure 27

9-1-37
D. Fuel Efficiency Data
PM
It is possible to check the weekly fuel efficiency data, Fuel Efficiency Data
daily fuel efficiency data, weekly operation history
data and daily operation data. Weekly Fuel Efficiency Data
Daily Fuel Efficiency Data
Weekly Operation History Data
Daily Operation Data
SPC
S USB
EX1402169
Figure 28
1) Weekly Fuel Efficiency Data

Weekly Fuel Efficiency Data
The amount of fuel used by each operating P+ P S E
hr
mode in a week can be checked. 120 24
90 18
60 12
30 6
0 0
7 6 5 4 3 2 1
Days Before
EX1402170
Figure 29
2) Daily Fuel Efficiency Data

Daily Fuel Efficiency Data
The amount of fuel used in a day can be /hr
checked. 10.0
8.0
6.0
4.0
2.0
0.0
12 11 10 9 8 7 6 5 4 3 2 1
Hours Before
EX1402171
Figure 30
3) Weekly Operation History Data

Weekly Operation History Data
The amount of fuel used, operating period and
Days Amount of Operation Daily Average
daily average fuel efficiency in a week can be Before Fuel Used Period Fuel Efficiency
checked. 1 0 9.1 hr 0.0 /hr
2 0 16.6 hr 0.0 /hr
3 0 0.0 hr 0.0 /hr
4 0 0.0 hr 0.0 /hr
5 0 0.0 hr 0.0 /hr
6 0 0.0 hr 0.0 /hr
7 0 0.0 hr 0.0 /hr
EX1402172
Figure 31

9-1-38
4) Daily Operational Data
Daily Operational Data
The operation period, average fuel efficiency
and amount of fuel used in a day can be
Operation Period 150.3 hr
checked.
Average Fuel Efficiency 0.0 /hr
Amount of Fuel Used 0
EX1402173
Figure 32
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 Entertainment Configuration
SPC
S USB
EX1301034
Figure 33
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
Auto Shut-off Setting
Option Motion Setting
SPC
S USB
EX1301035
Figure 34
A. Attachment Setting (Optional)

PM
In this menu, performance of the breaker and Attachment Setting
two-way select and setting items can be selected.
Breaker Setting
Breaker Setting  Two-way Setting
Two way Setting
Press the ESC button to return to the previous
screen.
SPC
S USB
WE1400332
Figure 35

9-1-39
1) Breaker Select and Setting List
Breaker Setting
After proceeding to breaker setting , breaker
select and setting screen will appear. When the No Select Setting Flow Pressure
cursor is placed on the list, operate the jog 1 Set 240 lpm 140 bar
switch clockwise/counterclockwise to move the 2 Set 30 lpm 30 bar
cursor.
3 Set 30 lpm 30 bar
Then, click on the jog switch to select breaker 4 Set 30 lpm 30 bar
and setting item. 5 Set 30 lpm 30 bar
When turning the jog switch counterclockwise
or pressing the Key 2 ( ), the cursor moves in WE1400343
the follows: Figure 36
Breaker 1 Select Breaker 1 Setting 
Breaker 2 Select Breaker 2 Setting 
Breaker 5 Select Breaker 5 Setting
Once the cursor is placed on 1 Select, it does
not move further to the left.
When turning the jog switch clockwise or
pressing the Key 3 ( ), the cursor moves in the Breaker Setting
follows:
No Select Setting Flow Pressure
Breaker 1 Select Breaker 1 Setting  1 Set 240 lpm 140 bar
Breaker 2 Select Breaker 2 Setting  2 Set 30 lpm 30 bar
Breaker 3 Select Breaker 3 Setting 
3 Set 30 lpm 30 bar
Breaker 4 Select Breaker 4 Setting  Select Complete!
Breaker 5 Select Breaker 5 Setting 4 Set 30 lpm 30 bar
5 Set 30 lpm 30 bar

Once the cursor is placed on 5 Setting, it does
not move further to the right. WE1400344
When the selection is completed, the "Select Figure 37
Complete!" pop-up window is displayed for 3
seconds, and the checkbox of the selected list
is updated.
2) Breaker Setting
Breaker Setting
The breaker setting screen is used to set up the
max flow, the use or non-use of button type, 2 No Select Setting Flow Pressure
pump option. 1 Set 240 lpm 140 bar
When the cursor is placed on breaker setting 2 Set 30 lpm 30 bar

button, click on the jog switch to access the 3 Set 30 lpm 30 bar
breaker setting screen. 4 Set 30 lpm 30 bar
5 Set 30 lpm 30 bar
WE1400345
Figure 38

9-1-40
If the system is set up as the owner's password
Owner Password
locked, access the attachment setting list
screen by using owner's password input screen.
On the owner's password input screen, press
the ESC button to return to the previous screen.
3 4 5 6 7 8 9 : ; <
Enter Owner Password
EX1301416
Figure 39
Max E/G Limit

Breaker 1 Setting
It indicates the maximum engine rpm of the
Max E/G Limit 2000 rpm Button Type Toggle
equipment.
2 Pump Option Enabled Max Pressure 140 bar
For the corresponding max. engine rpm by User Setting Max Flow 320 lpm
equipment, refer to the EPOS specifications.
Min : Max :
30 400
WE1400346
Figure 40
Button Type
This item sets the applicability of the toggle of the
breaker button 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.
2 Pump Option
2 pump option is displayed as long as it is enabled in
the option setting in the service menu.
If the user setting max flow is below 1 pump flow, the
light is turned off and the caption is displayed as not
enable.
– If the user setting max flow is 1 pump flow or
over, the light is turned on and the caption is
displayed as enable.
Max Pressure
The maximum pressure of the breaker can be set.
The configurable max. pressure range is different by
equipment. For details, refer to the EPOS
specifications.
The maximum pressure indication/setting resolution
is 10 bar (10.2 kg/cm2, 145 psi)..

9-1-41
User Setting Max Flow
User setting max flow indicates the maximum flow
that user will actually use.
The allowable maximum value for user setting max
flow is the vehicle's maximum discharge flow. For
maximum discharge flow by equipments, refer to the
EPOS specifications.
The value for user setting max flow is displayed at
intervals of the value of the allowable maximum input
value subtracted by the allowable minimum input
value and then divided by 10.
User Setting Max Flow Bar Gauge
The bar gauge indicates the current value of user
setting max flow between the minimum and
maximum input values with 11 bars.
The minimum value on the bar gauge is the vehicle's
minimum discharge flow. For minimum discharge
flow by equipment, refer to the EPOS specifications.
When turning the jog switch counterclockwise or
pressing the Key 2 ( ), the cursor moves in the
follows:
Button Type Max Pressure User Setting Max
Flow
However, when the cursor is on the button type, it
does not move further.
When turning the jog switch clockwise or pressing the
Key 3 ( ), the cursor moves in the follows:
Flow
However, when the cursor is on the button type, it
3) Two-way Select and Setting List
Two Way Setting
After proceeding to two-way setting, two-way
select and setting screen will appear. No Select Setting Flow Pressure
When the cursor is placed on the list, operate 1 Set 240 lpm 140 bar
the jog switch clockwise/counterclockwise to 2 Set 30 lpm 30 bar

move the cursor. 3 Set 30 lpm 30 bar
Then, click on the jog switch to select breaker 4 Set 30 lpm 30 bar
and setting item. 5 Set 30 lpm 30 bar
When turning the jog switch counterclockwise

WE1400347
or pressing the Key 2 ( ), the cursor moves in
Figure 41
the follows:
Two-way 1 Select Two-way 1 Setting 

9-1-42
When the cursor is on the 1 select, it does not
move further.
When turning the jog switch clockwise or
follows:
Two-way 1 Select Two-way 1 Setting 
When the cursor is on the 5 setting, it does not
move further. Two Way Setting
When the selection is completed, the "Select No Select Setting Flow Pressure
Complete!" pop-up window is displayed for 3 1 Set 240 lpm 140 bar
seconds, and the checkbox of the selected list 2 Set 30 lpm 30 bar
is updated.
3 Set 30 lpm 30 bar
Select Complete!
4 Set 30 lpm 30 bar
5 Set 30 lpm 30 bar
WE1400348
Figure 42
4) Two-way Setting
Two Way Setting
The two-way setting screen is used to set up the
max flow, the use or non-use of button type, 2 No Select Setting Flow Pressure
pump option. 1 Set 240 lpm 140 bar
when the cursor is placed on two-way setting 2 Set 30 lpm 30 bar

button, click on the jog switch to access the two- 3 Set 30 lpm 30 bar
way setting screen. 4 Set 30 lpm 30 bar
5 Set 30 lpm 30 bar
WE1400349
Figure 43
If the system is set up as the owner's password

Owner Password
locked, access the attachment setting list
screen by using owner's password input screen.
On the owner's password input screen, press
the ESC button to return to the previous screen.
3 4 5 6 7 8 9 : ; <
EX1301416
Figure 44

9-1-43
Max E/G Limit
Two Way 1 Setting
It indicates the maximum engine rpm of the
Max E/G Limit 2000 rpm Button Type Not Enabled
equipment.
2 Pump Option Enabled Max Pressure 140 bar
For the corresponding max. engine rpm by User Setting Max Flow 320 lpm
equipment, refer to the EPOS specifications.
Button Type Min : Max :
30 400
As the button type is not used in two-way setting, it is
displayed as not enabled.
2 Pump Option WE1400350
Figure 45
2 pump option is displayed as long as it is enabled in
the option setting in the service menu.
If the user setting max flow is below 1 pump flow, the
light is turned off and the caption is displayed as not
enabled.
– If the user setting max flow is 1 pump flow over,
the light is turned on and caption is displayed as
enabled.
Max Pressure
The maximum pressure of the breaker can be set.
The configurable max. pressure range is different by
equipment. For details, refer to the EPOS
specifications.
The maximum pressure indication/setting resolution
is 10 bar.
User Setting Max Flow
User setting max flow indicates the maximum flow
that user will actually use.
The allowable maximum value for user setting max
flow is the vehicle's maximum discharge flow. For
maximum discharge flow by equipments, refer to the
EPOS specifications.
The allowable value of user setting max flow is limited
between the minimum and maximum input values,
and it is displayed with a resolution equivalent to the
increment between two successive bars.
User Setting Max Flow Bar Gauge
The bar on the gauge indicates the current value of
user setting max flow in 11 incremental steps
between the minimum and maximum input values
with 11 bars.
The minimum value on the bar gauge is the vehicle's
minimum discharge flow. For minimum discharge
flow by equipment, refer to the EPOS specifications.
When turning the jog switch counterclockwise or
follows:

9-1-44
Flow Max Pressure User Setting Max Flow
However, when the cursor is on the max pressure, it
When turning the jog switch clockwise or pressing the
Key 3 ( ), the cursor moves in the follows:
Flow Max Pressure User Setting Max Flow
When the cursor is on the user setting flow, it does
not move further.
• Breaker Setting
Max. Limit Min. Limit
Max. E/G Limit 1,700 rpm -
Max. Press. (ATT) 280 bar 140 bar
• Two-way Setting
Max. Limit Min. Limit
Max. E/G Limit 1,700 rpm -
Max. Press. (ATT) 340 bar 140 bar

9-1-45
B. 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
SPC
S USB
EX1301037
Figure 46
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
SPC
S USB
EX1301038
Figure 47
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 48
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 49

9-1-46
C. 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 Auto Shut-off Setting
for dial to access it. Option Motion Setting
SPC
S USB
EX1301039
Figure 50
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 51
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 52
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 53
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.

9-1-47
D. Auto Shut-off Setting
PM
NOTE: This function is not available in some Vehicle Configuration
models.
Attachment Setting
In the auto shut-off setting screen, the engine of the Camera Setting
equipment can be set to shut off automatically when Forced Dial Input
the equipment is not operated for a preset time. Auto Shut-off Setting
Select auto shut-off setting in the vehicle settings and Option Motion Setting
proceed to the setting screen. SPC
S USB
EX1301426
Figure 54
In the auto shut-off setting screen, the cursor will

Auto Shut-off# Setting
initially be over auto shut-off function in use.
NOTE: This feature is off in factory defaults. Auto Shut-off Function in
Available
Use
To use the feature, place the cursor over auto shut-
off function in use and click the jog switch to select Auto Shut-off Time Setting 5 Min
the feature. 3 60
The engine can be set to shut off automatically after a

maximum of 60 minutes to a minimum of 3 minutes.
In factory defaults, the time is set to 5 minutes. EX1301427
Further, this feature is off in factory defaults. Figure 55
The following conditions must be met if this feature is
to be used.
Auto Shut-off (ASD) Active Condition
Input Output
DeSOx Switch
Auto Idle Pilot Cutoff Engine Coolant Hydraulic
GP Menu (SCR Regen Signal) Dial Status Time Signal Pop-up Alarm
Mode Switch rpm Temp. Temp.
(DL06 Engine Only)
1 minute 10 seconds
More than More than at Setting Engine
Active ON ON OFF OFF 10 rpm Normal before before
50°C 20°C Time Stop Signal
stopping stopping
Deactive Except Above Condition Time Count Reset
When this feature is activated and the above

conditions are met, "Engine will shut off" will pop up 1
minute before the engine shuts off.
Further, 10 seconds before the engine shuts off, the
pilot buzzer will be activated to alert the user.
WARNING
When the auto shut-off feature is used, the engine
shuts off automatically after the preset time, and
thus particular care must be taken that no safety
problems occur when it is used.

9-1-48
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 Auto Shut-off Setting
and proceed to the settings screen. Option Motion Setting
SPC
S USB
EX1301428
Figure 56
'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 57
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.

9-1-49
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
SPC
S USB
EX1402174
Figure 58
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 59

9-1-50
3. Entertainment
PM
This menu is used to replay videos and MP3. User Menu
Turn the jog switch and move the cursor to see a reversed
to select the menu.
Vehicle GP
Vehicle State Configuration Entertainment Configuration
SPC
S USB
EX1301040
Figure 60
Video  MP3
PM
Press the ESC button to return to the previous screen. Entertainment
Video
MP3
SPC
S USB
EX1301041
Figure 61
If the use of entertainment is limited, this pop-up window

PM
will be created.
Entertainment
To lift the use limits, you should change the limit setup in
the GP configuration.
Video The entertainment
The pop-up window will automatically disappear in 3 MP3
use is restricted!
seconds. Press the ESC button or the jog switch to remove
pop-up window.
For details, See "GP Configuration" on page -58. SPC
S USB
EX1301042
Figure 62
If the use of entertainment is not limited, this pop-up

PM
window will be created. The pop-up window will
Entertainment
automatically disappear in 3 seconds.
Press the ESC button or the jog switch to remove pop-up Be careful playing
Video
window. entertainment menu on
MP3 travel or operating!
WARNING
SPC
AVOID DEATH OR SERIOUS INJURY S USB
EX1301043
Listening to entertainment clips, such as video, music, Figure 63
etc., can cause an accident, resulting in death or
serious injury. Do not play entertainment files when
operating the machine.

9-1-51
A. Video
PM
From the entertainment screen, select video to Entertainment
access it.
Video
MP3
SPC
S USB
EX1301041
Figure 64
When there is no USB storage system, a pop-up

PM
window is displayed for 3 seconds, saying "USB"
Entertainment
Storage is not installed". and the video is not played.
Video USB Storage is not

MP3 installed.
SPC
S USB
EX1301044
Figure 65
When initially accessing the video player, the USB

Video
storage system file tree is displayed on the screen,
operate the jog switch clockwise/counterclockwise to Hard Disk MOVIE
select and play a video. ..(3)
If there is a video file that played last, it will Video(1).avi
automatically be replayed. Video(2).avi

Video(3).avi
Video(4).avi
FG018511
Figure 66
If the format is not supported, a pop-up window is 33=33=59

displayed for 3 seconds, saying "This file is not 33=36=7<
available!" and the video is not played.
This file is not available!
EX1301451
Figure 67

9-1-52
Formats that can be supported are given below.
Formats that can be supported

File Type AVI, MP4, MKV, MOV
Supported Resolution 720*480, 720*384, 720*304, 704*448, 704*304, 640*480, 640*360,
640*272, 640*352, 672*288, 512*384, 576*432, 480*320, 480*360,
320*240
Supported Video Codec H.264, MPEG4, Xvid, MPEG1/2
Supported Audio Codec MP3
Supported File Size Under 1.7 GB
Supported USB Format FAT32
The screen composition of the video player is given 33=33=59
below. 33=36=7<
The top section displays the current playing time of

the total playing time.
The screen center shows the video being played.
The bottom displays the video player function
operation symbol and cursor.
The video player function operation symbol and jog
switch are operated in the following order. EX1301452
Play/Pause  Replay the Previous File  Video Figure 68
Progress Bar  Replay the Next File  Video
Files List
If no operation continues for more than 5 seconds,
the video will automatically be converted into the
whole screen.
On the whole screen, click on the jog switch or the
ESC button to remove whole screen.
FG018214
Figure 69
Play/Pause 33=33=59
33=36=7<
Locate the cursor on the play/pause symbol and click

on the jog switch to execute the video's play/pause
functions.
With the play being on, click on the jog switch to
display the pause symbol at the center of the screen,
thus allowing the video to pause.
With the pause being on, click on the jog switch to
cause the pause symbol at the center of the screen to
disappear, resuming the video playing. EX1301453
Figure 70

9-1-53
Replay the Previous File 33=33=59
33=36=7<
Locate the cursor at the replay the previous file

symbol and click on the jog switch to replay the
previous file.
EX1301454
Figure 71
Locate the cursor at the video progress bar and click 33=33=59
on the jog switch to convert into the fast forward/ 33=36=7<
rewinding mode.
On the fast forward/rewinding mode, operate the jog
switch clockwise/counterclockwise to conduct fast
forward/rewinding.
Fast forward/rewinding can be conducted at an
interval of 30 seconds per click during which the jog
switch is turned.
On the fast forward/rewinding mode, press the ESC EX1301455
button to disable the fast forward/rewinding mode. Figure 72
Replay the Next File 33=33=59

33=36=7<
Locate the cursor at the replay the next file symbol

and click on the jog switch to replay the next file.
EX1301456
Figure 73
Video Files List 33=33=59

33=36=7<
Locate the cursor at the video files list symbol and

click on the jog switch to move to the video file list
screen.
EX1301457
Figure 74

9-1-54
Select and replay a video.
Video
Hard Disk MOVIE
..(3)
Video(1).avi
Video(2).avi
Video(3).avi
Video(4).avi
FG018557
Figure 75
B. MP3
PM
From the entertainment screen, select MP3 to access Entertainment
it.
Video
MP3
SPC
S USB
EX1301053
Figure 76
If there is no USB storage system, a pop-up window

PM
is displayed for 3 seconds, saying "USB Storage is
Entertainment
not installed". and the MP3 player is not run.
Video USB Storage is not

installed.
MP3
SPC
S USB
EX1301054
Figure 77
When initially accessing the MP3 player, the file tree

screen of USB storage system is displayed. Operate
Hard Disk MP3
the jog switch clockwise/counterclockwise to select
and play an MP3 file. ..(0)
If there is an MP3 file played last, the file will Music(1) .mp3
automatically be played. Music(2) .mp3

Music(3) .mp3
Music(4) .mp3
FG018560
Figure 78

9-1-55
The screen composition of MP3 player is given
Singer - Title
below.
The top section displays the name of the file being
played and the current playing time of the total Title
playing time.
The screen center shows the album image of the file
being played, the album name, the song name and Next
the name of the next file to be played.
The bottom displays the MP3 player function
operation symbol and cursor. FG020124
Figure 79
The MP3 player function operation symbol and jog
switch are operated in the following order.
Play/Pause  Replay the Previous File  MP3
Progress Bar  Replay the Next File  MP3 Files
List  Background MP3 Play
Play/Pause
Singer - Title
Locate the cursor at the play/pause symbol and click
on the jog switch to execute the MP3 play/pause
functions. Title
With play being on, click the jog switch to display the
pause symbol at the center of the screen, causing the
MP3 to pause. Next
With pause being on, click on the jog switch to cause

the pause symbol at the center of the screen to
disappear, resuming the MP3 playing. FG020125
Figure 80
Replay the Previous File

Singer - Title
symbol, and click on the jog switch to replay the
previous file. Title
Next
FG020126
Figure 81

9-1-56
Fast Forward/Rewinding
Singer - Title
Locate the cursor at the video progress bar and click
on the jog switch to convert into the fast forward/
rewinding mode. Title
On the fast forward/rewinding mode, operate the jog
switch clockwise/counterclockwise to conduct fast
forward/rewinding. Next
Fast forward/rewinding can be conducted at an

interval of 30 seconds per click during which the jog
switch is turned. FG020127
Figure 82
On the fast forward/rewinding mode, press the ESC
button to disable the fast forward/rewinding mode.
Replay the Next File
Singer - Title
symbol and click on the jog switch to replay the next
file. Title
Next
FG020128
Figure 83
MP3 Files List

Singer - Title
Locate the cursor at the MP3 files list symbol and
click on the jog to move to the file list screen.
Title
Next
FG020129
Figure 84
Select a file and replay the MP3.
Hard Disk MP3
..(0)
Music(1) .mp3
Music(2) .mp3
Music(3) .mp3
Music(4) .mp3
FG018560
Figure 85

9-1-57
Background MP3 Play
Singer - Title
Position the cursor on the "HOME" button and
pressing the jog switch, MP3 is played by the initial
screen. Title
Next
FG020130
Figure 86
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S PLAY
EX1301432
Figure 87
4. GP Configuration
PM
This menu is used to set up password, brightness, default User Menu
screen and time, and to input service phone number. Turn
the jog switch and move the cursor to see an reversed
to select the menu.
Vehicle GP
Password Setting  Brightness Setting  Default Vehicle State Configuration Entertainment Configuration
Power Mode Setting  Default Screen Setting  Time
Setting  Service Phone Number Setting  Unit
SPC
S USB
Setting  Notification Setting  Entertainment Use

EX1301052
Setting
Figure 88
Press the ESC button to return to previous screen.
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 Default Screen Setting
manage usage of operations and functions of the Time Setting
vehicle. SPC
S USB
EX1402178
Figure 89

9-1-58
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 click the jog switch (or press "Enter" SPC
on the keypad). S USB
EX1301055
Figure 90
2) Password entry
Owner Password
When the password entry screen appears, use
the jog switch (or 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 : ; <
Rotate the jog switch to select digits from 0 to 9 Enter Owner Password
below, and click Enter on the jog switch to input
the password.
If the password is input incorrectly, use the EX1301416
button on the lower right to delete the input Figure 91
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 : ; <
EX1301433
Figure 92
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 93

9-1-59
Password change
Owner Password Change
To change the owner password, select
password change with the jog switch (or the
keypad).
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301435
Figure 94
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 95
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 Entertainment Use Setting
use ischecked.
In this case, the user has the same
privileges as the owner, and the
EX1301437
user’s settings take precedence in
equipment settings. Figure 96
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.
c) Entertainment use setting
Setting of password input for
entertainment (video/MP3) use setting.

9-1-60
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 97
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 98
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 -59).
To set a user password, place the cursor over SPC
User Password Setting in the Password Setting S USB
screen and click the jog switch (or press "Enter" EX1301440
on the keypad). Figure 99
2) Password entry
When the password input screen appears, input
the password with the jog switch (or keypad)
and move to the settings screen. (refer to
"Owner Password Setting 2" on page 2-71.)
The default password is "1111".

9-1-61
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 100
Password change
User Password Change
To change the user password, select password
change, and change the user password using
the jog switch (or keypad).
3 4 5 6 7 8 9 : ; <
Enter Password
EX1301442
Figure 101
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 102
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 Entertainment Use Setting
Setting of password input upon operation
of equipment.
b) Attachment setting EX1301443
Setting of password input for attachment
Figure 103
setting.
c) Entertainment use setting
Setting of password input for
entertainment (video/MP3) use setting.

9-1-62
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 104
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, click on the jog switch to
Password Setting
display the screen brightness setting and camera
Brightness Setting
brightness setting screen.
Default Power Mode Setting
Default Screen Setting
Time Setting
SPC
S USB
EX1402179
Figure 105
If you want to change the screen brightness, select

PM
the screen brightness setting to display the
Brightness Setting
brightness adjustment screen.
Screen Brightness Setting
Camera Brightness Setting
SPC
S USB
EX1301056
Figure 106

9-1-63
Turn the jog switch 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
E F
F
C
EX1301057
Figure 107
If you want to change the camera screen brightness,

PM
select the camera brightness setting to display the
Brightness Setting
camera screen brightness adjustment screen.
Screen Brightness Setting
Camera Brightness Setting
S USB
EX1301058
Figure 108
Turn the jog switch 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 109

9-1-64
C. Default Power Mode Setting
PM
placed on default power mode setting, click on the jog
switch to access the default power mode setting. Password Setting
Brightness Setting
Fuel Saving Mode is Enable Default Power Mode Setting
ON OFF ON
Time Setting
P+ P+ SPC
PWR+ PWR+ S USB
P P EX1402180
PWR PWR
Figure 110
S S
STD STD
E E Default Power Mode Setting

ECO ECO
Fuel Saving Mode Enable

Fuel Saving Mode is Disable
Smart Power Control Enable
ON OFF ON
P+ P+
PWR+ PWR+
P P
PWR PWR
EX1301446
S S
STD STD
Figure 111
E E
ECO ECO
Smart Power Control is Enable
ON OFF ON
SPC
Mode
SPC
Mode
STD
Mode
Smart Power Control is Disable
ON OFF ON
SPC SPC
Mode Mode
STD STD
Mode Mode

9-1-65
D. Default Screen Setting
PM
Sets the main screen display on the instrument GP Configuration
panel.
Default Power Mode Setting
Time Setting
Service Phone Number Setting
Unit Setting
S
SPC
USB
EX1402181
Figure 112
The initial screen shows basic information, including

the fuel level, coolant temperature and hydraulic oil PM
temperature. H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
S
SPC
PLAY
EX1301432
Figure 113
Enter the "Default Screen Setting" menu and select

"Enable" for this function. Then, the main screen
shows the camera view next time the starter switch is
turned to the ON position. Move the Camera Screen at
Boot Time
Enabled
EX1402182
Figure 114
rpm
S
SPC
EX1402183
Figure 115

9-1-66
E. Time Setting
PM
placed on time setting, click the jog switch to access
the time setting. Default Power Mode Setting
Turn the jog switch and locate the cursor at a target Time Setting
of change. Then, click on the jog switch to change the Service Phone Number Setting
target. Unit Setting
SPC
S USB
EX1403722
Figure 116
Turn the jog switch to change numbers of each item.

Time Setting
If the setup is completed, click on the jog switch to
store the setup details.
TIME 09 : 47 : 24 PM
When the time setting is completed, locate cursor to
'SET' and press the job switch. DATE 2013 / 10 / 29 SET
If the SET button is not pressed, time setting would

not be completed.
screen. EX1301447
Figure 117
F. Service Phone Number Setting

PM
placed on service phone number setting, click on the
jog switch to access the service phone number Default Power Mode Setting
setting. Default Screen Setting

Time Setting
Unit Setting
SPC
S USB
EX1403723
Figure 118
Turn the jog switch and locate the cursor at a desired

number. Then, click on the jog switch 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 119

9-1-67
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
TRIP
/h rpm ECO
Min Max
SPC
S USB
EX1301064
Figure 120
G. Unit Setting
PM
placed on unit setting, click the jog switch to access
the unit setting. Default Power Mode Setting
Time Setting
Unit Setting
SPC
S USB
EX1403724
Figure 121
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 122
H. Language Setting
PM
placed on language setting, click on the jog switch to
access the language setting. Default Screen Setting
Time Setting
Unit Setting
Language Setting
SPC
S USB
EX1403725
Figure 123

9-1-68
On the language selection screen, turn the jog switch
Language Setting
and move the cursor to select a language. Then, click
on the jog switch to adopt the selected language.
screen.
Language
Korean, English, Chinese, Persian, Turkish,
Indonesian, Polish, Arabic, Russian, Thai, Hindi,
Japanese, French, German, Nederlands, Italian,
Portuguese, Spanish, Finnish, Swedish, EX1301062
Norwegian, Danish, Vietnamese, Greek Figure 124
I. Notification Setting
PM
placed on notification setting, click on the jog switch
to access the notification setting. Time Setting
Unit Setting
Language Setting
Notification Setting
SPC
S USB
EX1301060
Figure 125
Depending on the notification setting screen details,

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, turn the jog switch

Maintenance Notification Pop up Avalible
and move the cursor to a desired location. Then, click
on the jog switch to select enable or disable.
All notice items at the vehicle release time are set as
Enable.
EX1301450
Figure 126

9-1-69
J. Entertainment Use Setting
PM
placed on entertainment use setting, click on the jog
switch to access the entertainment use setting. Service Phone Number Setting
Unit Setting
Language Setting
Entertainment Use Setting
SPC
S USB
EX1301061
Figure 127
Depending on the entertainment use setting details,

Entertainment Use Setting
the use of video and MP3 is limited.
Prohibition on Engine Running
Prohibition on Working or Travel
EX1301063
Figure 128

9-1-70
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
2
When normal mode screen is displayed, if jog switch (1, Figure
129), power mode selector button (2, Figure 129) and
multimedia button are pressed simultaneously for more than 3
seconds, normal mode screen (Figure 130) will be changed to
special menu screen (Figure 131).
4 3
1 FG018857
Figure 129
Normal Mode Screen

NOTE: Normal mode screen display fuel gauge, engine
H H
coolant temperature gauge, hydraulic oil temperature
gauge, ECO gauge and engine speed (rpm),
DEF(AdBlue) gauge, trip meter.
E F
C E F C
TRIP
/h rpm ECO
Min Max
EX1301002
Figure 130

9-1-71
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
SPC
S USB
EX1301082
Figure 131
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 129) 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 129)" Vehicle Configuration
button and the "Machine Info" will be displayed. SPC
S USB
EX1301082
Figure 132
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
129) is pressed display will be turned to previous screen. User Selection Signal
Doosan Connect Information
SPC
S USB
EX1301083
Figure 133

9-1-72
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. Alternator Voltage V Indicating alternator voltage.
7. Battery Voltage V Indicating battery voltage.
8. Engine Dial Voltage mV Indicating dial voltage.
9. Flow Control Lever LH Voltage mV Indicating LH joystick thumb wheel switch voltage
10. Flow Control Lever RH Voltage mV Indicating RH joystick thumb wheel switch voltage
11. Fuel Level % Fuel residual quantity radio of fuel tank
12. Hydraulic Oil Temperature °C Hydraulic oil temperature
13. Power Shift P/V 1 mA Current in pump proportional valve.
14. Coolant Fan Control P/V mA Current in coolant fan control proportional valve.
15. Flow Control P/V mA Current in flow control proportional valve.
16. Two-way P/V (Open) mA Current in two-way (open) flow control proportional valve.
17. Two-way P/V (Close) mA Current in two-way (close) flow control proportional valve.
18. Rotating P/V (CW) mA Current in rotating (CW) flow control proportional valve.
19. Rotating P/V (CCW) mA Current in rotating (CCW) flow control proportional valve.
20. Pressure Control P/V 1 mA Current in 1 way pressure proportional valve.
21. Pressure Control P/V 2 mA Current in 2 way pressure proportional valve.
Submenu Selections
Vehicle Analog Vehicle Analog
Vehicle Analog
Figure 134 WE1400655

9-1-73
Vehicle Digital Descriptions
Digital Items Mark Remark

Lights up when output at alternator "R (I)" terminal is
1. Alternator
above 12 ±1 V.
Lights up when the boost button is "ON" with the
2. Power Max Switch
work mode selected to "BOOST".
Lights up when the boost button is "ON" with the
3. Breaker Operator Switch
work mode selected to "BREAKER".
Lights up when the travel speed selector switch is set
4. Hi-Speed Selector Switch (Manual)
to "I" position.
Lights up when the travel speed selector switch is set
5. Hi-Speed Selector Switch (Auto)
to "II" position.
6. Working Light Switch Lights up when the light switch is set to "II" position.
7. Quick Coupler Lights up when the quick coupler switch is "ON".
Lights up when the air-conditioning relay in the
8. Air Conditioner Switch
air-conditioning unit is "ON".
Lights up when the one touches deceleration button
9. One Touch Deceleration Switch
is "ON".
Lights up when the intelligent floating boom switch is
10. Intelligent Floating Boom Switch
set to "I" position or the "II" position.
11. Pilot Cutoff Switch Lights up when the pilot cutoff switch is "ON".
Lights up when the air cleaner indicator contact is
12. Air Cleaner Indicator
"ON".
ON/OFF Lights up when the pilot filter pressure switch is
13. Pilot Filter
"ON".
Lights up when the return filter pressure switch is
14. Return Filter
"ON".
Lights up when the overload warning selector switch
15. OWD Selector Switch
is "ON".
16. Option Pedal Pressure Switch (2 way) Lights up when the option pedal switch is "ON".
17. Joystick Pattern-ISO
18. Joystick Pattern-BHL
19. Swing Pressure Switch Lights up when the swing pressure switch is "ON".
20. Water in Fuel Lights up when WIF sensor is "ON".
21. Start up Switch Lights up when the starter switch is "START"
22. Swing Alarm Selector Switch
23. Travel Alarm Selector Switch
24. SPC Switch
25. Option Pedal Pressure Switch (1 way)
Lights up when the breaker operating solenoid valve
26. Breaker S/V
is "ON".
Lights up when the relief press up solenoid valve is
27. Relief Press. Up S/V
"ON".
Lights up when the high-speed solenoid valve is
28. High-Speed S/V
"ON".
Lights up when the 2 pump select solenoid valve is
29. 2 Pump Select S/V
"ON".
30. Back Buzzer Relay Lights up when the back buzzer relay is "ON".
31. Doosan Connect Status Lights up when TMS is "ON".
32. Option Pedal Safety S/V
33. Preheat Relay

9-1-74
Submenu Selections
Option Pedal Pressure Switch (2 way)
EX1300997
Figure 135

9-1-75
Engine Signal Description
Analog Items Display Remark

1. Engine Speed rpm Engine Speed
2. Throttle Position % Throttle Position
3. % Load at Current Speed % % Load at Current Speed
4. Fuel Rate L/H Fuel Rate
5. Boost Pressure bar Boost Pressure
6. Engine Oil Pressure bar Engine Oil Pressure
7. Fuel Temperature °C Fuel Temperature
8. Engine Oil Temperature °C Engine Oil Temperature
9. Coolant Water Temperature °C Coolant Water Temperature
10. DOC Intake Temperature °C DOC Intake Temperature
11. Intake Manifold Temperature °C Intake Manifold Temperature
12. APP Command % APP Command
13. Total Fuel Used L Total Fuel Used
14. SCR Upstream Temperature °C SCR Upstream Temperature
15. SCR Downstream Temperature °C SCR Downstream Temperature
16. DEF Level % DEF Level
17. DEF Temperature °C DEF Temperature
Submenu Selections
Engine Signal
Engine Speed 770 rpm
Throttle Position 0 %
% Load at Current Speed 0 %
Fuel Rate 0.0 L/H
Boost Pressure 0 bar
Engine Oil Pressure 0 bar
Engine Signal
Fuel Temperature -40 C
Engine Oil Temperature -273 C Coolant Water Temperature -40 C
DOC Intake Temperature -273 C
Intake Manifold Temperature -40 C
APP Command 0.0 %
Total Fuel Used 0 L
SCR Upsteam Temperature -273 C
Engine Signal SCR Downsteam Temperature -273 C
DEF Temperature -40 C DEF Level 0 %
EX1403137
Figure 136

9-1-76
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 137

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 138
Graph
PM
1. Entering Submenus: When a cursor is located in "Graph" Service Menu
of special menu screen press enter jog switch (1 on Figure
Monitoring
129) and "Graph" screen is displayed.
Graph
2. Exiting Submenus: If escape button (ESC, 4 on Figure Failure Information
129) is pressed, this information screen will be returned to Operating Hour Information
previous screen. Vehicle Configuration
SPC
S USB
EX1301615
Figure 139
Graph Data Monitoring

PM
Real time monitoring of the selected data. Service Menu
Graph Data Setting
SPC
S USB
EX1301084
Figure 140

9-1-77
Battery Voltage V Current Value : 24.7
40.0
Engine Dial Volt.
Rotating P/V (CCW)
0
1 19 Sec
EX1301616
Figure 141
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 142
Failure Information
PM
1. Entering Submenus: When a cursor is located in "Failure Service Menu
Info" of special menu screen press jog switch (1 on Figure
Monitoring
129) and "Failure Info" screen is displayed.
Graph
2. Exiting Submenus: If escape button (ESC, 4 on Figure Failure Information
129) is pressed, this information screen will be returned to Operating Hour Information
previous screen. Vehicle Configuration
SPC
S USB
EX1301086
Figure 143
* 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
SPC
S USB
EX1301087
Figure 144

9-1-78
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 using the jog switch (1, Figure 129). 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 145
– 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
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.

9-1-79
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 using the jog switch (1, Figure 129). 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 146
occurrences of the same fault, until first
occurrence time.)

9-1-80
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 147) press
Monitoring
jog switch (1 on Figure 129) and "Operating Hrs" screen
will be displayed (Figure 148). Graph
Failure Information
SPC
S USB
EX1301088
Figure 147
2. Operating Hours Screen

4 hr
0 hr
14 hr
0 hr
0 hr
0 hr
0 hr
0 hr
EX1301626
Figure 148
3. Exiting Submenus: If escape button (ESC, 4 on Figure

129) is pressed for more than 1 second, this information
screen will be returned to previous screen.

9-1-81
Information contents of operation hour
Item Information Contents Detection Method

Power Plus Mode Operation hours used Power Plus Power Plus Mode status (Instrument
Mode are displayed. panel) and Alternator signal (CN1-2) is
"HI"
Power Mode Operation hours used Power Mode Power Mode status (Instrument panel)
are displayed. and Alternator signal (CN1-2) is "HI"
Standard Mode Operation hours used standard Standard Mode status (Instrument panel)
mode are displayed. and Alternator signal (CN1-2) is "HI".
Economy Mode Operation hours used economy Economy Mode status (Instrument
mode are displayed. panel) and Alternator signal (CN1-2) is
"HI"
Auto Idle Operation hours used auto idle Auto Idle Mode status (Instrument panel)
status are displayed. and Alternator signal (CN1-2) is "HI"
The operation hours for Lift Mode
Lift Mode
are displayed.
The operation hours for Breaker
Breaker Mode
Mode are displayed.
The operation hours for Two-way
Two-way Mode
Mode are displayed.
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)

9-1-82
Example of Machine Operation Info Screen
Operating Hour Information Operating Hour Information

4 hr Lift Mode 0 hr
0 hr Breaker Mode 0 hr
14 hr Two Way Mode 0 hr
0 hr
0 hr
0 hr
0 hr
0 hr
Operating Hour Information Operating Hour Information

17 hr 0 hr
1 hr 0 hr
1 hr 0 hr
1 hr 0 hr
0 hr 0 hr
0 hr 20 hr
EX1301077
Figure 149

9-1-83
1. Vehicle Configuration
PM
A. Entering Submenus: When a cursor is located in Service Menu
"Vehicle Configuration" of special menu screen
Monitoring
(Figure 150) press jog switch (1 on Figure 129) and
Graph
"Vehicle Configuration" screen will be displayed
(Figure 152). Failure Information
Operation Hour Information
SPC
S USB
EX1301089
Figure 150
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 151
B. Vehicle Configuration Screen (Figure 152).

Option Setting
Program Update
Vehicle Serial Number
Vehicle Information Delete
Version Information
SPC
S USB
EX1301090
Figure 152
C. Exiting Submenus: If escape button (ESC, 4 on

Figure 129) is pressed, this information screen will be
returned to previous screen.

9-1-84
Option Setting
1. Entering Submenus: When a cursor is located in "Option Vehicle Configuration
Setting" of special menu screen (Figure 153) press jog
switch (1 on Figure 129) and "Option Setting screen" will Option Setting
be displayed (Figure 154) Program Update

Version Information
SPC
S USB
EX1301090
Figure 153
2. Option Setting
• Attachment Option Vehicle Configuration
When a cursor is located in check box of breaker or Option Setting
two-way, press jog switch (1 on Figure 129) and then, Program Update
the check box light turns "ON". Vehicle Serial Number
Version Information
SPC
S USB
EX1301090
Figure 154
• Two Pump Option

Option Setting
When a cursor is located in check box of two pump.
Option, press jog switch (1 on Figure 129) and then,
the check box light turns "ON". Attachment Option Breaker Two Way
• Two-way Option Pedal Two Pump Option Enable
Place the cursor on the check box for the two-way Two Way Option Pedal Enable
option pedal and select a function by pressing the jog
switch.
NOTE: Option setting can only be made for those
EX1301635
vehicles with the option in question.
Selecting a vehicle without the option can Figure 155
cause a problem in terms of performance
and safety.

9-1-85
3. Program Update
Entering Submenus: When a cursor is located in "Program Vehicle Configuration
Update" of special menu screen (Figure 156) press jog
Option Setting
switch (1 on Figure 129) and "Program Update Screen" will
be displayed (Figure 157). Program Update
NOTE: When USB memory is installed in USB port, Vehicle Information Delete
program update can be updated. Version Information
SPC
S USB
EX1301091
Figure 156
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 157
4. Vehicle Serial Number

Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration
Serial Number" of special menu screen (Figure 158) press
Option Setting
jog switch (1 on Figure 129) and "Vehicle Serial Number
Program Update
Screen" will be displayed (Figure 159).
Vehicle serial number can be input by turning the jog Vehicle Information Delete
switch and pressing the jog switch. Version Information
SPC
S USB
EX1301092
Figure 158
3 4 5 6 7 8 9 : ; <
Enter Serial Number
EX1301638
Figure 159

9-1-86
5. Vehicle Information Delete
Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration
Information Delete" of special menu screen (Figure 160)
Option Setting
press jog switch (1 on Figure 129) and "Vehicle Information
Delete Screen" will be displayed (Figure 161) Program Update
NOTE: When press jog switch (1 on Figure 129) in the Vehicle Information Delete
selected menu the menu will be initialized. Version Information
- Delete Failure Log SPC
S USB
- Reset Operation Hour EX1301093

- GP Setting Reset Figure 160

Delete Failure Log
Reset Operation Hour
GP Setting Reset
EX1301094
Figure 161
6. Version Information
Entering Submenus: When a cursor is located in "Version Vehicle Configuration
Information" of special menu screen (Figure 162) press jog
Option Setting
switch (1 on Figure 129) and "Version Information Screen"
Program Update
will be displayed (Figure 163).
Vehicle Information
S USB
EX1301096
Figure 162
Version Information
EPOS S/W Version V0510 [2010.06.24]
GP S/W Version V0101 [2010.05.24]
GP OS Version V0101 [2011.05.19]
FG018893
Figure 163

9-1-87
FAILURE CODE
Failure Code at Machine

GP (Graphic Panel): Code displays on Panel Gauge
FMI (Failure Mode Identifier): Code displays on DMS
DTC (Diagnostic Trouble Code): Code displays on Diagnostic tool
HEX: Hexadecimal, DEC: Decimal number
GP Correct Value
Measuring Severity
Display SPN Name FMI GP Display Description
Point Active Passive Level
Code
6-12/
VCO001 Can (Gauge Panel) 11 Gauge Panel Communication Error
6-13
R = 60 ±5 4
1-39/
VCO002 Can (ECU) 11 E-ECU Communication Error
1-40
VPV001 05 Current of Pump P/V (A) is Below Normal 2-98/ R = 13.5 ±2
Pump P/V (A) 4
VPV001 06 Current of Pump P/V (A) Is Above Normal 2-99 (25°C (77°F))
VPV003 05 Current of Flow Control P/V (C) is Below Normal 2-108/ R = 13.5 ±2
Flow Control P/V ( C) 3
VPV003 06 Current of Flow Control P/V (C) is Above Normal 2-109 (25°C (77°F))
VPV005 05 Current of Press. Control 1 P/V (H) is Below Normal 1-26/ R = 9.5 ±2
Press. Control 1 P/V (H) 3
VPV005 06 Current of Press. Control 1 P/V (H) is Above Normal 1-27 (25°C (77°F))
VPV006 05 Current of Press. Control 2 P/V (I) is Below Normal 1-44/ R = 9.5 ±2
Press. Control 2 P/V (I) 3
VPV006 06 Current of Press. Control 2 P/V (I) is Above Normal 1-63 (25°C (77°F))
Current of Flow Control P/V (C) 2-way RH-open is
VPV007 05
Flow Control P/V (C) Below Normal 1-6/ R = 18 ±2
3
2-way RH-open Current of Flow Control P/V (C) 2-way RH-open is 1-25 (25°C (77°F))
VPV007 06
Above Normal
Current of Flow Control P/V (D) 2-way RH-close is
VPV008 05
Flow Control P/V (D)  Below Normal 2-82/ R = 18 ±2
3
2-way RH-close Current of Flow Control P/V (D) 2-way RH-close is 2-83 (25°C (77°F))
VPV008 06
Above Normal
Current of Flow Control P/V (E) Rotating CW is Below
VPV009 05
Flow Control P/V (E) Normal 1-7/ R = 18 ±2
3
Rotating CW Current of Flow Control P/V (E) Rotating CW is 1-8 (25°C (77°F))
VPV009 06
Above Normal
Current of Flow Control P/V (F) Rotating CCW is
VPV010 05
Flow Control P/V (F) Below Normal 2-90/ R = 18 ±2
3
Rotating CCW Current of Flow Control P/V (F) Rotating CCW is 2-91 (25°C (77°F))
VPV010 06
Above Normal
VSV001 05 Current of Breaker Operating S/V is Below Normal 1-1/ V = V_volt
Breaker Operating S/V 3
VSV001 06 Current of Breaker Operating S/V is Above Normal 2-97 (Note 4)
VSV002 05 Current of Relief Press. Up S/V (B) is Below Normal 1-1/
Relief Press. Up S/V (B) V = V_volt 3
VSV002 06 Current of Relief Press. Up S/V (B) is Above Normal 2-96
VSV007 05 Current of Option Safety S/V is Below Normal 1-1/
Option Safety S/V V = V_volt 3
VSV007 06 Current of Option Safety S/V is Above Normal 2-116
VSV008 05 Current of Cruise S/V (F), Current Below Normal 1-1/
CRUISE S/V V = V_volt 3
VSV008 06 Current of Cruise S/V (F), Current Above Normal 2-113
VSV009 05 Current of Forward S/V (G), Current Below Normal
FORWARD S/V 2-112 V = V_volt 3
VSV009 06 Current of Forward S/V (G), Current Above Normal
VSV010 05 Current of Reverse S/V (H), Current Below Normal
REVERSE S/V 2-105 V = V_volt 3
VSV010 06 Current of Reverse S/V (H), Current Above Normal
VSV011 05 Current of 2 Pump Select S/V (I) is Below Normal 1-1/
2 Pump Select S/V (I) V = V_volt 3
VSV011 06 Current of 2 Pump Select S/V (I) is Above Normal 2-104
VRY002 05 Current of Alarm Relay is Below Normal 1-1/
Alarm Relay V = V_volt 3
VRY002 06 Current of Alarm Relay is Above Normal 2-119
VRY003 05 Backup Lamp Relay, Current Below Normal
Backup Lamp Relay 2-117 V = V_volt 3
VRY003 06 Backup Lamp Relay, Current Above Normal
VSV013 05 Inching S/V, Current Below Normal
Inching S/V 2-89 V = V_volt 3
VSV013 06 Inching S/V, Current Above Normal
VSV014 05 Low Speed S/V, Current Below Normal
Low-speed S/V 2-88 V = V_volt 3
VSV014 06 Low Speed S/V, Current Above Normal
VSV015 05 High Speed S/V, Current Below Normal
High-speed S/V 2-114 V = V_volt 3
VSV015 06 High Speed S/V, Current Above Normal

9-1-88
GP Correct Value
Measuring Severity
Display SPN Name FMI GP Display Description
Point Active Passive Level
Code
VRY007 05 Starter Relay, Current Below Normal 1-1/
Starter Relay V = V_volt 0
VRY007 06 Starter Relay, Current Above Normal 2-115
VSP001 02 Front Pump Press. Sensor, Incorrect Signal
Front Pump Press. 1-34/
VSP001 03 Front Pump Press. Sensor, Voltage Above Normal V=1V 2
Sensor 1-10
VSP001 04 Front Pump Press. Sensor, Voltage Below Normal
VSP002 02 Rear Pump Press. Sensor, Incorrect Signal
Rear Pump Press. 1-15/
VSP002 03 Rear Pump Press. Sensor, Voltage Above Normal V=1V 2
Sensor 1-10
VSP002 04 Rear Pump Press. Sensor, Voltage Below Normal
VSP003 02 OWD Press. Sensor, Incorrect Signal
1-32/
VSP003 OWD Press. Sensor 03 OWD Press. Sensor, Voltage Above Normal V=1V 2
1-10
VSP003 04 OWD Press. Sensor, Voltage Below Normal
VSP004 03 Px (Front) Press. Sensor, Voltage Above Normal 1-33/
Px (Front) Press. Sensor V=1V 2
VSP004 04 Px (Front) Press. Sensor, Voltage Below Normal 1-28
VSP005 Py (Travel) Press. 03 Py (Travel) Press. Sensor, Voltage Above Normal 1-14/
V=1V 2
VSP005 Sensor 04 Py (Travel) Press. Sensor, Voltage Below Normal 1-28
VSP006 03 Boom Up Press. Sensor, Voltage Above Normal 1-46/
Boom Up Press. Sensor V=1V 2
VSP006 04 Boom Up Press. Sensor, Voltage Below Normal 1-10
VSP010 03 Arm In Press. Sensor, Voltage Above Normal
Arm In Press. Sensor 1-65/1-10 V=1V 2
VSP010 04 Arm In Press. Sensor, Voltage Below Normal
VSE001 00 Oil Temp. Sensor Signal is Above Normal Range R=
2.45 ±0.25
1-36/
VSE001 Oil Temp. Sensor 03 Oil Temp. Sensor Voltage is Above Normal (25°C (77°F)) 3
1-28
R = 320 ±2
VSE001 04 Oil Temp. Sensor Voltage is Below Normal (80°C (176°F))
VSE002 03 Fuel Sensor Voltage is Above Normal Empty:
1-37/
Fuel Sensor 5 ±0.2 3
VSE002 04 Fuel Sensor Voltage is Below Normal 1-10
Full: 500 ±10
VSE003 03 Machine Speed Sensor Voltage is Above Normal 1-68/
Machine Speed Sensor 3
VSE003 04 Machine Speed Sensor Voltage is Below Normal 2-118
VSE004 01 Wif Sensor Signal is Above Normal Range V = 0.5 V
VSE004 03 Wif Sensor Voltage is Above Normal 1-38/ excess
Wif Sensor 3
1-28 V = 4.5 V less
VSE004 04 Wif Sensor Voltage is Below Normal than
VSE005 03 Spare Speed, Voltage Above Normal
Spare - - - 3
VSE005 04 Spare Speed, Voltage Below Normal
VSE006 03 Spare, Voltage Above Normal
Spare - - - 3
VSE006 04 Spare, Voltage Below Normal
VS5001 03 Thumb Wheel (RH) Voltage is Above Normal V = 1.0 ±0.1 V

1-30/ V = 2.5 ±0.2 V
Thumb Wheel (RH) 3
1-29 neutral
VS5001 04 Thumb Wheel (RH) Voltage is Below Normal V = 4.0 ±0.1 V
VS5002 03 Thumb Wheel (LH) Voltage is Above Normal V = 1.0 ±0.1 V

1-66/ V = 2.5 ±0.2 V
Thumb Wheel (LH) 3
1-29 neutral
VS5002 04 Thumb Wheel (LH) Voltage is Below Normal V = 4.0 ±0.1 V
VS5004 Parking Brake Press. 03 Parking Brake Press. Sensor, Voltage Above Normal
1-11/1-13 V=1V 3
VS5004 Sensor 04 Parking Brake Press. Sensor, Voltage Below Normal
VS5005 03 Dial Voltage is Above Normal 1-31/ V = 1.0 ±0.1 V
Dial 3
VS5005 04 Dial Voltage is Below Normal 1-11 V = 4.0 ±0.1 V
VAL001 03 Alternator Potential Voltage is Above Normal
Alternator Potential 1-2 V = 27 ±0.1 V 4
VAL001 04 Alternator Potential Voltage is Below Normal
VAL002 Accelerator Pedal 05 Accel. Pedal Switch, Current Below Normal
2-93 4
VAL002 Switch 06 Accel. Pedal Switch, Current Above Normal
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.

9-1-89
Failure Code at Engine Side
GP (Graphic Panel): Code displays on Panel Gauge
FMI (Failure Mode Identifier): Code displays on DMS
DTC (Diagnostic Trouble Code): Code displays on Diagnostic tool
HEX: Hexadecimal, DEC: Decimal number
DTC Code
P Code
GP Display Code FMI GP Display Description Severity Remarks
DTC
HEX DEC
Throttle valve position sensor: DFC for throttle

E000051-03 2E9 33 51 3 -
valve position sensor voltage SRC high
E000051-04 2E8 33 51 4 -
valve position sensor voltage SRC low
Accelerator pedal position: Signal Range Check
E000091-03 123 5B 91 3 -
High for APP1
E000091-04 122 5B 91 4 -
Low for APP1
Oil pressure sensor: Maximum oil pressure
E000100-00 521 64 100 0 -
error in plausibility check
Oil pressure sensor: Minimum oil pressure error
E000100-01 1521 64 100 1 -
in plausibility check
Oil pressure sensor: SRC high for oil pressure
E000100-03 1522 64 100 3 -
sensor
Oil pressure sensor: SRC low for Oil pressure
E000100-04 1523 64 100 4 -
sensor
Boost pressure sensor: SRC high for Boost
E000102-03 238 66 102 3 -
pressure sensor
Boost pressure sensor: SRC low for Boost
E000102-04 237 66 102 4 -
pressure sensor
Air Inlet temperature: SRC High for Charge air
E000105-03 113 69 105 3 -
cooler downstream Temperature
Air Inlet temperature: SRC low for Charge air
E000105-04 112 69 105 4 -
Air Inlet temperature: Diagnostic fault check for
E000105-05 1113 69 105 5 SRC high in engine inlet valve air temperature -
upstream sensor
E000105-06 1112 69 105 6 SRC low in engine inlet valve air temperature -
upstream sensor
Barometric pressure sensor in ECU: Physical
E000108-00 2227 6C 108 0 -
Range Check high for Environment Pressure
E000108-01 1227 6C 108 1 -
Range Check low for Environment Pressure
Barometric pressure sensor in ECU: SRC High
E000108-03 2229 6C 108 3 -
for Environment Pressure
Barometric pressure sensor in ECU: SRC low
E000108-04 2228 6C 108 4 -
Coolant temperature: Physical Range Check
E000110-00 116 6E 110 0 -
high for coolant temperature
E000110-01 1118 6E 110 1 -
low for coolant temperature
Coolant temperature: SRC high for coolant
E000110-03 118 6E 110 3 -
temperature

9-1-90
DTC Code
P Code
DTC
HEX DEC
Coolant temperature: SRC low for coolant

E000110-04 1119 6E 110 4 -
temperature
Coolant temperature: Defect fault check for
E000110-12 1117 6E 110 12 -
dynamic plausibility test of coolant temperature
Rail pressure sensor: maximum rail pressure
E000129-00 1093 81 129 0 -
exceeded [1]
Rail pressure sensor: check of minimum rail
E000129-01 1320 81 129 1 -
pressure
Rail pressure sensor: Rail pressure sensor
E000129-03 193 81 129 3 -
voltage above upper limit
E000129-04 192 81 129 4 -
voltage below lower limit
Rail pressure sensor: Rail pressure raw value is
E000129-05 191 81 129 5 -
above maximum offset
E000129-06 1191 81 129 6 -
below minimum offset
E000129-12 1095 81 129 12 -
exceeded [2]
E000129-31 1096 81 129 31 -
exceeded [3]
Air mass flow sensor: Sensitivity drift high error
E000132-00 1101 84 132 0 -
for HFM sensor
Air mass flow sensor: Sensitivity drift error low
E000132-01 101 84 132 1 -
for HFM sensor
Air mass flow sensor: SRC high error for raw
E000132-03 103 84 132 3 -
value in HFM sensor
Air mass flow sensor: SRC low error for raw
E000132-04 102 84 132 4 -
value in HFM sensor
Air mass flow sensor: SCB of hardware signal
E000132-12 100 84 132 12 -
of HFM sensor
Air mass flow sensor: Battery voltage error of
E000132-31 1100 84 132 31 -
HFM sensor
CP metering unit: signal range check high error
E000157-03 1255 9D 157 3 -
of metering unit
CP metering unit: signal range check low error
E000157-04 1256 9D 157 4 -
of metering unit
CP metering unit: Open load of metering unit
E000157-05 125B 9D 157 5 -
output
CP metering unit: Over temperature of device
E000157-12 252 9D 157 12 -
driver of metering unit
CP metering unit: Intermittent contact between
E000157-31 125A 9D 157 31 -
ECU and MeUn
E000158-00 563 9E 158 0 Battery: High Battery Voltage indication -
E000158-01 562 9E 158 1 Battery: Low Battery voltage indication -
E000158-03 1563 9E 158 3 Battery: SRC high for battery voltage sensor -
E000158-04 1562 9E 158 4 Battery: SRC low for battery voltage sensor -
Air mass flow sensor temperature: Physical
E000172-00 96 AC 172 0 -
Range high error for air temperature senso
Air mass flow sensor temperature: SRC high for
E000172-03 98 AC 172 3 -
air temperature senso

9-1-91
DTC Code
P Code
DTC
HEX DEC
Air mass flow sensor temperature: SRC low for

E000172-04 97 AC 172 4 -
Fuel temperature sensor: Physical Range
E000174-00 181 AE 174 0 -
Check high for fuel temperature
E000174-01 180 AE 174 1 -
Check low for fuel temperature
Fuel temperature sensor: SRC high for fuel
E000174-03 183 AE 174 3 -
temperature sensor
Fuel temperature sensor: SRC low for fuel
E000174-04 182 AE 174 4 -
temperature sensor
Oil temperature sensor: Physical Range Check
E000175-00 196 AF 175 0 -
high for Oil Temperature
E000175-01 195 AF 175 1 -
low for Oil Temperature
Oil temperature sensor: SRC High for Oil
E000175-03 198 AF 175 3 -
Temperature
Oil temperature sensor: SRC low for Oil
E000175-04 197 AF 175 4 -
Temperature
Overspeed detection in component engine
E000606-00 219 25E 606 0 protection: Overspeed detection in component -
engine protection
Solenoid powerstage 1 (cylinder 1): open load
E000734-05 201 2DE 734 5 -
of Solenoid powerstage 1
Solenoid powerstage 1 (cylinder 1): general
E000734-06 262 2DE 734 6 -
short circuit of Solenoid powerstage 1
Solenoid powerstage 1 (cylinder 1): special
E000734-12 263 2DE 734 12 pattern for special cases of Solenoid -
powerstage 1
E000735-05 202 2DF 735 5 -
E000735-06 265 2DF 735 6 -
E000735-12 266 2DF 735 12 pattern for special cases of Solenoid -
powerstage 2
E000736-05 203 2E0 736 5 -
E000736-06 268 2E0 736 6 -
E000736-12 269 2E0 736 12 pattern for special cases of Solenoid -
powerstage 3
E000737-05 204 2E1 737 5 -
E000737-06 271 2E1 737 6 -
powerstage 4
E000738-05 205 2E2 738 5 -

9-1-92
DTC Code
P Code
DTC
HEX DEC

E000738-06 274 2E2 738 6 -
powerstage 5
E000739-05 120B 2E3 739 5 -
E000739-06 1277 2E3 739 6 -
powerstage 6
Auto fan clutch PWM out: Short circuit to battery
E000977-03 694 3D1 977 3 -
error of fan clutch PWM out
Auto fan clutch PWM out: No load error of fan
E000977-05 481 3D1 977 5 -
clutch PWM out
Auto fan clutch PWM out: Short circuit to ground
E000977-06 693 3D1 977 6 -
Auto fan clutch PWM out: Over temperature
E000977-12 1481 3D1 977 12 -
Engine ECU temperature: Physical Range
E001207-00 669 4B7 1207 0 -
Check high for ECU temperature sensor [1]
E001207-01 668 4B7 1207 1 -
Check low for ECU temperature sensor [1]
Engine ECU temperature: SRC high for ECU
E001207-03 1669 4B7 1207 3 -
temperature sensor
Engine ECU temperature: SRC low for ECU
E001207-04 1668 4B7 1207 4 -
temperature sensor
E001207-12 166A 4B7 1207 12 -
E001207-31 166B 4B7 1207 31 -
Monitoring Misfire detection multiple cylinder:
E001322-12 300 52A 1322 12 -
Monitoring Misfire detection multiple cylinder
Injection Misfire detection cylinder 1: Injection
E001323-12 301 52B 1323 12 -
Misfire detection cylinder 1
E001324-12 302 52C 1324 12 -
E001325-12 303 52D 1325 12 -
E001326-12 304 52E 1326 12 -
E001327-12 305 52F 1327 12 -
E001328-12 306 530 1328 12 -
Timeout error of CAN-Receive-Frame TCU:
E001482-12 D121 5CA 1482 12 -
Timeout Error of CAN-Receive-Frame TSC1TE
Auto fan clutch speed: Fan speed above
E001639-03 527 667 1639 3 -
maximum threshold

9-1-93
DTC Code
P Code
DTC
HEX DEC
Auto fan clutch speed: Fan speed below

E001639-04 528 667 1639 4 -
minimum threshold
Auto fan clutch speed: Fan Speed signal long
E001639-12 526 667 1639 12 -
period fault path
Urea tank level sensor: Error of Urea Tank
E001761-00 103B 6E1 1761 0 Level Sensor evaluation with Physical Range -
Check high
E001761-01 203B 6E1 1761 1 Level Sensor evaluation with Physical Range -
Check low
Urea tank level sensor: DFC for SRC high error
E001761-03 203D 6E1 1761 3 -
of the urea tank level sensor
Urea tank level sensor: DFC for SRC low error
E001761-04 203C 6E1 1761 4 -
E001761-12 103C 6E1 1761 12 Urea tank level sensor: Status of tank level -
Urea temperature sensor: Physical Range
E003031-00 205B BD7 3031 0 -
Check high for Urea Temperature Sensor
E003031-01 105B BD7 3031 1 -
Check low for Urea Temperature Sensor
Urea temperature sensor: Error Tank
E003031-02 115B BD7 3031 2 -
temperature sensor plausibility max threshold
Urea temperature sensor: SRC high for Urea
E003031-03 205D BD7 3031 3 -
temperature sensor
Urea temperature sensor: SRC low for Urea
E003031-04 205C BD7 3031 4 -
temperature sensor
E003031-12 115A BD7 3031 12 -
temperature sensor plausibility min threshold
Urea temperature sensor: Error Urea tank
E003031-31 115C BD7 3031 31 -
temperature is overheated
Urea tank heating valve (Coolant valve): Short
E003363-03 20B4 D23 3363 3 circuit to battery error for Urea tank heating -
valve
E003363-04 20B3 D23 3363 4 circuit to ground error for Urea tank heating -
valve
Urea tank heating valve (Coolant valve): No
E003363-12 20B1 D23 3363 12 -
load error for Urea tank heating valve
Urea tank heating valve (Coolant valve): Over
E003363-31 10B1 D23 3363 31 -
Temperature error for Urea tank heating valve
Throttle valve control: Permanent governor
E003464-00 12E1 D88 3464 0 -
deviation max for throttle valve
E003464-01 12E2 D88 3464 1 -
deviation min for throttle valve
Throttle valve control: DFC for throttle valve drift
E003464-12 2E1 D88 3464 12 -
at open position
Monitoring of sensor supply voltage in ECU:
E003509-02 643 DB5 3509 2 -
Error Sensor supplies 1
E003059-31 699 BF3 3059 31 -
E003509-12 653 DB5 3509 12 -

9-1-94
DTC Code
P Code
DTC
HEX DEC
Monitoring of 12V sensor supply voltage in

E003510-03 1602 DB6 3510 3 -
ECU: 12V sensor supply 1 voltage is too high
E003510-04 1603 DB6 3510 4 -
ECU: 12V sensor supply 1 voltage is too low
Sensor supply voltage monitoring 1: Over
E003511-03 6B2 DB7 3511 3 -
voltage on sensor supply 1
Sensor supply voltage monitoring 1: Under
E003511-04 6B1 DB7 3511 4 -
E003512-03 6B5 DB8 3512 3 -
E003512-04 6B4 DB8 3512 4 -
E003513-03 16B2 DB9 3513 3 -
E003513-04 16B1 DB9 3513 4 -
Urea quality sensor: Diagnostic fault check for
E003516-00 206D DBC 3516 0 urea quality sensor whether physical signal -
above the maximum limit
E003516-01 206C DBC 3516 1 urea quality sensor whether physical signal -
below the minimum limit
SAE J1939 error for SCR catalyst reagent
temperature 2 Preliminary FMI: SAE J1939
E003519-05 1128 DBF 3519 5 -
error for catalyst reagent temperature 2
Preliminary FMI message (Open circuit)
E003519-31 112A DBF 3519 31 -
Preliminary FMI message (Short circuit)
properties Preliminary FMI: SAE J1939 error for
E003520-00 1120 DC0 3520 0 -
Diesel Exhaust Fluid Properties Preliminary FMI
message
E003520-01 1121 DC0 3520 1 -
message
E003520-05 1122 DC0 3520 5 -
message (Tank open circuit)
E003520-06 206A DC0 3520 6 -
message
E003520-12 1123 DC0 3520 12 -
message

9-1-95
DTC Code
P Code
DTC
HEX DEC

E003520-31 1124 DC0 3520 31 -
message (Tank short circuit)
SAE J1939 error for SCR catalyst Tank level
Preliminary FMI: SAE J1939 error for SPN3532
E003532-05 203A DCC 3532 5 -
Catalyst Tank Level Preliminary FMI (Open
circuit)
E003532-31 1126 DCC 3532 31 -
Catalyst Tank Level Preliminary FMI (Short
circuit)
Monitoring of internal 12V supply voltage in
E003597-03 1604 E0D 3597 3 -
ECU: Internal 12V supply voltage is too high
E003597-04 1605 E0D 3597 4 -
ECU: internal 12V supply voltage is too low
Supply Module monitoring 2: Detection of filled
E004332-12 1704 10EC 4332 12 -
system in InitState (Supply module monitoring)
Urea pump module pressure sensor: Physical
E004334-00 204B 10EE 4334 0 Range Check high for Urea Pump Module -
Pressure Sensor
E004334-01 104B 10EE 4334 1 Range Check low for Urea Pump Module -
Pressure Sensor
Urea pump module pressure sensor: SRC error
E004334-03 204D 10EE 4334 3 -
max for Urea Pump Module Pressure Sensor
E004334-04 204C 10EE 4334 4 -
min for Urea Pump Module Pressure Sensor
Urea pump module pressure sensor: plausibility
E004334-12 1726 10EE 4334 12 error min for Urea Pump Module Pressure -
Sensor
Urea pump module pressure sensor: Plausibility
E004334-31 1725 10EE 4334 31 error max for Urea Pump Module Pressure -
Sensor
Backflow line heater: Short circuit to battery
E004354-03 20BC 1102 4354 3 -
error for Backflow line heater
Backflow line heater: Short circuit to ground
E004354-04 20BB 1102 4354 4 -
Backflow line heater: No load error for Backflow
E004354-12 20B9 1102 4354 12 -
line heater
Backflow line heater: Over Temperature error
E004354-31 10B9 1102 4354 31 -
for Backflow line heater
Pressure line heater: Short circuit to battery
E004355-03 20C0 1103 4355 3 -
error for Pressure line heater
Pressure line heater: Short circuit to ground
E004355-04 20BF 1103 4355 4 -
Pressure line heater: No load error for Pressure
E004355-12 20BD 1103 4355 12 -
line heater
Pressure line heater: Over Temperature error
E004355-31 10BD 1103 4355 31 -
for Pressure line heater
Suction line heater: Short circuit to battery error
E004356-03 20C4 1104 4356 3 -
for Suction line heater

9-1-96
DTC Code
P Code
DTC
HEX DEC
Suction line heater: Short circuit to ground error

E004356-04 20C3 1104 4356 4 -
Suction line heater: No load error for Suction
E004356-12 20C1 1104 4356 12 -
line heater
Suction line heater: Over Temperature error for
E004356-31 10C1 1104 4356 31 -
Suction line heater
Supply module heater: Short circuit to battery
E004357-03 20C8 1105 4357 3 -
error for Supply module heater
Supply module heater: Short circuit to ground
E004357-04 20C7 1105 4357 4 -
Supply module heater: No load error for Supply
E004357-12 20C5 1105 4357 12 -
module heater
Supply module heater: Over Temperature error
E004357-31 10C5 1105 4357 31 -
for Supply module heater
Urea catalyst upstream temperature: Physical
E004360-00 436 1108 4360 0 Range Check high for Urea catalyst upstream -
temperature
E004360-01 1436 1108 4360 1 Range Check low for Urea catalyst upstream -
temperature
Urea catalyst upstream temperature: SRC high
E004360-03 438 1108 4360 3 -
for Urea catalyst upstream temperature sensor
Urea catalyst upstream temperature: SRC low
E004360-04 437 1108 4360 4 -
SCR downstream Temperature: Physical
E004363-00 43B 110B 4363 0 Range Check high for Urea catalyst -
downstream Temperature sensor
E004363-01 143B 110B 4363 1 Range Check low for Urea catalyst downstream -
Temperature sensor
SCR downstream Temperature: SRC high for
E004363-03 43D 110B 4363 3 -
Urea catalyst downstream Temperature sensor
SCR downstream Temperature: SRC low for
E004363-04 43C 110B 4363 4 -
SCR downstream Temperature: Diagnostic fault
E004363-12 143C 110B 4363 12 check for Plausibility errors in Urea catalyst -
downstream Temperature
SAE J1939 error for SCR catalyst Reagent
Tank 1 temperature Preliminary FMI: SAE
E004365-05 205A 110D 4365 5 -
J1939 error for SPN 4365 Catalyst Reagent
Tank 1 Temp Prelim FMI (Open circuit)
E004365-31 112C 110D 4365 31 -
Tank 1 Temp Prelim FMI (Short circuit)
Urea pump motor 1: Pump Motor Speed
E004375-12 1721 1117 4375 12 -
Deviation
Urea pump motor 1: Permanent Pump Motor
E004375-31 1722 1117 4375 31 -
Speed Deviation
Urea reverting valve: Short circuit to battery
E004376-03 20A3 1118 4376 3 -
error for Urea reverting valve

9-1-97
DTC Code
P Code
DTC
HEX DEC
Urea reverting valve: No load error for Urea

E004376-05 20A0 1118 4376 5 -
reverting valve
Urea reverting valve: Short circuit to ground
E004376-06 20A2 1118 4376 6 -
Urea reverting valve: Over Temperature error
E004376-12 10A0 1118 4376 12 -
for Urea reverting valve
Urea reverting valve: Reverting Valve is
E004376-31 10A2 1118 4376 31 -
Blocked closed
DOC upstream temperature: Physical Range
E004765-00 2080 129D 4765 0 Check high for DOC upstream temperature -
sensor
DOC upstream temperature: Diagnostic fault
E004765-03 546 129D 4765 3 check for SRC high in DOC upstream -
temperature
E004765-04 545 129D 4765 4 check for SRC low in DOC upstream -
temperature
Pressure control regulator: PCR governor
E005465-00 2263 1559 5465 0 -
deviation above limit
E005465-01 1263 1559 5465 1 -
deviation below limit
Rail pressure monitoring 1: maximum positive
E520196-12 251 7F004 520196 12 -
deviation of rail pressure exceeded
Timeout error of CAN Module C: Bus off error
E520197-12 C046 7F005 520197 12 -
CAN C
Timeout error of CAN Module C: Error passive
E520197-31 C054 7F005 520197 31 -
CAN C
Crankshaft sensor: DFC for crankshaft signal
E520199-02 336 7F007 520199 2 -
diagnosis disturbed signal
E520199-05 335 7F007 520199 5 -
diagnosis no signal
Camshaft sensor: DFC for camshaft signal
E520200-02 341 7F008 520200 2 -
E520200-05 340 7F008 520200 5 -
diagnosis no signal
Camshaft sensor: DFC for camshaft offset
E520200-12 1340 7F008 520200 12 -
angle exceeded
EEPROM erase error: EEP Erase Error based
E520201-12 62F 7F009 520201 12 on the error in erasing of sector (for Emulation -
only)
EEPROM read error: EEP Read Error based on
E520202-12 162F 7F00A 520202 12 -
the error in reading blocks from memory media
Monitoring of PRV -1: pressure relief valve
E520203-12 89 7F00B 520203 12 -
reached maximum allowed opening coun
EEPROM write error: EEP Write Error based on
E520204-12 1630 7F00C 520204 12 -
the error in storing the blocks in memory media
Monitoring in case of Digital signal controlled
E520205-03 1484 7F00D 520205 3 fans: Short circuit to battery error of Fan digital -
signal
E520205-05 480 7F00D 520205 5 -
fans: No load error of Fan digital signal

9-1-98
DTC Code
P Code
DTC
HEX DEC

E520205-06 485 7F00D 520205 6 fans: Short circuit to ground error of Fan digital -
signal
E520205-12 484 7F00D 520205 12 fans: Over temperature error of Fan digital -
signal
Timeout error of CAN Module A: Bus off error
E520206-12 C028 7F00E 520206 12 -
CAN A
Timeout error of CAN Module A: Error passive
E520206-31 C036 7F00E 520206 31 -
CAN A
Engine temperature sensor plausibility 0: Air
E520336-12 1000 7F090 520336 12 -
temperature monitoring plausibility check array 0
E520337-12 1001 7F091 520337 12 -
E520338-12 1002 7F092 520338 12 -
E520339-12 1003 7F093 520339 12 -
E520340-12 1004 7F094 520340 12 -
Engine temperature sensor plausibility Tot: Air
E520341-12 1005 7F095 520341 12 -
temperature monitoring plausibility check
ECU hardware chip CY320 error: ECU
E520601-12 160B 7F199 520601 12 -
hardware chip CY320 error
Hydraulic oil temperature CAN time out:
E520602-12 C141 7F19A 520602 12 -
Timeout Error of CAN-Receive-Frame AAI
Timeout error of CAN-Receive-Frame DEC1V:
E520603-12 C122 7F19B 520603 12 -
Timeout Error of CAN-Receive-Frame DEC1V
ECU hardware chip CY146 error 1: ECU
E520604-12 607 7F19C 520604 12 -
hardware chip CY146 error 1
Timeout error of CAN-Receive-Frame EGR
E520606-12 C10A 7F19E 520606 12 valve: Timeout Error of CAN-Receive-Frame -
EGRErr
EGR valve actuator communication error: EGR
E520607-12 D10B 7F19F 520607 12 -
SRA Error for communication Loss 1
Air control governor deviation error: Positive
E520609-00 402 7F1A1 520609 0 -
governor deviation above limit
Air control governor deviation error: Negative air
E520609-01 401 7F1A1 520609 1 -
control governor deviation below limit
Power stage for intake air heater: Short circuit
E520610-03 542 7F1A2 520610 3 to battery error of powerstage for intake air -
heater
Power stage for intake air heater: No load error
E520610-05 543 7F1A2 520610 5 -
of powerstage for intake air heater
E520610-06 541 7F1A2 520610 6 to ground error of powerstage for intake air -
heater
Power stage for intake air heater: Over
E520610-12 540 7F1A2 520610 12 temperature error of powerstage for intake air -
heater

9-1-99
DTC Code
P Code
DTC
HEX DEC
Timeout error of CAN-Receive-Frame Vehicle

E520611-12 D127 7F1A3 520611 12 cut off switch: Timeout Error of CAN-Receive- -
Frame AUXIO1
Accel pedal CAN max error: Timeout Error of
E520612-00 C124 7F1A4 520612 0 -
CAN-Receive-Frame DEC1V
Vehicle cutoff switch error: DFC for error at
E520613-12 D125 7F1A5 520613 12 -
vehicle cutoff switch
ECU power stage test: Powerstage diagnosis
E520616-00 1564 7F1A8 520616 0 -
disabled due to high Battery voltage
E520616-01 1565 7F1A8 520616 1 -
disabled due to low Battery voltage
Monitoring of ADC - 1: Diagnostic fault check to
E520618-12 60B 7F1AA 520618 12 -
report the NTP error in ADC monitoring
Monitoring of injection - 1: Number of injections
E520624-12 1315 7F1B0 520624 12 -
is limited by charge balance of booster capacity
Detection of failed engine start: Detection of
E520625-12 A0F 7F1B1 520625 12 -
Failed Engine Start
Injection bank short circuit 0: Time out of SCG
E520626-02 162D 7F1B2 520626 2 -
measurement of Injection bank 1
Injection bank short circuit 0: Short Circuit to
E520626-06 162E 7F1B2 520626 6 -
Ground Monitoring Test in Injection bank 1
Injection bank short circuit 0: Short circuit of
E520626-12 62D 7F1B2 520626 12 -
Injection bank 1
E520627-12 1607 7F1B3 520627 12 -
Diagnostic Fault Check for Supply Module:
E520632-00 1764 7F1B8 520632 0 Diagnostic Fault Check for Supply Module -
temperature Duty cycle in failure range
Heater Temperature Duty cycle in invalid range
E520632-03 1767 7F1B8 520632 3 Diagnostic Fault Check period outside valid -
range
E520632-05 1768 7F1B8 520632 5 Diagnostic Fault Check to detect faulty PWM -
signal
E520632-06 1766 7F1B8 520632 6 Temperature measurement module not -
available
E520632-31 176A 7F1B8 520632 31 Diagnostic Fault Check for Supply Module -
Temperature Duty cycle in invalid range
ECU power stage module: Diagnostic fault
E520633-02 161A 7F1B9 520633 2 check to report "WDA active" due to errors in -
query /response communication
E520633-03 161C 7F1B9 520633 3 check to report "ABE active" due to overvoltage -
detection

9-1-100
DTC Code
P Code
DTC
HEX DEC

E520633-04 161B 7F1B9 520633 4 check to report "ABE active" due to -
undervoltage detection
E520633-12 161D 7F1B9 520633 12 check to report "WDA/ABE active" due to -
unknown reason
Rail PRV monitoring: maximum rail pressure
E520635-12 1306 7F1BB 520635 12 -
exceeded [4]
Rail PRV monitoring: maximum rail pressure
E520635-31 1307 7F1BB 520635 31 -
exceeded [5]
Actuator relay0 error: Short circuit to battery
E520637-03 659 7F1BD 520637 3 -
error at actuator relay 0
Actuator relay0 error: Short circuit to ground
E520637-05 658 7F1BD 520637 5 -
E520638-03 2671 7F1BE 520638 3 -
E520638-05 2670 7F1BE 520638 5 -
E520639-03 2686 7F1BF 520639 3 -
E520639-05 2685 7F1BF 520639 5 -
E520640-12 1045 7F1C0 520640 12 -
Monitoring of complete ROM test: Diagnostic
E520641-12 160F 7F1C1 520641 12 fault check to report multiple error while -
checking the complete ROM memory
ECU shut off path error 1: Loss of
E520642-12 1610 7F1C2 520642 12 synchronization sending bytes to the MM from -
CPU
Monitoring of overrun: Diagnostic fault check to
E520643-12 101A 7F1C3 520643 12 -
report the error due to Over Run
Monitoring of voltage supply: Reported
E520644-00 1600 7F1C4 520644 0 -
OverVoltage of VDD5
Monitoring of voltage supply: Reported
E520644-01 1601 7F1C4 520644 1 -
UnderVoltage of VDD5
E520645-03 68B 7F1C5 520645 3 ECU main relay: DFC for stuck main relay error -
ECU main relay: Early opening defect of main
E520645-05 68A 7F1C5 520645 5 -
relay
Forced regeneration switch: plausibility test of
E520652-03 107C 7F1CC 520652 3 -
regeneration switch
Forced regeneration switch: Short circuit to
E520652-12 107A 7F1CC 520652 12 -
battery error of regeneration switch
Forced regeneration inhibit switch: Short circuit
E520653-03 107B 7F1CD 520653 3 -
to battery error of regeneration inhibit switch
MSC Errors of R2S2: Reported MSCErrors of a
E520654-12 161E 7F1CE 520654 12 -
R2S2
Timeout error of Upstream NOx Sensor:
E520656-12 C29D 7F1D0 520656 12 -
Timeout Error of CAN-Receive-Frame AT1IG1
Timeout error of Downstream NOx Sensor:
E520657-12 C29E 7F1D1 520657 12 -
Timeout Error of CAN-Receive-Frame AT1O1

9-1-101
DTC Code
P Code
DTC
HEX DEC
Nox sensor plausibility error: DFC for plausibility

E520662-00 2201 7F1D6 520662 0 -
error Max for upstream NOx sensor
Nox sensor plausibility error: DFC for plausibility
E520662-01 1201 7F1D6 520662 1 -
error Min for upstream NOx sensor
SCR Long term adaption factor: Long term
E520663-00 12FF 7F1D7 520663 0 -
adaption factor exceeds threshold
SCR Long term adaption factor: Long term
E520663-01 1300 7F1D7 520663 1 -
adaption factor below threshold
E520664-31 10EE 7F1D8 520664 31 ETA threshold error: DFC for SCR efficiency -
Monitoring of dosing release: Monitoring of the
E520666-12 2BA8 7F1DA 520666 12 -
time until the dosing release is given
Urea dosing valve: Short circuit to ground error
E520669-06 1713 7F1DD 520669 6 in high side powerstage of Urea dosing valve -
actuator
E520669-12 1712 7F1DD 520669 12 Urea dosing valve: Dosing Valve is blocked -
Urea dosing valve: Over temperature error on
E520669-31 1714 7F1DD 520669 31 -
powerstage of Urea dosing valve actuator
Plausibility of Urea Quantity and Pump Speed:
E520670-12 170D 7F1DE 520670 12 -
Reporting of the error for the PUQP function
Diagnostic fault check for EPA emergency
E520671-02 D102 7F1DF 520671 2 function: DFC for Non pause Error of EPA -
emergency function
Diagnostic fault check for EPA emergency
E520671-12 D101 7F1DF 520671 12 function: DFC for Check sum error of EPA -
emergency function
limitation counter when the urea fill level is in
E520672-12 1710 7F1E0 520672 12 the limitation range: Maximum number restarts -
allowed by restriction counter is exceeded
Urea tank heating plausibility error: Stuck in
E520673-12 170E 7F1E1 520673 12 -
range check of Urea tank temperature sensor
E520674-12 D10A 7F1E2 520674 12 valve error message: Timeout Error of CAN- -
Transmit-Frame EGRVlv
EGR valve actuator initializing Error: EGR SRA
E520675-12 C40B 7F1E3 520675 12 -
Error during initialization
EGR valve actuator communication error 2:
E520676-12 D10C 7F1E4 520676 12 -
EGR SRA Error for communication Loss 2
EGR valve actuator Overload error: EGR SRA
E520677-12 D40B 7F1E5 520677 12 -
Error for Overload
EGR valve actuator position deviation: EGR
E520678-12 D40C 7F1E6 520678 12 -
SRA Error in position deviation
EGR valve actuator Position Estimation error:
E520679-12 D40D 7F1E7 520679 12 -
EGR SRA Error in position estimation
EGR valve actuator Shortcut detection: EGR
E520680-12 D40E 7F1E8 520680 12 -
SRA Error for Short detection
EGR valve actuator temperature Alert: EGR
E520681-12 D40F 7F1E9 520681 12 -
SRA Error for temperature alert
EGR valve actuator temperature Error: EGR
E520682-12 D410 7F1EA 520682 12 -
SRA error in measurement of temperature
EGR valve actuator Temperature warning: EGR
E520683-12 D411 7F1EB 520683 12 -
SRA Error for temperature warning

9-1-102
DTC Code
P Code
DTC
HEX DEC
EGR valve actuator Torque limitation error:

E520684-12 D412 7F1EC 520684 12 -
EGR SRA Error for Torque limitation
E520685-12 1608 7F1ED 520685 12 -
E520686-12 1609 7F1EE 520686 12 -
E520687-12 160A 7F1EF 520687 12 -
E520688-12 1316 7F1F0 520688 12 is limited by quantity balance of high pressure -
pump
E520689-12 1317 7F1F1 520689 12 -
is limited by system
E520690-12 1318 7F1F2 520690 12 -
is limited by runtime
E520691-02 1207 7F1F3 520691 2 -
E520691-06 1209 7F1F3 520691 6 -
E520691-12 206 7F1F3 520691 12 -
Injection bank 2
E520693-12 62B 7F1F5 520693 12 Injection Chip error: Injection Chip error -
CP metering unit - high Side Circuit Error: short
E520694-03 254 7F1F6 520694 3 -
circuit to battery in the high side of the MeUn
CP metering unit - high Side Circuit Error: short
E520694-04 253 7F1F6 520694 4 -
circuit to ground in the high side of the MeUn
CP metering unit - Low Side Circuit Error: short
E520695-03 1254 7F1F7 520695 3 -
circuit to battery of metering unit output
CP metering unit - Low Side Circuit Error: short
E520695-04 1253 7F1F7 520695 4 -
circuit to ground of metering unit output
E520696-12 160C 7F1F8 520696 12 -
report the ADC test error
E520697-12 160D 7F1F9 520697 12 report the error in Voltage ratio in ADC -
monitoring
Monitoring of communication module - 1:
E520698-12 60C 7F1FA 520698 12 Diagnostic fault check to report errors in query / -
response communication
Monitoring of communication module - 2:
E520699-12 160E 7F1FB 520699 12 Diagnostic fault check to report errors in SPI -
communication
ECU shut off path error 2: DFC to set a torque
E520700-12 1611 7F1FC 520700 12 limitation once an error is detected before -
MoCSOP's error reaction is set
ECU shut off path error 3: Wrong set response
E520701-12 1612 7F1FD 520701 12 -
time
ECU shut off path error 4: Too many SPI errors
E520702-12 1613 7F1FE 520702 12 -
during MoCSOP execution
ECU shut off path error 5: Diagnostic fault
E520703-12 1615 7F1FF 520703 12 -
check to report that WDA is not working correct

9-1-103
DTC Code
P Code
DTC
HEX DEC
ECU shut off path error 6: OS timeout in the

E520704-12 1616 7F200 520704 12 shut off path test. Failure setting the alarm task -
period.
E520705-12 1617 7F201 520705 12 -
check to report that the positive test failed
E520706-12 1618 7F202 520706 12 check to report the timeout in the shut off path -
test
ECU shut off path error of Voltage detection:
E520707-03 1619 7F203 520707 3 Diagnostic fault check to report the error in -
overvoltage monitoring
ECU shut off path error of Voltage detection:
E520707-04 1614 7F203 520707 4 Diagnostic fault check to report the error in -
undervoltage monitoring
Shut-off request of the injection cut-off: Injection
E520708-12 1008 7F204 520708 12 -
cut off demand (ICO) for shut off coordinator
Monitoring of PRV -2: pressure relief valve is
E520709-12 108C 7F205 520709 12 -
forced to open; perform pressure increase
E520710-12 108D 7F206 520710 12 -
forced to open; perform pressure shock
E520711-12 108E 7F207 520711 12 -
open
Monitoring of PRV -5: Quantity balance check if
E520712-12 1036 7F208 520712 12 -
a successful PRV opening is ensured
Monitoring of PRV -6: Averaged rail pressure is
E520713-12 1037 7F209 520713 12 -
outside the expected tolerance range
E520714-12 108F 7F20A 520714 12 -
reached maximum allowed open time
Rail pressure monitoring 2: leakage is detected
E520715-12 1251 7F20B 520715 12 -
based on fuel quantity balance
Rail pressure monitoring 3: maximum negative
E520716-12 1252 7F20C 520716 12 rail pressure deviation with metering unit on -
lower limit is exceeded
Rail pressure monitoring 4: minimum rail
E520717-12 87 7F20D 520717 12 -
pressure exceede
Rail pressure monitoring 5: maximum rail
E520718-12 88 7F20E 520718 12 -
pressure exceede
Rail pressure monitoring 6: maximum rail
E520719-12 1090 7F20F 520719 12 -
pressure exceeded (second stage)
Rail pressure monitoring 7: set point of metering
E520720-12 1050 7F210 520720 12 -
unit in overrun mode not plausible
Rail pressure monitoring 8: set point of metering
E520721-12 1257 7F211 520721 12 -
unit in idle mode not plausible
Plausibility check for NOx sensor: DFC for
E520722-12 1214 7F212 520722 12 Stuck in range error check for downstream NOx -
sensor
Plausibility check for NOx sensor: DFC for peak
E520722-31 2214 7F212 520722 31 -
plausibility check for downstream NOx sensor
Inducement count "Blocked EGR valve" Level
E520723-12 12E5 7F213 520723 12 1: Inducement Level 1 is active due to "EGR -
valve blocked"

9-1-104
DTC Code
P Code
DTC
HEX DEC

valve blocked"
valve blocked"
Inducement count "Blocked EGR valve"
E520726-12 12E8 7F216 520726 12 Warning: Inducement warning is active due to -
"EGR valve blocked"
Inducement count "Interruption of Dosing" Level
E520727-12 12E9 7F217 520727 12 1: Inducement Level 1 is active due to -
"Interruption of Dosing"
E520728-12 12EA 7F218 520728 12 2: Inducement Level 2 is active due to -
E520729-12 12EB 7F219 520729 12 3: Inducement Level 2 is active due to -
Inducement count "Interruption of Dosing"
E520730-12 12EC 7F21A 520730 12 Warning: Inducement warning is active due to -
Inducement count DEF Level: Inducement
E520731-12 12ED 7F21B 520731 12 -
warning information for reagent level
Inducement count Reagent "Consumption"
E520732-12 12EE 7F21C 520732 12 Level 1: Inducement Level 1 is active due to -
"Reagent Consumption"
E520733-12 12EF 7F21D 520733 12 Level 2: Inducement Level 2 is active due to -
E520734-12 12F0 7F21E 520734 12 Level 3: Inducement Level 3 is active due to -
E520735-12 12F1 7F21F 520735 12 Warning: Inducement warning is active due to -
Inducement count "Reagent quality" Level 1:
E520736-12 12F2 7F220 520736 12 Inducement Level 1 is active due to "Reagent -
Quality"
Quality"
Quality"
Inducement count "Reagent quality" Warning:
E520739-12 12F5 7F223 520739 12 Inducement warning is active due to "Reagent -
Quality"
Inducement count "Tampering" Level 1:
E520740-12 12F6 7F224 520740 12 Inducement Level 1 is active due to -
"Tampering"
"Tampering"

9-1-105
DTC Code
P Code
DTC
HEX DEC

"Tampering"
Inducement count "Tampering" Level Warning:
E520743-12 12F9 7F227 520743 12 Inducement warning is active due to -
"Tampering"
Throttle valve H-bridge: Open load error for
E520744-05 2E0 7F228 520744 5 -
throttle valve powerstage
Throttle valve H-bridge: Over temperature error
E520744-12 2EB 7F228 520744 12 -
for throttle valve Hbridge
Throttle valve H-bridge Short Circuit 1: Short
E520745-03 2E3 7F229 520745 3 circuit to battery on Out1 error for throttle valve -
Hbridge
E520745-04 2E2 7F229 520745 4 circuit to ground on Out1 error for throttle valve -
Hbridge
E520746-03 12E3 7F22A 520746 3 circuit to battery on Out2 error for throttle valve -
Hbridge
E520746-04 12E4 7F22A 520746 4 circuit to ground on Out2 error for throttle valve -
Hbridge
Throttle valve control Jammed: Jammed valve
E520747-00 2E4 7F22B 520747 0 -
of throttle valve (open)
Throttle valve control Jammed: Jammed valve
E520747-01 2E5 7F22B 520747 1 -
of throttle valve (close)
Overheating protection: Diagnostic fault check
E520750-12 12FC 7F22E 520750 12 to report the error due to cooling injection in -
Over Run
Supply Module monitoring error (Backflow Line
E520751-12 1700 7F22F 520751 12 plausibility error): General backflow line -
plausibility error (Supply module monitoring)
Supply Module monitoring (pressure check
E520752-12 1701 7F230 520752 12 error): General pressure check error (Supply -
module monitoring)
Supply Module monitoring (Pressure
E520753-12 1702 7F231 520753 12 stabilization error): Pressure stabilization error -
(Supply module monitoring)
Supply Module monitoring 1: Monitoring of ECU
E520754-12 1703 7F232 520754 12 over temperature regardless of the state -
Supply Module monitoring (Over Pressure error
E520755-12 20E9 7F233 520755 12 1): Monitoring of Metering Control Malfunction -
Max (Supply module monitoring)
Supply Module monitoring (Under Pressure
E520757-12 20E8 7F235 520757 12 error): Monitoring of Metering Control -
Malfunction Min (Supply module monitoring)
Supply Module monitoring (Over Pressure error
E520758-12 1706 7F236 520758 12 2): Monitoring of over pressure (Supply module -
monitoring)
Supply Module monitoring (Pressure build-up
E520759-12 124A 7F237 520759 12 error): Monitoring of Pressure Build Up error -
Asymmetric (Supply module monitoring)

9-1-106
DTC Code
P Code
DTC
HEX DEC
Supply Module monitoring (Pressure build-up

E520759-31 124B 7F237 520759 31 error): Monitoring of Pressure Build Up Error -
Symmetric (Supply module monitoring)
Supply Module monitoring (Pressure Drop
E520760-12 1708 7F238 520760 12 Error): General pressure drop check error -
Supply Module monitoring (Pressure reduction
E520761-12 1709 7F239 520761 12 error): Monitoring of Pressure Reduction -
Malfunction Max (Supply module monitoring)
SCR catalyst downstream temperature sensor
static plausibility: Error for SCR catalyst
E520762-12 170A 7F23A 520762 12 -
downstream temperature sensor static
plausibility
Urea tank level plausibility error: Urea tank
E520763-00 170B 7F23B 520763 0 -
sensor indicates too high fill level
Urea tank level plausibility error: Urea tank
E520763-01 170C 7F23B 520763 1 -
sensor indicates too low fill level
Detection of SCR wrong temperature value:
E520764-12 1711 7F23C 520764 12 -
Detection of SCR wrong temperature value
Low side switch error of Urea dosing valve:
E520765-03 1715 7F23D 520765 3 Short circuit to battery error in powerstage of -
Urea dosing valve actuator
Low side switch error of Urea dosing valve:
E520765-06 1716 7F23D 520765 6 Short circuit to ground error in powerstage of -
High side switch error of Urea dosing valve:
E520766-03 1717 7F23E 520766 3 Short circuit to battery error in high side -
powerstage of Urea dosing valve actuator
High side switch error of Urea dosing valve:
E520766-06 1718 7F23E 520766 6 Short circuit error in high side powerstage of -
Supply module heater plausibility error 1: Error
E520767-12 1719 7F23F 520767 12 -
supply module heater plausibility
E520768-12 171A 7F240 520768 12 urea supply module heater temperature sensor -
dynamic plausibility
E520768-31 171B 7F240 520768 31 urea supply module heater temperature sensor -
cold start plausibility
Supply module temperature sensor plausibility
E520769-12 171C 7F241 520769 12 error: Error urea supply module temperature -
sensor dynamic plausibility
Supply module temperature sensor plausibility
E520769-31 171D 7F241 520769 31 error: Error urea supply module temperature -
sensor cold start plausibility
Urea catalyst upstream temperature plausibility
E520770-12 171E 7F242 520770 12 error: Error for SCR catalyst upstream -
Urea catalyst upstream temperature plausibility
E520770-31 1720 7F242 520770 31 error: Error for SCR catalyst upstream -
Urea pump motor 2: Pump motor not available
E520771-12 1723 7F243 520771 12 -
for actuation

9-1-107
DTC Code
P Code
DTC
HEX DEC
Urea pump motor 3: Short circuit to battery error

E520772-03 208D 7F244 520772 3 -
on powerstage for urea pump motor
Urea pump motor 3: No load error on
E520772-05 208A 7F244 520772 5 -
powerstage for urea pump motor
Urea pump motor 3: Short circuit to ground error
E520772-06 208C 7F244 520772 6 -
on powerstage for urea pump motor
Urea pump motor 3: Over temperature error on
E520772-12 1724 7F244 520772 12 -
powerstage for urea pump motor
SAE J1939 error for Catalyst reagent
E520780-12 D126 7F24C 520780 12 concentration: SAE J1939 error for catalyst -
reagent concentration message
SAE J1939 error for Urea tank: SAE J1939
E520781-12 D5A3 7F24D 520781 12 -
error for urea tank level message
SAE J1939 error for Urea tank: SAE J1939
E520781-31 D5A4 7F24D 520781 31 -
error for urea tank temperature message
Timeout error of Catalyst reagent concentration:
E520782-12 D5AA 7F24E 520782 12 -
Timeout Error of CAN-Receive-Frame A1DEFI
Timeout error of Catalyst Tank level and
E520783-12 D5AB 7F24F 520783 12 Temperature: Timeout Error of CAN-Receive- -
Frame AT1T1I
SAE J1939 error for Urea catalyst Tank Level
E520784-12 D128 7F250 520784 12 Indicator: SAE J1939 error for Urea catalyst -
Tank Level Indicator
SAE J1939 error for Catalyst Reagent
E520785-12 D146 7F251 520785 12 Temperature2: SAE J1939 error for Urea -
catalyst temperature2
SAE J1939 error for Catalyst Tank Level 2: SAE
E520787-12 D148 7F253 520787 12 -
J1939 error for Urea catalyst Tank Level 2
Plausibility check for hardware switch interface
of regeneration inhibition and regeneration
E520788-12 107C 7F254 520788 12 demand switch: DFC for Regeneration inhibition -
hardware switch and Forced regeneration
hardware switch plausibility test
Diagnostic fault check to represent inducement
E520789-12 1302 7F255 520789 12 override is active: shows if inducement override -
is active
Diagnostic fault check to represent Level 1 is
E520790-12 1303 7F256 520790 12 active due to Repeat offense error: Repeat -
offense level 1 error
Monitoring of Upstream Nox Sensor: Open
E520794-05 2203 7F25A 520794 5 -
circuit monitoring for upstream Nox sensor
Monitoring of Upstream Nox Sensor: Short
E520794-06 2202 7F25A 520794 6 -
circuit monitoring for upstream Nox sensor
Monitoring of Downstream Nox Sensor: Open
E520795-05 2216 7F25B 520795 5 -
circuit monitoring for downstream Nox sensor

9-1-108
DTC Code
P Code
DTC
HEX DEC
Monitoring of Downstream Nox Sensor: Short

E520795-06 2215 7F25B 520795 6 -
circuit monitoring for downstream Nox sensor
Diagnostic fault check to report the accelerator
E520796-12 1012 7F25C 520796 12 pedal position error: Diagnostic fault check to -
report the accelerator pedal position error
Diagnostic fault check to report the engine
E520797-12 1013 7F25D 520797 12 speed error: Diagnostic fault check to report the -
engine speed error
Diagnostic fault check to report the plausibility
error between level 1 energizing time and level
E520798-12 1014 7F25E 520798 12 2 information: Diagnostic fault check to report -
the plausibility error between level 1 energizing
time and level 2 information
Error in the plausibility of the start of energizing
angles: Diagnostic fault check to report the error
E520799-12 1015 7F25F 520799 12 -
due to plausibility between the injection begin v/
s injection type
Error in the plausibility check of the ZFC
E520800-12 1016 7F260 520800 12 energizing times: Diagnostic fault check to -
report the error due to non plausibility in ZFC
Diagnosis fault check to report the demand for
normal mode due to an error in the PoI2
E520801-12 1017 7F261 520801 12 quantity: Diagnosis fault check to report the -
demand for normal mode due to an error in the
PoI2 quantity
Diagnosis fault check to report the error to
demand for an ICO due to an error in the PoI2
E520802-12 1018 7F262 520802 12 shutoff: Diagnosis fault check to report the error -
to demand for an ICO due to an error in the
PoI2 shutoff
Diagnosis fault check to report the error to
demand for an ICO due to an error in the PoI3
E520803-12 1019 7F263 520803 12 efficiency factor: Diagnosis fault check to report -
the error to demand for an ICO due to an error
in the PoI3 efficiency factor
Diagnostic fault check to report the error due to
injection quantity correction: Diagnostic fault
E520804-12 101B 7F264 520804 12 -
check to report the error due to injection
quantity correction
Diagnostic fault check to report the plausibility
error in rail pressure monitoring: Diagnostic fault
E520805-12 101C 7F265 520805 12 -
check to report the plausibility error in rail
pressure monitoring
Diagnostic fault check to report the error due to
E520806-12 101D 7F266 520806 12 torque comparison: Diagnostic fault check to -
report the error due to torque comparison
Diagnosis of current path limitation forced by
E520807-02 1020 7F267 520807 2 ECU monitoring level 2: Diagnosis of set path -
limitation forced by ECU monitoring level 2
E520807-12 101E 7F267 520807 12 ECU monitoring level 2: Diagnosis of current -
path limitation forced by ECU monitoring level 2

9-1-109
DTC Code
P Code
DTC
HEX DEC

E520807-31 101F 7F267 520807 31 ECU monitoring level 2: Diagnosis of lead path -
limitation forced by ECU monitoring level 2
Error dosing valve plausibility: Error dosing
E520808-12 1763 7F268 520808 12 -
valve plausibility
Monitoring of SCR DeSox: The demand for a
E520809-12 1038 7F269 520809 12 desulphurization of the SCR catalyst is not -
fulfilled
Monitoring of SCR DeSox: The engine
operation mode was changed for a
E520809-31 1039 7F269 520809 31 -
desulphurization of the SCR catalyst without
being able to finish it successfully
Deviation from the dosing quantity detected
E520810-12 170F 7F26A 520810 12 during Test Injection: Deviation from the urea -
dosing quantity detected during Test Injection
Inducement emergency state: shows if
E520811-12 1130 7F26B 520811 12 -
inducement emergency state is active
Diagnostic fault check for Urea quality
Temperature sensor: Diagnostic fault check for
E520812-00 1131 7F26C 520812 0 -
urea quality sensor Temperature whether
physical signal above the maximum limit
Diagnostic fault check for Urea quality
Temperature sensor: Diagnostic fault check for
E520812-01 1132 7F26C 520812 1 -
urea quality sensor Temperature whether
physical signal below the minimum limit
Injector adjustment value error 1 (cylinder 1):
E520813-02 268C 7F26D 520813 2 Check of missing injector adjustment value -
programming 1
E520814-02 2690 7F26E 520814 2 Check of missing injector adjustment value -
programming 2
E520815-02 268E 7F26F 520815 2 Check of missing injector adjustment value -
programming 3
E520816-02 2691 7F270 520816 2 Check of missing injector adjustment value -
programming 4
E520817-02 268D 7F271 520817 2 Check of missing injector adjustment value -
programming 5
E520818-02 268F 7F272 520818 2 Check of missing injector adjustment value -
programming 6
E520819-12 1620 7F273 520819 12 ECU reset 0: Visibility of software Resetss 1 -
Without empty pressure reduction: Pressure
E520822-12 1730 7F276 520822 12 line heater error and temperature condition to -
perform an after run
External actuator relay: Open load error at low
E520619-03 1047 7F1AB 520619 3 -
side of external actuator relay
External actuator relay: Short circuit to battery
E520619-04 1046 7F1AB 520619 4 -
error at low side of external actuator relay

9-1-110
DTC Code
P Code
DTC
HEX DEC
External actuator relay: Short circuit to battery

E520619-05 1048 7F1AB 520619 5 -
error at low side of external actuator relay
Engine emergency stop switch: DFC for engine
E000970-31 1102 3CA 970 31 -
emergency stop switch
Dynamic monitoring of upstream Nox sensor 02
E003217-12 134 C91 3217 12 signal: DFC for dynamic monitoring of -
upstream Nox sensor O2 signal
Upstream Nox sensor heater temperature
E003219-31 1203 C93 3219 31 monitoring: Fault detection of heater availability -
for upstream Nox sensor
Dynamic monitoring of downstream Nox sensor
E003227-12 140 C9B 3227 12 O2 signal: DFC for dynamic monitoring of -
downstream Nox sensor O2 signal
Downstream Nox sensor heater temperature
E003229-31 1204 C9D 3229 31 monitoring: Fault detection of heater availability -
for downstream Nox sensor
E520198-12 640 7F006 520198 12 Monitoring of Air heater relay -
E520721-12 1257 7F211 520721 12 -
valve position sensor voltage SRC high
E520722-12 1214 7F212 520722 12 -
valve position sensor voltage SRC low
E520722-31 2214 7F212 520722 31 -
High for APP1
E520723-12 12E5 7F213 520723 12 -
Low for APP1
Oil pressure sensor: Maximum oil pressure
E520724-12 12E6 7F214 520724 12 -
error in plausibility check
Oil pressure sensor: Minimum oil pressure error
E520725-12 12E7 7F215 520725 12 -
in plausibility check
Oil pressure sensor: SRC high for oil pressure
E520726-12 12E8 7F216 520726 12 -
sensor
Oil pressure sensor: SRC low for Oil pressure
E520727-12 12E9 7F217 520727 12 -
sensor
Boost pressure sensor: SRC high for Boost
E520728-12 12EA 7F218 520728 12 -
pressure sensor
Boost pressure sensor: SRC low for Boost
E520729-12 12EB 7F219 520729 12 -
pressure sensor
Air Inlet temperature: SRC High for Charge air
E520730-12 12EC 7F21A 520730 12 -
Air Inlet temperature: SRC low for Charge air
E520731-12 12ED 7F21B 520731 12 -
E520732-12 12EE 7F21C 520732 12 SRC high in engine inlet valve air temperature -
upstream sensor
E520733-12 12EF 7F21D 520733 12 SRC low in engine inlet valve air temperature -
upstream sensor
E520734-12 12F0 7F21E 520734 12 -
Range Check high for Environment Pressure
E520735-12 12F1 7F21F 520735 12 -
Range Check low for Environment Pressure

9-1-111
DTC Code
P Code
DTC
HEX DEC
Barometric pressure sensor in ECU: SRC High

E520736-12 12F2 7F220 520736 12 -
Barometric pressure sensor in ECU: SRC low
E520737-12 12F3 7F221 520737 12 -
E520738-12 12F4 7F222 520738 12 -
high for coolant temperature
E520739-12 12F5 7F223 520739 12 -
low for coolant temperature
Coolant temperature: SRC high for coolant
E520740-12 12F6 7F224 520740 12 -
temperature
Coolant temperature: SRC low for coolant
E520741-12 12F7 7F225 520741 12 -
temperature
Coolant temperature: Defect fault check for
E520742-12 12F8 7F226 520742 12 -
dynamic plausibility test of coolant temperature
E520743-12 12F9 7F227 520743 12 -
exceeded [1]
Rail pressure sensor: check of minimum rail
E520744-05 2E0 7F228 520744 5 -
pressure
E520744-12 2EB 7F228 520744 12 -
voltage above upper limit
E520745-03 2E3 7F229 520745 3 -
voltage below lower limit
E520745-04 2E2 7F229 520745 4 -
above maximum offset
E520746-03 12E3 7F22A 520746 3 -
below minimum offset
E520746-04 12E4 7F22A 520746 4 -
exceeded [2]
E520747-00 2E4 7F22B 520747 0 -
exceeded [3]
Air mass flow sensor: Sensitivity drift high error
E520747-01 2E5 7F22B 520747 1 -
for HFM sensor
Air mass flow sensor: Sensitivity drift error low
E520750-12 12FC 7F22E 520750 12 -
for HFM sensor
Air mass flow sensor: SRC high error for raw
E520751-12 1700 7F22F 520751 12 -
value in HFM sensor
Air mass flow sensor: SRC low error for raw
E520752-12 1701 7F230 520752 12 -
value in HFM sensor
Air mass flow sensor: SCB of hardware signal
E520753-12 1702 7F231 520753 12 -
of HFM sensor
Air mass flow sensor: Battery voltage error of
E520754-12 1703 7F232 520754 12 -
HFM sensor
CP metering unit: signal range check high error
E520755-12 20E9 7F233 520755 12 -
of metering unit
CP metering unit: signal range check low error
E520757-12 20E8 7F235 520757 12 -
of metering unit
CP metering unit: Open load of metering unit
E520758-12 1706 7F236 520758 12 -
output
CP metering unit: Over temperature of device
E520759-12 124A 7F237 520759 12 -
driver of metering unit

9-1-112
DTC Code
P Code
DTC
HEX DEC
CP metering unit: Intermittent contact between

E520759-31 124B 7F237 520759 31 -
ECU and MeUn
E520760-12 1708 7F238 520760 12 Battery: High Battery Voltage indication -
E520761-12 1709 7F239 520761 12 Battery: Low Battery voltage indication -
E520762-12 170A 7F23A 520762 12 Battery: SRC high for battery voltage sensor -
E520763-00 170B 7F23B 520763 0 Battery: SRC low for battery voltage sensor -
Air mass flow sensor temperature: Physical
E520763-01 170C 7F23B 520763 1 -
Range high error for air temperature senso
Air mass flow sensor temperature: SRC high for
E520764-12 1711 7F23C 520764 12 -
Air mass flow sensor temperature: SRC low for
E520765-03 1715 7F23D 520765 3 -
E520765-06 1716 7F23D 520765 6 -
Check high for fuel temperature
E520766-03 1717 7F23E 520766 3 -
Check low for fuel temperature
Fuel temperature sensor: SRC high for fuel
E520766-06 1718 7F23E 520766 6 -
temperature sensor
Fuel temperature sensor: SRC low for fuel
E520767-12 1719 7F23F 520767 12 -
temperature sensor
E520768-12 171A 7F240 520768 12 -
high for Oil Temperature
E520768-31 171B 7F240 520768 31 -
low for Oil Temperature
Oil temperature sensor: SRC High for Oil
E520769-12 171C 7F241 520769 12 -
Temperature
Oil temperature sensor: SRC low for Oil
E520769-31 171D 7F241 520769 31 -
Temperature
Overspeed detection in component engine
E520770-12 171E 7F242 520770 12 protection: Overspeed detection in component -
engine protection
E520770-31 1720 7F242 520770 31 -
E520771-12 1723 7F243 520771 12 -
E520772-03 208D 7F244 520772 3 pattern for special cases of Solenoid -
powerstage 1
E520772-05 208A 7F244 520772 5 -
E520772-06 208C 7F244 520772 6 -
E520772-12 1724 7F244 520772 12 pattern for special cases of Solenoid -
powerstage 2
E520780-12 D126 7F24C 520780 12 -
E520781-12 D5A3 7F24D 520781 12 -

9-1-113
DTC Code
P Code
DTC
HEX DEC

E520781-31 D5A4 7F24D 520781 31 pattern for special cases of Solenoid -
powerstage 3
E520782-12 D5AA 7F24E 520782 12 -
E520783-12 D5AB 7F24F 520783 12 -
E520784-12 D128 7F250 520784 12 pattern for special cases of Solenoid -
powerstage 4
E520785-12 D146 7F251 520785 12 -
E520787-12 D148 7F253 520787 12 -
E520788-12 107C 7F254 520788 12 pattern for special cases of Solenoid -
powerstage 5
E520789-12 1302 7F255 520789 12 -
E520790-12 1303 7F256 520790 12 -
E520791-12 1304 7F257 520791 12 pattern for special cases of Solenoid -
powerstage 6
Auto fan clutch PWM out: Short circuit to battery
E520792-12 1305 7F258 520792 12 -
Auto fan clutch PWM out: No load error of fan
E520794-05 2203 7F25A 520794 5 -
clutch PWM out
Auto fan clutch PWM out: Short circuit to ground
E520794-06 2202 7F25A 520794 6 -
Auto fan clutch PWM out: Over temperature
E520795-05 2216 7F25B 520795 5 -
E520795-06 2215 7F25B 520795 6 -
E520796-12 1012 7F25C 520796 12 -
Engine ECU temperature: SRC high for ECU
E520797-12 1013 7F25D 520797 12 -
temperature sensor
Engine ECU temperature: SRC low for ECU
E520798-12 1014 7F25E 520798 12 -
temperature sensor
E520799-12 1015 7F25F 520799 12 -
E520800-12 1016 7F260 520800 12 -
Monitoring Misfire detection multiple cylinder:
E520801-12 1017 7F261 520801 12 -
Monitoring Misfire detection multiple cylinder
E520802-12 1018 7F262 520802 12 -
E520803-12 1019 7F263 520803 12 -

9-1-114
DTC Code
P Code
DTC
HEX DEC

E520804-12 101B 7F264 520804 12 -
E520805-12 101C 7F265 520805 12 -
E520806-12 101D 7F266 520806 12 -
E520807-02 1020 7F267 520807 2 -
Timeout error of CAN-Receive-Frame TCU:
E520807-12 101E 7F267 520807 12 -
Timeout Error of CAN-Receive-Frame TSC1TE
Auto fan clutch speed: Fan speed above
E520807-31 101F 7F267 520807 31 -
maximum threshold
Auto fan clutch speed: Fan speed below
E520808-12 1763 7F268 520808 12 -
minimum threshold
Auto fan clutch speed: Fan Speed signal long
E520809-12 1038 7F269 520809 12 -
period fault path
E520809-31 1039 7F269 520809 31 Level Sensor evaluation with Physical Range -
Check high
E520810-12 170F 7F26A 520810 12 Level Sensor evaluation with Physical Range -
Check low
Urea tank level sensor: DFC for SRC high error
E520811-12 1130 7F26B 520811 12 -
Urea tank level sensor: DFC for SRC low error
E520812-00 1131 7F26C 520812 0 -
E520812-01 1132 7F26C 520812 1 Urea tank level sensor: Status of tank level -
E520813-02 268C 7F26D 520813 2 -
Check high for Urea Temperature Sensor
E520814-02 2690 7F26E 520814 2 -
Check low for Urea Temperature Sensor
E520815-02 268E 7F26F 520815 2 -
Urea temperature sensor: SRC high for Urea
E520816-02 2691 7F270 520816 2 -
temperature sensor
Urea temperature sensor: SRC low for Urea
E520817-02 268D 7F271 520817 2 -
temperature sensor
E520818-02 268F 7F272 520818 2 -
Urea temperature sensor: Error Urea tank
E520819-12 1620 7F273 520819 12 -
temperature is overheated
E520820-12 1621 7F274 520820 12 circuit to battery error for Urea tank heating -
valve
E520821-12 1622 7F275 520821 12 circuit to ground error for Urea tank heating -
valve
Urea tank heating valve (Coolant valve): No
E520822-12 1730 7F276 520822 12 -
load error for Urea tank heating valve
Urea tank heating valve (Coolant valve): Over
E520619-03 1047 7F1AB 520619 3 -
Temperature error for Urea tank heating valve

9-1-115
DTC Code
P Code
DTC
HEX DEC

E520619-04 1046 7F1AB 520619 4 -
deviation max for throttle valve
E520619-05 1048 7F1AB 520619 5 -
deviation min for throttle valve
Throttle valve control: DFC for throttle valve drift
E000970-31 1102 3CA 970 31 -
at open position
E003217-12 134 C91 3217 12 -
E003219-31 1203 C93 3219 31 -
E003227-12 140 C9B 3227 12 -
E003229-31 1204 C9D 3229 31 -
ECU: 12V sensor supply 1 voltage is too high
E520198-12 640 7F006 520198 12 -
ECU: 12V sensor supply 1 voltage is too low
E520721-12 1257 7F211 520721 12 -
E520722-12 1214 7F212 520722 12 -
E520722-31 2214 7F212 520722 31 -
E520723-12 12E5 7F213 520723 12 -
E520724-12 12E6 7F214 520724 12 -
E520725-12 12E7 7F215 520725 12 -
E520726-12 12E8 7F216 520726 12 urea quality sensor whether physical signal -
above the maximum limit
E520727-12 12E9 7F217 520727 12 urea quality sensor whether physical signal -
below the minimum limit
E520728-12 12EA 7F218 520728 12 -
Preliminary FMI message (Open circuit)
E520729-12 12EB 7F219 520729 12 -
Preliminary FMI message (Short circuit)
E520730-12 12EC 7F21A 520730 12 -
message
E520731-12 12ED 7F21B 520731 12 -
message

9-1-116
DTC Code
P Code
DTC
HEX DEC

E520732-12 12EE 7F21C 520732 12 -
message (Tank open circuit)
E520733-12 12EF 7F21D 520733 12 -
message
E520734-12 12F0 7F21E 520734 12 -
message
E520735-12 12F1 7F21F 520735 12 -
message (Tank short circuit)
E520736-12 12F2 7F220 520736 12 -
Catalyst Tank Level Preliminary FMI (Open
circuit)
E520737-12 12F3 7F221 520737 12 -
Catalyst Tank Level Preliminary FMI (Short
circuit)
E520738-12 12F4 7F222 520738 12 -
ECU: Internal 12V supply voltage is too high
E520739-12 12F5 7F223 520739 12 -
ECU: internal 12V supply voltage is too low
Supply Module monitoring 2: Detection of filled
E520740-12 12F6 7F224 520740 12 -
system in InitState (Supply module monitoring)
E520741-12 12F7 7F225 520741 12 Range Check high for Urea Pump Module -
Pressure Sensor
E520742-12 12F8 7F226 520742 12 Range Check low for Urea Pump Module -
Pressure Sensor
E520743-12 12F9 7F227 520743 12 -
max for Urea Pump Module Pressure Sensor
E520744-05 2E0 7F228 520744 5 -
min for Urea Pump Module Pressure Sensor
Urea pump module pressure sensor: plausibility
E520744-12 2EB 7F228 520744 12 error min for Urea Pump Module Pressure -
Sensor
Urea pump module pressure sensor: Plausibility
E520745-03 2E3 7F229 520745 3 error max for Urea Pump Module Pressure -
Sensor
Backflow line heater: Short circuit to battery
E520745-04 2E2 7F229 520745 4 -
Backflow line heater: Short circuit to ground
E520746-03 12E3 7F22A 520746 3 -
Backflow line heater: No load error for Backflow
E520746-04 12E4 7F22A 520746 4 -
line heater

9-1-117
DTC Code
P Code
DTC
HEX DEC
Backflow line heater: Over Temperature error

E520747-00 2E4 7F22B 520747 0 -
for Backflow line heater
Pressure line heater: Short circuit to battery
E520747-01 2E5 7F22B 520747 1 -
Pressure line heater: Short circuit to ground
E520750-12 12FC 7F22E 520750 12 -
Pressure line heater: No load error for Pressure
E520751-12 1700 7F22F 520751 12 -
line heater
Pressure line heater: Over Temperature error
E520752-12 1701 7F230 520752 12 -
for Pressure line heater
Suction line heater: Short circuit to battery error
E520753-12 1702 7F231 520753 12 -
Suction line heater: Short circuit to ground error
E520754-12 1703 7F232 520754 12 -
Suction line heater: No load error for Suction
E520755-12 20E9 7F233 520755 12 -
line heater
Suction line heater: Over Temperature error for
E520757-12 20E8 7F235 520757 12 -
Suction line heater
Supply module heater: Short circuit to battery
E520758-12 1706 7F236 520758 12 -
Supply module heater: Short circuit to ground
E520759-12 124A 7F237 520759 12 -
Supply module heater: No load error for Supply
E520759-31 124B 7F237 520759 31 -
module heater
Supply module heater: Over Temperature error
E520760-12 1708 7F238 520760 12 -
for Supply module heater
E520761-12 1709 7F239 520761 12 Range Check high for Urea catalyst upstream -
temperature
E520762-12 170A 7F23A 520762 12 Range Check low for Urea catalyst upstream -
temperature
Urea catalyst upstream temperature: SRC high
E520763-00 170B 7F23B 520763 0 -
Urea catalyst upstream temperature: SRC low
E520763-01 170C 7F23B 520763 1 -
E520764-12 1711 7F23C 520764 12 Range Check high for Urea catalyst -
downstream Temperature sensor
E520765-03 1715 7F23D 520765 3 Range Check low for Urea catalyst downstream -
Temperature sensor
SCR downstream Temperature: SRC high for
E520765-06 1716 7F23D 520765 6 -
SCR downstream Temperature: SRC low for
E520766-03 1717 7F23E 520766 3 -
SCR downstream Temperature: Diagnostic fault
E520766-06 1718 7F23E 520766 6 check for Plausibility errors in Urea catalyst -
downstream Temperature

9-1-118
DTC Code
P Code
DTC
HEX DEC

E520767-12 1719 7F23F 520767 12 -
Tank 1 Temp Prelim FMI (Open circuit)
E520768-12 171A 7F240 520768 12 -
Tank 1 Temp Prelim FMI (Short circuit)
Urea pump motor 1: Pump Motor Speed
E520768-31 171B 7F240 520768 31 -
Deviation
Urea pump motor 1: Permanent Pump Motor
E520769-12 171C 7F241 520769 12 -
Speed Deviation
Urea reverting valve: Short circuit to battery
E520769-31 171D 7F241 520769 31 -
Urea reverting valve: No load error for Urea
E520770-12 171E 7F242 520770 12 -
reverting valve
Urea reverting valve: Short circuit to ground
E520770-31 1720 7F242 520770 31 -
Urea reverting valve: Over Temperature error
E520771-12 1723 7F243 520771 12 -
for Urea reverting valve
Urea reverting valve: Reverting Valve is
E520772-03 208D 7F244 520772 3 -
Blocked closed
DOC upstream temperature: Physical Range
E520772-05 208A 7F244 520772 5 Check high for DOC upstream temperature -
sensor
E520772-06 208C 7F244 520772 6 check for SRC high in DOC upstream -
temperature
E520772-12 1724 7F244 520772 12 check for SRC low in DOC upstream -
temperature
E520780-12 D126 7F24C 520780 12 -
deviation above limit
E520781-12 D5A3 7F24D 520781 12 -
deviation below limit
Rail pressure monitoring 1: maximum positive
E520781-31 D5A4 7F24D 520781 31 -
deviation of rail pressure exceeded
Timeout error of CAN Module C: Bus off error
E520782-12 D5AA 7F24E 520782 12 -
CAN C
Timeout error of CAN Module C: Error passive
E520783-12 D5AB 7F24F 520783 12 -
CAN C
E520784-12 D128 7F250 520784 12 -
E520785-12 D146 7F251 520785 12 -
diagnosis no signal
E520787-12 D148 7F253 520787 12 -
E520788-12 107C 7F254 520788 12 -
diagnosis no signal
Camshaft sensor: DFC for camshaft offset
E520789-12 1302 7F255 520789 12 -
angle exceeded

9-1-119
DTC Code
P Code
DTC
HEX DEC
EEPROM erase error: EEP Erase Error based

E520790-12 1303 7F256 520790 12 on the error in erasing of sector (for Emulation -
only)
EEPROM read error: EEP Read Error based on
E520791-12 1304 7F257 520791 12 -
the error in reading blocks from memory media
E520792-12 1305 7F258 520792 12 -
reached maximum allowed opening coun
EEPROM write error: EEP Write Error based on
E520794-05 2203 7F25A 520794 5 -
the error in storing the blocks in memory media
E520794-06 2202 7F25A 520794 6 fans: Short circuit to battery error of Fan digital -
signal
E520795-05 2216 7F25B 520795 5 -
fans: No load error of Fan digital signal
E520795-06 2215 7F25B 520795 6 fans: Short circuit to ground error of Fan digital -
signal
E520796-12 1012 7F25C 520796 12 fans: Over temperature error of Fan digital -
signal
Timeout error of CAN Module A: Bus off error
E520797-12 1013 7F25D 520797 12 -
CAN A
Timeout error of CAN Module A: Error passive
E520798-12 1014 7F25E 520798 12 -
CAN A
E520799-12 1015 7F25F 520799 12 -
E520800-12 1016 7F260 520800 12 -
E520801-12 1017 7F261 520801 12 -
E520802-12 1018 7F262 520802 12 -
E520803-12 1019 7F263 520803 12 -
Engine temperature sensor plausibility Tot: Air
E520804-12 101B 7F264 520804 12 -
temperature monitoring plausibility check
ECU hardware chip CY320 error: ECU
E520805-12 101C 7F265 520805 12 -
hardware chip CY320 error
Hydraulic oil temperature CAN time out:
E520806-12 101D 7F266 520806 12 -
Timeout Error of CAN-Receive-Frame AAI
Timeout error of CAN-Receive-Frame DEC1V:
E520807-02 1020 7F267 520807 2 -
Timeout Error of CAN-Receive-Frame DEC1V
E520807-12 101E 7F267 520807 12 -
E520807-31 101F 7F267 520807 31 valve: Timeout Error of CAN-Receive-Frame -
EGRErr
EGR valve actuator communication error: EGR
E520808-12 1763 7F268 520808 12 -
SRA Error for communication Loss 1
Air control governor deviation error: Positive
E520809-12 1038 7F269 520809 12 -
governor deviation above limit

9-1-120
DTC Code
P Code
DTC
HEX DEC
Air control governor deviation error: Negative air

E520809-31 1039 7F269 520809 31 -
control governor deviation below limit
E520810-12 170F 7F26A 520810 12 to battery error of powerstage for intake air -
heater
Power stage for intake air heater: No load error
E520811-12 1130 7F26B 520811 12 -
of powerstage for intake air heater
E520812-00 1131 7F26C 520812 0 to ground error of powerstage for intake air -
heater
Power stage for intake air heater: Over
E520812-01 1132 7F26C 520812 1 temperature error of powerstage for intake air -
heater
Timeout error of CAN-Receive-Frame Vehicle
E520813-02 268C 7F26D 520813 2 cut off switch: Timeout Error of CAN-Receive- -
Frame AUXIO1
Accel pedal CAN max error: Timeout Error of
E520814-02 2690 7F26E 520814 2 -
CAN-Receive-Frame DEC1V
Vehicle cutoff switch error: DFC for error at
E520815-02 268E 7F26F 520815 2 -
vehicle cutoff switch
E520816-02 2691 7F270 520816 2 -
disabled due to high Battery voltage
E520817-02 268D 7F271 520817 2 -
disabled due to low Battery voltage
E520818-02 268F 7F272 520818 2 -
report the NTP error in ADC monitoring
E520819-12 1620 7F273 520819 12 -
is limited by charge balance of booster capacity
Detection of failed engine start: Detection of
E520820-12 1621 7F274 520820 12 -
Failed Engine Start
E520821-12 1622 7F275 520821 12 -
E520822-12 1730 7F276 520822 12 -
E520619-03 1047 7F1AB 520619 3 -
Injection bank 1
E520619-04 1046 7F1AB 520619 4 -
E520619-05 1048 7F1AB 520619 5 Diagnostic Fault Check for Supply Module -
E000970-31 1102 3CA 970 31 Diagnostic Fault Check for Supply Module -
Heater Temperature Duty cycle in invalid range
E003217-12 134 C91 3217 12 Diagnostic Fault Check period outside valid -
range
E003219-31 1203 C93 3219 31 Diagnostic Fault Check to detect faulty PWM -
signal

9-1-121
DTC Code
P Code
DTC
HEX DEC

E003227-12 140 C9B 3227 12 Temperature measurement module not -
available
E003229-31 1204 C9D 3229 31 Diagnostic Fault Check for Supply Module -
E520198-12 640 7F006 520198 12 Diagnostic Fault Check for Supply Module -
Temperature Duty cycle in invalid range
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

9-1-122
9-1-123
ELECTRONIC HYDRAULIC CONTROL SYSTEM (EPOS)
Control System Schematic
16
6 6
7 7
11 14
8
8
13 15
E/G
4 4 5
3
9 10
Power Mode
Work Mode
Auto Idle Mode
2 Machine Information
25
E/G Speed
PM
H H
Order E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
24 23
1
21 19 22
17 20
WE1400678
Figure 164

9-1-124
Reference Reference
Number Number
1 Instrument Panel 13 Solenoid Valve (High-speed)
2 EPOS Controller 14 Solenoid Valve (Breaker)
3 Engine Controller (ECU) 15 Travel Motor
4 Main Pump 16 Main Relief Valve
5 Aux Pump 17 Engine Control Dial
6 Control Valve 19 Work/Travel Selector Switch
7 Pressure Switch 20 Boost Switch (Right Work Lever)
8 Pump Pressure Sensor 21 Sensors
Electromagnetic Proportional 22 Aux Mode Switch
9
Pressure Reducing Valve 23 Aux Mode Resistance
Electromagnetic Proportional 24 Accelerator Pedal
10 Pressure Reducing Valve
25 Jog Switch Control Panel
(Mode Control)
11 Solenoid Valve (Boost)

9-1-125
POWER PLUS MODE CONTROL
6 6
E/G
4 4
3
25
10
2
PM
H H
24 C
E
E F
F
C
TRIP
/h rpm ECO
Min Max
SPC
S USB
19 23 22 1
17
WE1400679
Figure 165
Reference Reference
Number Number
Electromagnetic Proportional
Instrument Panel
1 10 Pressure Reducing Valve
(Power Mode Selector Switch)
(Mode Control)
2 EPOS Controller 17 Engine Control Dial
3 Engine Controller (ECU) 19 Work/Travel Selector Switch
4 Main Pump 22 Aux Mode Switch
5 Aux Pump 23 Aux Mode Resistor
6 Control Valve 24 Accelerator Pedal
25 Jog Switch Control Panel

9-1-126
The Jog Switch Control Panel permits the selection of the
appropriate engine power depending on the working condition.
One of the four. Power Plus Mode, Power Mode, Standard Mode
or Economy 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 jog switch on the jog switch control panel. 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 Power Plus Mode Power Mode Standard Mode Economy Mode
Output (%) 100% Approximately 90% Approximately 80% Approximately 75%

9-1-127
Operation
1. Power Plus Mode

This mode must be selected for high-speed work. In this
mode the engine output is most efficiently utilized because
of 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
EPPR (Electromagnetic Proportional Pressure Reducing)
valve which in turn varies the pump output quantity.
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 FG018900
volume to maintain the engine speed at the rated level. Figure 166
On the other hand, if the load is decreased the controller

PM
increases the discharge volume of the pump to maintain
the engine speed at the rated level. H H
By repeating these control operations, the engine speed is Power Mode

maintained at the rated speed so maximum power can be
P+ P S E
E F
generated. rpm
C C
In Power Mode, the EPOS controller receives engine Speed
speed signals from the engine control dial and the engine 0 25 (mph) Min Max
controller (ECU) and converts it to an operating signal E DIG ISO USB
current and is then transferred to the pump's EPPR valve. FG018901

Now the EPPR valve converts the electric signal to the
Figure 167
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 168
Reference Reference
Number Number
A Engine Horsepower (hp) Pump Discharge Pressure
D
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume (lpm)

9-1-128
2. Power Mode, Standard Mode, Economy Mode
Power Mode, Standard Mode or Economy Mode is
selected on the work type. When the standard/economy
mode is selected it will reduce noise and fuel consumption
in comparison with Power Plus Mode. The EPOS controller
compares the target engine speed with the actual engine
speed and controls the signal to the EPPR valve which in
turn varies the pump output quantity and it is the same
method with power volume.
A C
Power Plus Mode

Power Mode
Standard Mode
Economy Mode
B D FG018902
Figure 169
Reference Reference
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)

9-1-129
POWER MODE CONTROL - CIRCUIT DIAGRAM
34
26 15A 10A
B
1
BR
4
E 25
7-2
Starter Switch (ACC) A
7-5
7-6
24
7-4
7-3
1-1
7-1
1-3
6-12 1-39
6-13
23
1-40 CAN A
1-21
22
2-98 1
5
1-23 GND 2 10
1-24 RxD 2-99 3
6
1-43 TxD 4
3 1
17
2 GND 1-11 3 HIGH
CW
3 SIG 1-31 2
1-46
4 (+5V) 1-19 1
1-47 LOW
5
1-10
6 1-4 35
1-03 14
1-05 32 3 4
1-5 Position Idle
1-28 Sensor Validation 27
1-29 2
1-52
P1
1-75
1-76 1
1-25 A B C E F D
1-20
1-01 Starter
Switch 1-12
1-26 (ACC) 1-29
1-49
33 2-93
1-73 1
1-11 2 3 26
1-74 10A
15A
1-69 BR B 10A
28
AMP 040 36P

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
4 5
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 98 99 100 101 102 103 104 105 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 90 91 92 93 94 95 96 97 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
1 2 82 83 84 85 86 87 88 89 114 115 116
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 GAUGE (CN7) GAUGE (CN6)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
EPOS (CN1) EPOS (CN2)
ECU (CN1)
WE1400680
Figure 170

9-1-130
Reference Reference
Number Number
1 Instrument Panel 25 Battery Relay
3 Engine Controller 26 Fuse
4 EPOS Controller 27 Circuit Breaker 1
EPPR Valve (Electromagnetic 28 Starter Switch
10
Proportional Pressure Reducing) 32 Jog Switch Control Panel
17 Engine Control Dial 33 Engine Emergency Stop Switch
22 Aux Mode Switch 34 Circuit Breaker 2
23 Aux Mode Resistor 35 Accelerator Pedal
24 Battery
SMART POWER CONTROL (SPC)

The SPC (Smart Power Control) function controls engine speed
to reduce fuel consumption by determining high and low load
during excavation operation.
When SPC mode is selected, the engine rpm is reduced by
100 rpm from the working mode. In excavation work, the load at
boom-up and arm-in is detected to increase engine power to
operate the equipment at high power.
The selection and release of the SPC function can be made with
the SPC switch on the R.H stand.
When the start-up switch is turned on, the power mode is
automatically set to SPC Standard of SPC Mode. In this status,
use the button switch on the instrument panel or jog switch to
select SPC Power Plus Mode, SPC Power Mode, SPC Standard
Mode, or SPC Economy Mode. When a mode is selected, the
corresponding symbol appears at the bottom left of the
instrument panel.
Operation
1. Smart Engine Speed Control

This function controls engine speed according to the
workload which is determined with the actual torque of the
engine and high load (boom-up, arm crowd) pilot pressure.
The engine speed is classified into Heavy load mode and
Light load mode and matched automatically according to
the workload. The variable range of the engine speed is set
by 100 rpm that does not cause any problem in operation
sequence. The workload is determined with the actual
torque information of the engine and the joystick
information.

9-1-131
Engine Actual Torque Condtion “Smart Engine Speed Control”
All the engine speed to match automatically
Engine Actual Torque
depend on working load condition (joystick

lever & the engine auctual torque condition.)
100 % Engine Speed

80 %
Rated rpm Heavy Load Mode
50 %
100 rpm
Light Load Mode
Engine rpm
Rated rpm
300 rpm
Joystick Lever Condition

(Heavy Load Condition)
Low Idle
Boom Up (Pilot 20 bar )

Engine Control
Dial Position
Arm Crowd
(Pilot 15 bar )
EX1403306
Figure 171
If the joystick lever condition meets the heavy load condition and the
Entering actual torque of the engine meets the heavy load area condition, the
Condition engine speed is shifted from light load mode to heavy load mode to set
Heavy Load the hydraulic power to the maximum working performance level.
Condition
If the joystick lever condition meets any one of the heavy load condition
Maintenance
and 50 % or above of the engine actual torque, the engine speed is
Condition
maintained at heavy load mode.
When the engine actual torque is reduced to less than 50% and the
Entering joystick lover condition meets all the conditions other than the heavy
Condition load condition, the engine speed is shifted to light load mode to improve
Light Load fuel efficiency.
Condition
If the joystick lever condition meets any condition other than the heavy
Maintenance
load condition or the engine actual torque is in the light load area (0 ~
Condition
80 %), the engine speed is maintained at light load mode.

9-1-132
2. Smart Pump Torque Control
This function controls the pump torque according to the
limitation applied to the engine by turbocharger lag time
and smoke limit. The engine limitation information is
obtained from the engine actual torque. In the fuel
economy mode, the pump responsibility is lowered than
that of the engine torque slightly for smooth operation of
the equipment.
Torque Control
Mode
%
Actual Torque Ramp Start Power
Total Power
Power
100
40
Torque Control
Lamp Determined Limiter
Power Limiter
Power Output Value Using
Ramp and Power
Pump Torque Engine Torque Pump Torque Engine Torque

Torque
Torque
T T
Engine rpm
Engine rpm
10 11 12 10 11 12
T T
EX1301793
Figure 172

9-1-133
ENGINE CONTROL SYSTEM
24
(Command Signal)
4 17
(Drive Signal)
WE1500076
Figure 173
Reference Reference
Number Number
3 Engine Controller 17 Engine Control Dial
4 EPOS Controller 24 Accelerator Pedal
When the engine control dial is moved the output voltage

changes according to the dial position.
The EPOS controller converts this output voltage of dial to digital
signal and sends it to the engine controller by CAN line.
According to the dial command, the quantity of fuel injection is
adjusted.

9-1-134
Engine Control Dial
1st Step 7th Step 13th Step
CCW CW
Mechanical Mechanical
Stop Stop
3
4
2
5
4.0V
4
Output Voltage (V)
3 2.5V
2
1.0V
1
0 Step
1st 2nd ...... 7th ...... 12th 13th
CCW CW
Stop Stop
1 2 3
WE1400656
Figure 174
Reference Reference
Number Number
1 Knob 3 Magnetic
2 Hall Effect Sensor 4 Gear
The engine control dial has a built in potentiometer. 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.

9-1-135
Acceleration Pedal
Accelerator Ass’y EPOS

A 1-20
POSITION B 1-12
SENSOR
C 1-29
IDLE E 2-93
VALIDATION
F
D
Foot Pedal
Stroke 17.5
Detail A
PIN
A LOCATION DESCRIPTION COLOR CONNECTOR
B A APS SIGNAL BLACK 2 1 6
C B APS GRAND WHITE 1
D 2 5
C APS SUPPLY RED 3
E
D THROTTLE ACTIVE GREEN 5 3 4
F
E IDLE ACTIVE BLUE 6
Pedal Sensor F IVS SUPPLY ORANGE 4
WE1400681
Figure 175
The acceleration pedal has a built in potentiometer. When the

acceleration pedal is pressed output voltage (through "2 and 1"
terminals) will vary from the 5V supplied from the EPOS
controller as shown in the graph.

9-1-136
9-1-137
Engine Control Circuit Diagram
4
26 34
15A 15A
B
1
BR
E 25
7-2
Starter Switch (ACC)
A
7-5
7-6
1-1 24
7-4 1-3
7-3 35
5
7-1 2-96 1
6-12 1-39 36
6-13 1-40 1-81 (BREAKER)
CAN A
1-21 (RS1)
1-23 GND 17
GND 1-11 3
1-24 RxD CW HIGH
1-43 TxD SIG 1-31 2
(+5V) 1-19 1
LOW
3 1
1-4
2 27
3
1-5 37
1-46 Position Idle
4
1-47 Sensor Validation
5
1-10
6 P1
1-03 14
1-05 32 3 4
1-28
1-20 A B C E F D
1-29 2
1-52 1-12
1-75
1 1-29
1-76
1-25 2-93
1-01 Starter
Switch
1-26 (ACC)
1-49
1-73
26
10A
15A
1-69 BR B 10A
28
AMP 040 36P

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
4 5
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 10 9 8 7 6 5 4 3 2 1
98 99 100 101 102 103 104 105 8 7 6 5 4 3 2 1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 90 91 92 93 94 95 96 97 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
1 2 82 83 84 85 86 87 88 89 114 115 116
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
GAUGE (CN7) GAUGE (CN6)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ECU (CN1)
WE1400682
Figure 176

9-1-138
Reference Reference
Number Number
1 Instrument Panel 27 Circuit Breaker 1
3 Engine Controller 28 Starter Switch
4 EPOS Controller 32 Jog Switch Control Panel
17 Engine Control Dial 34 Circuit Breaker 2
24 Battery 35 Solenoid Valve (Pressure Up)
25 Battery Relay 36 Power Boost Switch
26 Fuse 37 Accelerator Pedal

9-1-139
AUTOMATIC DECELERATION CONTROL 
(AUTO IDLE CONTROL)
E/G
3 4
1
5 5
WE1500077
Figure 177
Reference Reference
Number Number
1 Jog Switch Control Panel 3 Engine Controller
(Auto Idle Switch) 4 Engine Control Dial
2 EPOS Controller 5 Pressure Sensor

9-1-140
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 canceled through the Auto Idle
Selector Switch 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
sensors in the control valve. When the work levers are in the
neutral position, the sensor is below 15.5 bar (15.8 kg/cm2,
224.8 psi).

9-1-141
ENGINE OVERHEAT PROTECTION SYSTEM
6 6
E/G
4 4 5
3
31
7
(Pump control signal)
2
1
(E/G overheating signal) PM
H H
E F
C E F C
TRIP
rpm ECO
(E/G overheating signal)

/h Min Max
SPC
S USB
WE1400683
Figure 178
Reference Reference
Number Number
1 Instrument Panel 6 Control Valve
2 EPOS Controller EPPR Valve (Electromagnetic
3 Engine Controller 7 Proportional Pressure Reducing
Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump
When the engine coolant temperature increases to over 105°C

(221°F), the engine controller detects it from the sensor
mounted in the coolant line and will send a signal to the EPOS
controller. The EPOS controller sends a overheat signal to the
instrument panel turning "ON" the warning light and buzzer
simultaneously.
Also, the EPOS controller returns an overheat signal to the
engine controller and changes power mode to standard mode.
The engine speed is then set to a low speed by the engine
controller.
When coolant temperature falls below 100°C (212°F), normal
operation will resume.

9-1-142
1. Coolant Overheat Prevention System
The engine controller detects the engine coolant
temperature with the temperature sensor in the coolant
line. If the coolant is overheated, the engine controller send
the overheat signal to the EPOS controller which conveys
the signal to the instrument panel.
If the coolant is overheated, the pump output is reduced to
prevent engine overheat.
When the coolant temperature reaches about 103°C
(217°F), the pump output is reduced to 85% into the
Tropical mode. A pop-up screen appears on the instrument
panel to inform the operator of the mode shift.
If the coolant temperature exceeds 105°C (221°F), the
engine controller sends coolant overheat signal to the
EPOS controller which conveys the signal to the
instrument panel.
Receiving the engine overheat signal, the instrument panel
turns on the warning light and triggers the buzzer for
warning.
In addition, the EPOS controller sends a signal back to the
engine controller and shifts the power mode to the
standard mode.
The engine controller controls the engine speed to low
speed range.
In summary, in case of engine coolant overheat, the
system selects tropical mode, triggers warning buzzer,
shifts to standard power mode, reduce engine speed, and
reduces pump output.
When the coolant temperature is lowered to 100°C (212°F)
or below, the system resumes normal operating condition.

9-1-143
2. Hydraulic Oil Overheat Prevention System
During operation, the EPOS controller monitors the
hydraulic oil temperature with the hydraulic oil temperature
sensor. If the hydraulic oil is overheated, the EPOS
controller sends the overheat signal to the instrument
panel.
When the hydraulic oil is overheated, the pump output is
reduced to prevent engine overheat.
When the hydraulic oil temperature reaches about 97°C
(206.6°F), the pump output is reduced to 85% into the
Tropical mode. A pop-up screen appears on the instrument
panel to inform the operator of the mode shift.
If the hydraulic oil temperature exceeds 99°C (210.2°F),
the EPOS controller sends hydraulic oil overheat signal to
the instrument panel.
Receiving the hydraulic oil overheat signal, the instrument
panel turns on the warning light and triggers the buzzer for
warning.
In addition, the EPOS controller sends a signal back to the
engine controller and shifts the power mode to the
standard mode.
The engine controller controls the engine speed to low
speed range.
In summary, in case of hydraulic oil overheat, the system
selects tropical mode, triggers warning buzzer, shifts to
standard power mode, reduce engine speed, and reduces
pump output.
When the hydraulic oil temperature is lowered to 91°C
(196°F) or below, the system resumes normal operating
condition.

9-1-144
9-1-145
POWER BOOST MODE
Operation
16
6 6
11
E/G
4 4 5
3
PM
H H
E F
C E F C
TRIP
/h rpm ECO
Min Max
SPC
S USB
20 18
WE1400684
Figure 179
Reference Reference
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 EPOS Controller 16 Main Relief Valve
3 Engine Controller 18 Jog Switch Control Panel
4 Main Pump Power Boost Switch
20
5 Aux Pump (Top of Right Work Lever)
6 Control Valve

9-1-146
The Power Boost function is used to temporarily increase the
main relief pressure to enhance excavation ability. When the
Work Mode is set to "BOOST" by the jog switch control panel
and the power boost button on the right-hand work lever
(joystick) is pressed during work, the EPOS controller will
activate the power boost solenoid valve and increase the relief
valve pressure from 350 bar (357 kg/cm2, 5,076 psi) to 370 bar
(377 kg/cm2, 5,366 psi) for 7 seconds. 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.

9-1-147
Power Boost Control - Circuit Diagram
4
26 34
15A 15A
B
1
BR
E 25
7-2
Starter Switch (ACC)
A
7-5
7-6
1-1 24
7-4 1-3
7-3 35
5
7-1 2-96 1
6-12 1-39 36
6-13 1-40 1-81 (BREAKER)
CAN A
1-21 (RS1)
1-23 GND
1-24 RxD
1-43 TxD
3 1
2
3
17
GND 1-11 3
1-46 CW HIGH
4
1-47 SIG 1-31 2
5 1-19 1
1-10 (+5V)
6 LOW
1-03 14
1-05 32 3 4
1-4
1-28 1-5 27
1-29 2
1-52
1-75
1
1-76
1-25
1-01 Starter
Switch
1-26 (ACC)
1-49
1-73
26
10A
15A
1-69 BR B 10A
28
AMP 040 36P

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 106 107 108 109 110 111 112 113 119 120 121
4 5
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 10 9 8 7 6 5 4 3 2 1
98 99 100 101 102 103 104 105 8 7 6 5 4 3 2 1
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 117 118
3
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 90 91 92 93 94 95 96 97 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
1 2 82 83 84 85 86 87 88 89 114 115 116
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
GAUGE (CN7) GAUGE (CN6)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ECU (CN1)
WE1400689
Figure 180

9-1-148
Reference Reference
Number Number
1 Instrument Panel 28 Starter Switch
3 Engine Controller 32 Jog Switch Control Panel
4 EPOS Controller 34 Circuit Breaker 2
17 Engine Control Dial 35 Solenoid Valve (Pressure Up)
24 Battery Power Boost Switch
36
25 Battery Relay (Top of Right Work Lever)
26 Fuse
27 Circuit Breaker 1

9-1-149
CRUISE CONTROL
Operation
40
6
3
35 36
4 4
15 32
38
39
24 17
WE1400690
Figure 181
Reference Reference
Number Number
3 Engine Controller (ECU) 32 Pressure Switch (Py)
4 Main Pump 35 Cruise Solenoid Valve
5 Aux Pump 36 Forward Solenoid Valve
6 Control Valve 38 Cruise Switch
15 EPOS Controller 39 Brake Pedal
17 Engine Control Dial 40 Travel Motor
24 Accelerator Pedal
Cruise control is used for reducing operator's fatigue during long

travel distances.

9-1-150
1. Run Method
Forward/reverse switch is placed at forward position (F),
although accelerator pedal is not stepped on, the unit can
travel. Now, faster or slower travel speed can be obtained A A
by adjusting the engine speed control dial. When engine
speed control dial is adjusted to desired speed, the unit will B B
travel at a constant speed. If there is a change in the load,
a change of travel speed can occur. When the forward/ C C
reverse switch is placed in reverse position, this function
will not be operated.
FG022316
Reference Figure 182
Description
Number
A Forward Travel
B Neutral
C Reverse Travel
2. Cancel
When the brake is applied the cruise control will be O
canceled.
Bring the forward/reverse switch back to neutral (N), will
I
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 FG022343
approximately four seconds. When the cruise Figure 183
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

1. Forward/reverse switch is 1. When the brake is applied.
placed in FORWARD.
Condition 2. Accelerator pedal is stepped 2. Forward/reverse switch is
ON. placed in NEUTRAL or
REVERSE.
3. Cruise switch turns "ON."
Forward Solenoid Valve Operation Cancel
Cruise Solenoid Valve Operation Cancel
Speed Control Engine Speed Control Dial Accelerator Pedal

9-1-151
Cruise Control Circuit
5
4
1-61
11 3 2
+
1-14 B A
SIG. 1-1
1-28
- 1-3 BR
12 E
A 1-20
B 1-12
C 1-29
E 2-93
F
D
- + - +
7
13 2-112 12V 150AH 12V 150AH
1-19
+
1-13
SIG. 1
-
1-11
2-113
8
14
1 1-4
2 1-31
3 1-5
CW
9
0 1
1-80 3
I 2
1-58 9 10
(F)
1-76 13 10
(R)
1-57 12 10
(N)
10
WE1500078
Figure 184
Reference Reference
Number Number
1 Battery 8 Cruise Solenoid Valve
2 Battery Relay 9 Cruise Switch
3 Circuit Breaker 10 Forward/Reverse Switch
4 Fuse 11 Auto Idle Sensor (Py)
5 Stop Light Switch 12 Accelerator Pedal
6 EPOS Controller 13 Parking Brake Sensor
7 Forward Solenoid Valve 14 Engine Control Dial

9-1-152
If the cruise switch (9) is turned on during the forward run, the
"2" and "3" terminals of the cruise switch (9) is connected. Now
the current flows from the battery (1)  battery relay (2) 
circuit breaker (3)  fuse (4)  "10" and "9" terminals of
forward/reverse switch (10)  "2" and "3" terminals of cruise
switch (9)  "1-180" terminal of EPOS controller (6). The other
side, the current flows from the fuse (4)  cruise solenoid
valve (8)  "2-113" terminal of EPOS controller (6) and the
machine runs as a cruise state.
If the forward/reverse switch (10) is place in neutral or reverse
position during the cruise, the cruise function will be canceled.
Also if the brake pedal is pressed, the stop light switch (5) will be
turned "ON". Now, the current flows from the fuse (4)  stop
light switch (5)  "1-61" terminal of EPOS controller (6). So
cruise function will be canceled.

9-1-153
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 185
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
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.

9-1-154
3. Normal Operation Display Readout
Display System
Mode
Higher Digit Lower Digit Condition
Normal Operation
P+, P
Power Mode
HAOH340L
HAOH340L FG018940
Normal Operation
Power Mode S
Standard Mode
FG018938 FG018940
Normal Operation
E
Economy Mode
HAOH350L FG018940
Normal Operation
Digging
Digging Mode
FG018940 HAOH370L
Work Mode
Normal Operation
Lift
Lift Mode
FG018940 FG018939
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.

9-1-155
AIR CONDITIONER SYSTEM
Outline
C B
Figure 186 WE1401160
Solid-type heater and air conditioner are installed in the cover

behind the operator's seat.
Temperature of the operator's cabin is adjusted automatically to
the temperature set by operator.
(Please refer to the Operation and Maintenance Manual for
detailed full automatic control.
Vent mode selects the direction of discharged air.
Outlets by vent modes
Modes
Outlets A A+B B B+C C

9-1-156
Internal and External Filters
Internal and external air purification filters are installed for the
operator's room.
Filters must be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters must be cleaned more frequently and if
necessary, replaced with new ones.
How to Check Internal Air Filter

1. Press both levers on the left and right side at the top of the
filter installed at the rear of the operator's seat.
EX1300822
Figure 187
FG016045
Figure 188

9-1-157
How to Check External Air Filter
1. Open the door at the left side of machine and loosen four
marked bolts to remove cover.
FG016043
Figure 189
2. Turn marked knobs at the rear side of the cabin to open the
cover.
3. Remove 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 190

9-1-158
Air-Conditioning System Layout
11
3
10
2
1
5
7
4
8
6
8
9
WE1400657
Figure 191
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

9-1-159
Air Conditioner/Heater Circuit Diagram
CIRCUIT BREAKER
LAMP SWITCH
20A STARTER SWITCH

BATTERY RELAY
A/C CONTROL PANEL AIRCON UNIT BATT.
CN11-2 24V
LED 1~12 CN9-6
CN10-8
CN9-11
CN10-18
ILL CN9-5
RECEIVER DRIER
BLOWER A/C
RELAY RELAY
COMPRESSOR
CN8-10 CN10-16
A/C THERMO (LOW) CN9-8 CN10-5 CN11-4 0.85LW
CN8-11 CN10-6
FET
DIODE 4
1.25B CN11-1 - +
M
CN8-12 CN10-1 BLOWER
CN9-13 CN10-2 FRE (P1)

INTAKE
CN9-12 CN10-20 REC (P2) ACTUATOR
M
CN9-15 CN10-12 DEF (P1)

CN9-14 CN10-13 VENT (P2)
M
MODE
CN9-16 CN10-11 Vref MODE
ACTUATOR
CN9-17 CN10-10 MODE F/BACK
CN9-10
CN9-1 CN10-19 WARM (P1)

CN9-18 CN10-3 COOL (P2)
M
CN9-3 CN10-7 Vref MIX MIX
CN9-4 CN10-9 MIX F/BACK ACTUATOR
CN9-2 CN10-4 GND
CN8-2 CN10-15
DUCT
SENSOR
CN8-1 CN10-14
WATER
SENSOR
2
CN8-5 CN10-17 1 INCAR
SENSOR
SUN LOAD SENSOR
2 - + 1 CN10 AMP 20P CN11 KET 4P

CN8-3
2
CN8-4 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) WE1400692

Figure 192

9-1-160
Air Conditioner/Heater Unit
Airflow 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 193

9-1-161
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 194

9-1-162
Actuator - Airflow Direction Control
Change of discharged airflow according to selected airflow
direction mode
Change of airflow direction: Direction changes in the order of
VENT BI-LEVEL  FOOT  FOOT/DEF  VENT.
Actuator - Temperature Control

Change of discharged air temperature by controlling the position
of temperature control door.
N P2
c
b
a
P2 P1
a c b
WE1400658
Figure 195
Actuator - Airflow Direction Control
Airflow 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 - Temperature Control
Set Temperature Output Terminal Voltage

Max cooling c (+): CN10-9 Below 0.4V
Max heating b (-): CN10-4 Above 4.5V

9-1-163
Actuator - Internal/external Air Exchange
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 196
Mode Output Terminal Output

Moving of exchange door
Intake P1 (+), P2 (-)
by selecting intake.
Moving of exchange door
Recirculate P1 (-), P2 (+)
by selecting recirculate.
Airflow Control Module

Airflow is controlled through the control of voltage between
GATE and SOURCE.
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 197
Airflow 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
Input voltage is 27.5V.

The airflow is based on manual set.

9-1-164
Relay - Blower: Power is supplied to the blower motor when the
system is turned "ON."
87 85(-)
Specifications
87
Rated voltage 24V
86 85
86a
Rated current 20A
30
30 86(+)
WE1400659
Figure 198
Relay - A/C: Power is supplied to the magnetic clutch of the

compressor.
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 199
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.
Temperature (°C) Resistance (K)

0 11.36 ±0.1
2 10.39 ±0.2
2.5 10.17 ±0.2
3 9.95 ±0.2 Figure 200
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

9-1-165
Coolant Temperature Gauge 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 201
Internal Air Temperature Sensor: Built in the internal air filter,

it senses the internal temperature.

-30 528.2 ±22.9
-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 202
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
FG001064
25 30 ±0.9
Figure 203
30 24.2 ±0.7

9-1-166
Sun Sensor
Built beside the socket of spare power, it senses the quantity of
the sun radiation to regulate discharge temperature and airflow
as set by operator.
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 204
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 205
Refer to "Air Conditioner and Heater" of operation manual.

9-1-167
Terminal Terms
CN Term No. Terms CN Term No. Terms

Temperature control Coolant temperature
1 1
(warm) gauge 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 Backup 6 -
7 - 7 -
8 A/C output (LOW) 8 -
9 - 9 -
10 Ground 10 D.P.S CHECK
CN9 11 Illumination 11 Airflow module (gate)
Intake/Recirculate
12 12 Blower motor (feedback)
(Recirculate)
Intake/Recirculate
13
(Intake)
Airflow direction control
14
(VENT)
15
(DEF.)
16
Power (5V)
17
(feedback)
Temperature control
18
(cool)

9-1-168
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, airflow direction, Recirculate/Intake, Airflow,
Compressor
Ambient Air Temperature
Sensor 2. Auto mode is released when manually setting any switch
except, Temperature Control switch in Auto mode.
Coolant Temperature
Gauge Sensor 3. Upon the releasing of Auto mode, all of functions except
Sun sensor selected switch are controlled automatically.
Sensor Set Temperature 1. In case of sensor fault, the 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
Coolant Temperature Temperature 25 ~ 32°C: Max heating
Gauge Sensor
Airflow 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.

9-1-169
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)
A. A/C on (AUTO or manual)
B. Temperature sensed by the duct sensor is above
30°C
C. Airflow: 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 airflow) in 5 seconds after engine run.
5. Initial cooling control must be before max cooling.
6. Release condition (OR condition)
A. A/C "OFF"
B. Airflow: Manual control
C. 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.

9-1-170
1. Start condition (AND condition)
A. When airflow direction mode is one of the following
modes in the Auto or manual control mode
- BI-LEVEL, FOOT or FOOT/DEF
B. The coolant temperature gauge sensor is stable and
the coolant temperature gauge < 73°C
C. Airflow: Auto mode
D. Set temperature > Internal air temperature + 3°C
* Airflow falls gradually up to 12 seconds when operation
released.
Coolant Temperature 2. One time control in the cycle of engine OFF  engine run
Gauge Sensor 3. Initial heating control must be before max heating.
Starting Internal Air Temperature
Control of 4. Airflow is controlled only when the airflow direction is in the
Sensor manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
Heating (1)
Auto Mode 5. Control through the coolant temperature gauge sensor for
Set Temperature start.
6. Starting control of heating (2) starts in case of fault of the
coolant temperature gauge sensor during controlling.
7. Operation release (OR condition)
A. Only airflow is released if it is selected manually.
B. When handling the airflow direction mode switch,
only airflow direction is released but the airflow
control is performed only for the remaining period of
the starting control of heater.
C. When Max Cooling (17°C) is selected.
D. Coolant temperature gauge sensor > 73°C.

9-1-171
Starting Coolant Temperature 1. Entry condition (AND condition)
Control of Gauge Sensor A. Auto Mode
Heating (2)
Ambient Air Temperature
B. Ambient air temperature < 5°C and difference
Sensor
between ambient and internal air temperature 5°C
Internal Air Temperature
C. Failure of coolant temperature gauge sensor
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)
A. Airflow: Manual selection
B. When handling the airflow direction mode switch,
only airflow direction is released but the airflow
control is performed only for the remaining period of
the starting control of heater.
C. Difference between internal and ambient air
temperature>15°C
D. 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.)
* Airflow must 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.
Compressor 2.0 0.5 C 3.5 0.5 C

Control
External Temperature 1. Function: Prevention of compressor in winter.
Sensor
2. Control pattern.
*Only for Auto mode.

9-1-172
Self-diagnosis
How to start self-diagnosis
Starter Switch ON
Set temp to 25 C Set temp to 77 F
Press the SEL switch more than 3 times in

5 secs while pressing the A/C switch
Auto diagnosis starts after every graphic

in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON

and 0.5-sec OFF. In case of two or more errors, codes
concerned blink twice at a time.
For normal, E0 lights; for error, the first

error code is indicated.
For 2 or more error, error codes are indicated

upstreams/downstreams if the temp control switch is
set to up/down. (For normal condition, only EO lights.)
Press the SEL switch more than 3 times in

5 secs while pressing the A/C switch. Return to default status if no switch
operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis

starts.
FG001367
Figure 206

9-1-173
Error codes
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Coolant temperature gauge sensor short
E10 Coolant temperature gauge sensor open
E11 D.P.S open
E12 Position error of airflow direction actuator
E13 Position error of temperature control actuator
NOTE: The 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 207
Ambient Temperature Display

Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temperature in the set
temperature display department.
- Range of temperature display: -40 - +60°C
NOTE: Display of ambient temperature may be released in
the same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temperature display
mode.

9-1-174
Compressor
Categories Specifications Relief Valve
Output 155.3 cc/rev
Oil Level 150 cc
Refrigerant R134a
Rated Voltage 24V
Open: 35 ~ 42.2 kg/cm2
Relief Valve
Close: 28.1 kg/cm2
Compressor sucks in refrigerant which evaporates completely in

the evaporator and discharges it to the condenser. FG001365
Figure 208
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 temperature 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 209
MAX. 0.25 kg/cm2

32 2 kg/cm2
2.0 0.2 kg/cm2 6 2 kg/cm2
FG001462
Figure 210

9-1-175
REFRIGERANT 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 211
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.

9-1-176
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.

9-1-177
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 212
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.

9-1-178
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.

9-1-179
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

HAOH580
Figure 213

9-1-180
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 214
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 215
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.

9-1-181
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 216
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 217
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.

9-1-182
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 218
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 219
Initial charge amount: 100 g (3.5 ounces).

9-1-183
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.

9-1-184
Inspecting System For Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak 2
detecting device or soapy water, inspect system for leaks
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 3
equalized. Starting the inspection from the high side
will result in an accurate test.
4
Reference HDA6073L
Description
Number Figure 220
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.

9-1-185
WIPER SYSTEM
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) CN16-10
+
M
8 (Intermittent 1 mode) CN15-9
4 4
10 (Intermittent 2 mode) CN15-10
5 6 11 (Washer mode) CN16-11
1 7 8
12 - + CN16-2
P
1
6 13
8
9
9 2 7
AMP MIC 13P
CN12 CN13 KET 8P
4
10
2
B A
BR
3 E
AMP MIC 13P

4 5 6
1
1 2 3 4 5 6 4 3 2 1
1 2
7 8 9 10 11 12 13 9 8 7 6 5
(CN12) (CN13) (Wiper Motor)

WE1400693
Figure 221
Reference Reference
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Circuit Breaker 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch

9-1-186
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
current flows by 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 "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 by 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 "7" terminal of
the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact of
a cam switch connected to "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.

9-1-187
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 ±0.5 V) to LOW (0+0.5 V) 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 ±0.5 V) to LOW (0+0.5 V) 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."

9-1-188
9-1-189
LIGHTING SYSTEM
Lighting System Circuit Diagram
10A
4
10A
4
30A
20A
7
2 B 5
BR 9
3 E 10
6
12
1
4 13 21
10A
2-117
10A 8
1-61
1-53
18 14 14 18
*
* 20 20
19 19
11
15 16 17 16 15 WE1400694
Figure 222

9-1-190
Reference Reference
Number Number
1 Battery 12 Diode
2 Battery Relay 13 Backup Light Relay
3 Circuit Breaker 14 Headlight
4 Fuse 15 Rear Combination Light
5 Light Switch 16 Backup Light
6 Combination Switch 17 Registration Plate Light
7 Flasher Unit 18 Front Turn Signal Light
8 Stoplight Pressure SW 19 Side Turn Signal Light
9 Headlight Relay 20 Arm Position Light (Option)
10 Hazard Switch 21 EPOS Controller
11 Console
NOTE: * indicates optional items.
Type
Lighting system consists of headlight, work lights, cabin light
(optional), and S/W devices and relays to control them.
Operation
Connected Activated Relay/
Switch Position Lit Light
Terminal of Switch Operated Switch
Illumination Light of Switch/
Position Light of Headlight/
1st "2-3" Terminals - Position LIght of Rear
Light Switch (5) Combination Light
Position Light of Arm
"2-3" Terminals - "
2nd
"5-6" Terminals Headlight Relay (10) Low Beam of Headlight (2 ea.)
Operated Light Switch
"56-56b" Terminals Low Beam of Headlight (2 ea.)
(2nd)
Operated Light Switch
"56-56a" Terminals High Beam of Headlight (2 ea.)
(2nd)
"30-56a" Terminals - High Beam of Headlight (2 ea.)
Combination
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)
FNR Switch
(Reverse Position) ON EPOS Controller Backup Light Relay Backup Light (2 ea.)
(8)
Stoplight Switch Stoplight of Rear Combination
ON ON -
(9) Light (2 ea.)

9-1-191
OVERLOAD WARNING DEVICE
Overload Warning Device Circuit Diagram
2 B
BR
4
A
5 1-1
1 0 1-3
2 2-84
3 I
7 8
1
1-4
1-5
+
1-32
6 SIG
- 1-10
WE1400695
Figure 223
Reference Reference
Number Number
1 Battery 4 EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor

9-1-192
AUDIO CONTROLLER
Audio Controller Circuit Diagram
8
14
10
4
2
7 Stereo ANT.
3
2 15 5
Vcc(+5V)
3 16
MICOM 4
0.5WR 1
4 13
3
11
3 10A 10A 15A

9
(RH) (LH)
5
- + - + 9 17
7 1 6
B 2
2 3
17
10 4 BR
12 4 E
13
1 11
A
9 10 11 12 13 14 15 16 17 18
1 2 3 4 1 2 3 4 5 6 7 8 9 1
1 2 3 4 5 6 78 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
(Audio Control Panel) (Stereo) (Handsfree Unit)

WE1500075
Figure 224
Reference Reference
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Circuit Breaker 10 Antenna Module
5 Hands-free Unit 11 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

9-1-193
RAM LOCK DEVICE
Ram Lock Control Circuit
3 4
Parking Brake Switch Work/Travel Switch
5 1-72
9 7
O (P) 1 Ram Lock SW
2 0 (T) 3 CN17-9 Ram Lock
I 3 CN17-10 2 314A 1 5
1 PST AUTO Release LOCK 6 6

8 7
I(W) CN17-8 3 7
TML 9 2
8 80AA Ram Lock Press. SW
7 NC 6,12,15,16
3
14
10 13
11
10
B 9
BR
E 2
WE1400696
Figure 225
Reference Reference
Number Number
1 Battery 6 Ram Lock Pressure Switch
2 Battery Relay 7 Ram Lock Solenoid Valve
3 Parking Brake Switch 8 EPOS Controller
4 Work/Travel Switch 9 Diode
5 Ram Lock Switch 10 Fuse

9-1-194
1Options
One Way
Edition 1
DX210W-5 One Way

10-1-1
MEMO
One Way DX210W-5

10-1-2
Table of Contents
One Way
General .........................................................10-1-5
Caution for Installation............................................. 10-1-7
Installation Procedure ...................................10-1-8
Main Piping - One or Two-way ................................ 10-1-8
Main Piping - One Way ......................................... 10-1-10
Pilot Piping - One or Two-way............................... 10-1-12
Pilot Piping - One Way .......................................... 10-1-14
Boom Piping - One or Two-way ............................ 10-1-16
Arm Piping - One or Two-way ............................... 10-1-18
After Installation Precautions................................. 10-1-19
Air Bleeding ........................................................... 10-1-19
Completing Work ........................................10-1-20
DX210W-5 One Way

10-1-3
One Way DX210W-5
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 drive (A2) 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).
EX1403214
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 drive (A2) pump is controlled by an
instrument panel.
DX210W-5 One Way

10-1-5
Hydraulic Circuit
B7 A7 b7
5
T A L.H
Dozer/ 2
Bucket Boom Outrigger
4
B A
R.H
5
7
380 ± 5bar
A2 B6 A6 A5 B5 B7 A7
1.1.6 1.1.2
a7 1.1.5 1.1.4
1.1.7
C7
1.1.8
Travel Priority or 1.1.9
2 Pump Spool
P2
a2 P2 P21 b6 a6 a5 b5 b7 a7
XAs XBk XAk XAb BBXBo1 XAo1
(CR) (DU) (DN) XBb (OPEN) (CLOSE)
(UP)
6 T P
1
A3 A2
Ram Lock
Operating
A
Hammer
Y3
Inching
Cut-off
(Front) X1
Pilot
SD CH IC PB PS HO
C7
X3 C6
C1 C2 C3 C4 C5
P1
X1
(Rear)
Y3 P2 P3 GTS
A1 3
from JOYSTICK(R) BOTTON
WE1500201
Figure 3
Reference Reference
Number Number
1 Main Pump 5 Stop Valve
2 Control Valve 6 Proportional Valve
3 Solenoid Valve 7 Shuttle Valve
4 Pressure Proportional Relief V/V
One Way DX210W-5

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.
DX210W-5 One Way

10-1-7
INSTALLATION PROCEDURE
Install the parts as below pictures and needed parts refer to parts book.
Main Piping - One or Two-way
FR
ON
T
1-2
6
12
1-1
12
5
12
T 11
5
A
11 7
9
3
1
4
10
A7
⾒㍢ᤎ#᳢Ặ#
㝮ᢲ⠮#
CONTROL VALVE
MAIN FRAME
WE1500084
Figure 4
One Way DX210W-5

10-1-8
Reference Reference
Number Number
1 Valve, Relief; Proportional 6 Bolt; Set
1-1 Valve, Relief; Proportional 7 Bolt M10 x 1.5 x 75
1-2 Coil; 24V 8 Bolt, Socket
2 Plate, Mounting 9 Washer, Hard; M10
3 Hose Assembly, Hydraulic 10 O-ring
4 Flange; Split 11 O-ring
5 Tee 12 O-ring
DX210W-5 One Way

10-1-9
Main Piping - One Way
FR
ON
T
53
53
52
BOOM
51
8 3
1
7
5 8 A
2
A T
A
㝮ᢲ⠮#
MAIN FRAME
RELIEF VALVE
⾒㍢ᤎ#᳢Ặ#
CONTROL VALVE
101
6
4
9
104
102
103
OIL COOLER PIPE
WE1500488
Figure 5
One Way DX210W-5

10-1-10
Reference Reference
Number Number
1 Plate, Mounting 9 O-ring
2 Hose Assembly, Hydraulic 51 Hose Assembly, Hydraulic
3 Adapter 52 Hose Assembly, Hydraulic
4 Flange 53 O-ring
5 Bolt M10 x 1.5 x 22 101 Hose Assembly, Hydraulic
6 Bolt, Socket 102 Adapter
7 Washer, Spring 103 O-ring
8 O-ring 104 O-ring
DX210W-5 One Way

10-1-11
Pilot Piping - One or Two-way
FR
ON
T
MAIN FRAME OIL TANK
MAIN PUMP
X1
18
14 12
2
16 4
19
13 15
3
13
11
15 17
CONTROL VALVE
a7 19 A
20 10 17 T 19
8 P
11
19 5
SHUTTLE BLOCK 19 17
VALVE 8 19
20 1
b7 6 7
a7 19
9 2
20
A7 2-2 1
2-2 1-1
20
9
19 2-1
SHUTTLE VALVE
2-3
1-2
WE1500490
Figure 6
One Way DX210W-5

10-1-12
Reference Reference
Number Number
1 Valve; Proportional 9 Adapter
1-1 Valve 10 Adapter
1-2 Coil; Proportional 11 Elbow
2 Valve, Solenoid; (4-sol) 12 Elbow
2-1 Spool, Solenoid 13 Bolt
2-2 Check 14 Bolt
2-3 Coil 24V 15 Washer, Spring
3 Plate, Mounting 16 Washer, Spring
8 Adapter
DX210W-5 One Way

10-1-13
Pilot Piping - One Way
FR
ON
T
⛎⠦#㆛ㄖ
OIL TANK
1
8
9 9 5
7
10 9
b7
⾒㍢ᤎ#᳢Ặ
CONTROL VALVE 3
b7
10
4 B7
A7
6 9
8 SHUTTLE BLOCK
VALVE
HO
2
4-SOLENOID VALVE
WE1500489
Figure 7
One Way DX210W-5

10-1-14
Reference Reference
Number Number
1 Hose Assembly, Hydraulic 6 Elbow
2 Hose Assembly, Hydraulic 7 Tee
4 Plug 9 O-ring
5 Adapter 10 O-ring
DX210W-5 One Way

10-1-15
Boom Piping - One or Two-way
FR
ON
T
5
6
5 a
6
BOOM
a
15
a
14
15 9
10
16
14 7
8 13 10
7
16
13
WE1500491
Figure 8
One Way DX210W-5

10-1-16
Reference Reference
Number Number
1 Pipe 8 Clamp, Pipe
3 Pipe 10 Flange
5 O-ring 14 Washer; Hardened
6 Bolt 15 Bolt
7 Bolt 16 Rubber; Pipe
DX210W-5 One Way

10-1-17
Arm Piping - One or Two-way
FR
ON
5 T
3
4
5
3
4
5
5
3
4 3
4 2
9
6 8
6
8
BOOM
9 6
6
1 ARM
5
5
7
10
4
4
31-7
31
31-1 32
32-1
10
31-2 31-6
7 32-2 32-7
31-3 32-6
31-5 32-3
31-4 32-5
32-4
Figure 9
WE1500493
One Way DX210W-5

10-1-18
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 31-3 Adapter
2 Hose Assembly, Hydraulic 31-4 Cap
3 Flange 31-5 O-ring
4 O-ring 31-6 Plug
5 Bolt 31-7 O-ring
6 Clamp; Pipe 32 Valve Assembly, Stop (RH)
7 Bolt; Socket 32-1 Valve, Stop (RH)
8 Washer; Hardened 32-2 O-ring
9 Bolt 32-3 Adapter
10 Washer; Spring 32-4 Cap
31 Valve Assembly, Stop; (LH) 32-5 O-ring
31-1 Valve, Stop (LH) 32-6 Plug
31-2 O-ring 32-7 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 10. 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 10
• 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 hydraulic piping.
(The air breather of oil tank is actuated to bleed the air.)
DX210W-5 One Way

10-1-19
COMPLETING WORK
Breaker line overload relief valve can be changed from the
monitor (range 140 - 250 bar (142.8 - 255 kg/cm2)).
Set to 250 bar (255 kg/cm2). Check the pressure at maximum
flow.
(If maximum control pressure is out of tolerance, check EPPR
current)
How to Set Up Attachments

Breaker 1 Setting
Attachment setting items include attachment use, max E/G limit,
Attachment Use Dydlodeoh Button Type Wrjjoh
max pressure (ATT), max flow (ATT), min flow (ATT), and user Max E/G Limit 4;33 usp Max Press.(ATT) 473 edu
setting max flow. Operate the jog switch clockwise/ Max Flow(Pump) 7<3 osp Max Flow(ATT) 573 osp
counterclockwise to locate the cursor. Then, click on the jog 2 Pump Option Dydlodeoh Min Flow(ATT) 63 osp
switch to set up relevant items.
User Setting Max Flow <8 osp
The cursor movement order goes like this: 0 .
63 573
1. Breaker Setting
Attachment Use  Toggle  Max E/G Limit  Max EX1301419
Pressure Max Flow  Min Flow  User Setting Max
Figure 11
Flow
2. Two-way Setting
Attachment Use  Max E/G Limit  Max Pressure 
Max Flow  Min Flow  User Setting Max Flow
For details, See “Attachment Setting (Optional)” on page -9-1-
34, Electrical System Section in this manual.
One Way DX210W-5

10-1-20
Two-way
Edition 1
DX210W-5 Two-way
10-2-1
MEMO
Two-way DX210W-5
10-2-2
Table of Contents
Two-way
General .........................................................10-2-5
Structure.................................................................. 10-2-6
Installation Procedure .................................10-2-10
Main Piping - One or Two-way .............................. 10-2-10
Main Piping - Two-way .......................................... 10-2-12
Pilot Piping - One or Two-way............................... 10-2-14
Pilot Piping (1) - Two-way ..................................... 10-2-16
Pilot Piping (2) - Two-way ..................................... 10-2-18
Pilot Piping - Two-way (Pedal) .............................. 10-2-20
Boom Piping - One or Two-way ............................ 10-2-22
Arm Piping - One or Two-way ............................... 10-2-24
Air Bleeding ........................................................... 10-2-25
Completing Work ........................................10-2-26
DX210W-5 Two-way
10-2-3
Two-way DX210W-5
10-2-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
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 thumb wheel (variable) switch located at a right side
joystick lever is operated, 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 PPR valve
connected to a line. (the variable pressure is controlled
according to a current value)
EX1403216
The two-way PPR valve is used in the shear (two-way).
Figure 2
DX210W-5 Two-way
10-2-5
Structure
Main Control Valve (OPT Spool)

a7 b7
P (40 bar)
A B
LH-HI RH-HI
T
Current
EPOS Controller
Voltage
Joystick
(Right-hand)
WE1500090
Figure 3
Two-way DX210W-5
10-2-6
Hydraulic Circuit
Button Type
5
B7 A7 b7 T A L.H
4
T A
Dozer/
Bucket Boom Outrigger R.H
4 5
A B
380 ± 5bar LH-HI RH-HI

7 T
a7 from Joystick (R) PPC

2 Shear Select operating
Travel Priority or
2 Pump Spool
A2 B6 A6 A5 B5 B7 A7
P2
1.1.6 1.1.2
1.1.5 1.1.4
1.1.7
C7
1.1.8
1.1.9 8
a2 P2 P21 b6 a6 a5 b5 b7 a7
XAs XBk XAk XAb BB XBo1 XAo1
(UP)
1
A3
Ram Lock
A2
Operating
Hammer
Inching
Y3
Cut-off
(Front) X1 6
Pilot
T P
SD CH IC PB PS HO
A C7
C6
X3
C1 C2 C3 C4 C5
P1
X1
(Rear)
Y3 P2 P3 GTS
A1 3 from JOYSTICK(R) BOTTON
Figure 4 WE1500202
Reference Reference
Number Number
1 Main Pump 5 Stop Valve
2 Control Valve 6 Proportional Valve
3 Solenoid Valve 7 EPPR Valve (Two-way)
4 Pressure Proportional Relief V/V 8 Shuttle Valve
DX210W-5 Two-way
10-2-7
Pedal Type
5
B7 A7 b7 T A L.H
4
Dozer/ T A
Bucket Boom Outrigger R.H
4 5
P
380 ± 5bar A B
a7 Travel Priority or
2 2 Pump Spool LH-HI RH-HI
T 7
P2 from Joystick (R) PPC

2way Pedal Shear Select operating
8 RH
2
A2 B6 A6 A5 B5 B7 A7
1
1 2 LH 1.1.6 1.1.2
T P 1.1.5 1.1.4
1.1.7
C7
1.1.8
T 9 1.1.9 10
A P
a2 P2 P21 b6 a6
b5 b7 a7 a5
XAs XBk XAk XAb BB XBo1 XAo1
(UP)
1
A3
Ram Lock
A2
Operating
Hammer
Inching
Y3 Cut-off
(Front) X1
Pilot
6 T P
SD CH IC PB PS HO
A C7
C6
X3
C1 C2 C3 C4 C5
P1
X1
(Rear)
Y3 P2 P3 GTS
A1 3
from JOYSTICK(R) BOTTON
Figure 5 WE1500203
Reference Reference
Number Number
1 Main Pump 6 Proportional Valve
2 Control Valve 7 EPPR Valve (Two-way)
3 Solenoid Valve 8 Two-way Pedal Valve
4 Pressure Proportional Relief V/V 9 Two-way Pedal Safety Valve
5 Stop Valve 10 Shuttle Valve
Two-way DX210W-5
10-2-8
C. Stop engine.
position.
starter switch.
CAUTION
AVOID INJURY
DX210W-5 Two-way
10-2-9
Main Piping - One or Two-way
FR
ON
T
1-2
6
12
1-1
12
5
12
T 11
5
A
11 7
9
3
1
4
10
A7
⾒㍢ᤎ#᳢Ặ#
㝮ᢲ⠮#
CONTROL VALVE
MAIN FRAME
WE1500084
Figure 6
Two-way DX210W-5
10-2-10
Reference Reference
Number Number
1 Valve, Relief; Proportional 6 Bolt; Set
1-2 Coil; 24V 8 Bolt, Socket
2 Plate, Mounting 9 Washer, Hard; M10
5 Tee 12 O-ring
DX210W-5 Two-way
10-2-11
Main Piping - Two-way
1 FR
ON
1-2
T
1-1
52
52
51
BOOM
51
6 4
13 12 13
5
2
T 12
A
A
10
9 1
A T 3 A
8
㝮ᢲ⠮#
MAIN FRAME 7
11
RELIEF VALVE
B7
⾒㍢ᤎ#᳢Ặ#
CONTROL VALVE
WE1500494
Figure 7
Two-way DX210W-5
10-2-12
Reference Reference
Number Number
1 Valve, Relief; Proportional 8 Bolt, Socket
1-2 Coil; 24V 10 Washer, Spring
2 Plate, Mounting 11 O-ring
6 Tee 52 O-ring
7 Flange; Split
DX210W-5 Two-way
10-2-13
Pilot Piping - One or Two-way
FR
ON
T
MAIN FRAME OIL TANK
MAIN PUMP
X1
18
14 12
2
16 4
19
13 15
3
13
11
15 17
CONTROL VALVE
a7 19 A
20 10 17 T 19
8 P
11
19 5
SHUTTLE BLOCK 19 17
VALVE 8 19
20 1
b7 6 7
a7 19
9 2
20
A7 2-2 1
2-2 1-1
20
9
19 2-1
SHUTTLE VALVE
2-3
1-2
WE1500490
Figure 8
Two-way DX210W-5
10-2-14
Reference Reference
Number Number
1 Valve; Proportional 9 Adapter
1-1 Valve 10 Adapter
1-2 Coil; Proportional 11 Elbow
2 Valve, Solenoid; (4-sol) 12 Elbow
2-1 Spool, Solenoid 13 Bolt
2-2 Check 14 Bolt
2-3 Coil 24V 15 Washer, Spring
3 Plate, Mounting 16 Washer, Spring
8 Adapter
DX210W-5 Two-way
10-2-15
Pilot Piping (1) - Two-way
FR
ON ⛎⠦#㆛ㄖ#
T OIL TANK
8
3
6
4
7 1
b7
⾒㍢ᤎ#᳢Ặ#
CONTROL VALVE
b7
4 7
B7
6
A7 SHUTTLE BLOCK
VALVE
HO 2
4-SOLENOID VALVE
WE1500496
Figure 9
Two-way DX210W-5
10-2-16
Reference Reference
Number Number
1 Hose Assembly, Hydraulic 5 Tee, Shuttle Valve
3 Plug 7 O-ring
4 Adapter 8 O-ring
DX210W-5 Two-way
10-2-17
Pilot Piping (2) - Two-way
FR
ON
T
ACCEL
PEDAL VALVE
T
16
9
15
8 15
14
1
6
P
16
10 15
T 2
B 15 9
17 16
A
15 11 T
13 14
3 P
7
16
12 16 T
16 9 15 P SHUTTLE BLOCK
9 15 9 14 VALVE
15
PT BLOCK
B7
4
5
1 HO
1-1
4-SOLENOID VALVE
WE1500495
Figure 10
Two-way DX210W-5
10-2-18
Reference Reference
Number Number
1 Valve, EPPR; Dual 9 Adapter
1-1 Valve, EPPR 10 Elbow
2 Hose Assembly, Hydraulic 11 Elbow
3 Hose Assembly, Hydraulic 12 Bolt
4 Hose Assembly, Hydraulic 13 Washer, Spring
7 Plug 16 O-ring
8 Adapter 17 Elbow (90)
DX210W-5 Two-way
10-2-19
Pilot Piping - Two-way (Pedal)
FR
5 ON
T
4 7
29
35
17
35
30 39 1
ACCEL 24
28
PEDAL VALVE
34 40 T
3 T 27 24 40 40
6 1 1-2
FLOOR 31 P
PLATE 35 37 A 1-1
40 21 39 39 40
39 33 21
T
P 39 2
16
8 42 40 40
21 2-1
40 39
18
22 20
39
39 11
9 8 42 40 39
10 21
2 41
25 40
P 39 38 T
21 39 P
40
15 21 40
24 40 T 40 T
A B 26 39 23 P
36 11
39 38
39
32 14 PT BLOCK
SHUTTLE BLOCK
39 VALVE
12 B7
13
HO
4-SOLENOID VALVE
WE1500497
Figure 11
Two-way DX210W-5
10-2-20
Reference Reference
Number Number
1 Valve, Solenoid 21 Adapter
1-1 Spool, Solenoid 22 Adapter
1-2 Coil 24V 23 Adapter
2 Valve, EPPR; Dual 24 Elbow
2-1 Valve, EPPR 25 Elbow
3 Valve, Pedal 26 Tee, Shuttle Valve
4 Bracket 27 Tee
5 Rubber; Pedal 28 Bolt; Socket
6 Plate, Lock 29 Bolt; Socket
7 Plate 30 Bolt; Socket
8 Switch; Pressure 31 Bolt
9 Harness, Joint 32 Bolt
10 Hose Assembly, Hydraulic 33 Bolt M8 x 1.25 x 60
11 Hose Assembly, Hydraulic 34 Washer; Spring
20 Hose Assembly, Hydraulic 42 Reducer
DX210W-5 Two-way
10-2-21
Boom Piping - One or Two-way
FR
ON
T
5
6
5 a
6
BOOM
a
15
a
14
15 9
10
16
14 7
8 13 10
7
16
13
WE1500491
Figure 12
Two-way DX210W-5
10-2-22
Reference Reference
Number Number
3 Pipe 10 Flange
5 O-ring 14 Washer; Hardened
6 Bolt 15 Bolt
7 Bolt 16 Rubber; Pipe
DX210W-5 Two-way
10-2-23
Arm Piping - One or Two-way
FR
ON
5 T
3
4
5
3
4
5
5
3
4 3
4 2
9
6 8
6
8
BOOM
9 6
6
1 ARM
5
5
7
10
4
4
31-7
31
31-1 32
32-1
10
31-2 31-6
7 32-2 32-7
31-3 32-6
31-5 32-3
31-4 32-5
32-4
Figure 13
WE1500493
Two-way DX210W-5
10-2-24
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 31-3 Adapter
2 Hose Assembly, Hydraulic 31-4 Cap
3 Flange 31-5 O-ring
4 O-ring 31-6 Plug
5 Bolt 31-7 O-ring
6 Clamp; Pipe 32 Valve Assembly, Stop (RH)
7 Bolt; Socket 32-1 Valve, Stop (RH)
8 Washer; Hardened 32-2 O-ring
9 Bolt 32-3 Adapter
10 Washer; Spring 32-4 Cap
31 Valve Assembly, Stop; (LH) 32-5 O-ring
31-1 Valve, Stop (LH) 32-6 Plug
31-2 O-ring 32-7 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.
substances get into the hoses. 
attachments.
Air Bleeding
end of stroke.
DX210W-5 Two-way
10-2-25
COMPLETING WORK
Two way line overload relief valve can be changed from the
monitor (range 250 ~ 380 bar (255 ~ 387 kg/cm2)).
Set to 380 bar (387 kg/cm2). Check the pressure at maximum
flow.
(If maximum control pressure is out of tolerance, check EPPR
current)
Two-way DX210W-5
10-2-26
Rotating
Edition 1
DX210W-5 Rotating
10-3-1
MEMO
Rotating DX210W-5
10-3-2
Table of Contents
Rotating
General .........................................................10-3-5
Structure.................................................................. 10-3-6
Main Piping - Rotating ........................................... 10-3-10
Pilot Piping - Rotating............................................ 10-3-12
Boom Piping - Rotating ......................................... 10-3-14
Arm Piping - Rotating ............................................ 10-3-16
Air Bleeding ........................................................... 10-3-17
Completing Work ........................................10-3-17
DX210W-5 Rotating
10-3-3
10-3-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
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 thumbwheel switch located on the left joystick lever is
moved, the switch output signal (1.0 V ~ 4.0 V) supplies a
current to the rotating EPPR valve through the EPOS controller
and a control valve for rotating is controlled.
Moving thumb wheel right side is for clockwise rotation and
moving thumb wheel left side is for counterclockwise rotation.
Thumbwheel switch voltage output  EPOS controller input 
EPOS controller current output  rotating EPPR valve current EX1403215
supply  control valve spool variable supply. Figure 2
DX210W-5 Rotating
10-3-5
Structure
Rotating Control Valve

pb pa
P (40 bar)
A B
RH-HI LH-HI
T
Current
EPOS Controller
Voltage
Joystick
(Left-hand)
WE1401067
Figure 3
10-3-6
Hydraulic Circuit
Attachment
L.H R.H
A
100 bar
3 B
P
100 bar
A B pb pa
RH-HI LH-HI
T
2
80 bar
from Joystick (L) PPC
P T
Engine
1
WE1500096
Figure 4
Reference Reference
Number Number
1 Gear Pump (Rotating) 3 EPPR Valve
2 Control Valve (One Spool)
DX210W-5 Rotating
10-3-7
C. Stop engine.
position.
starter switch.
CAUTION
AVOID INJURY
10-3-8
DX210W-5 Rotating
10-3-9
Main Piping - Rotating
BOOM
FR
ON
T
BOOM PIPING
(ROTATION)
OIL COOLER
PIPE
29
14
31
20
19 25
51 23
31
11 30
12 3
27 32 S ENGINE
31 P
21
2
4 29
27 31 15
8 31
9 SUCTION
10 PIPE
7
31 20
31 13
13 18
17
28
B A 16
22
29
24
PT
1 6
33
MAIN FRAME WE1500498

Figure 5
10-3-10
Reference Reference
Number Number
1 Valve; One Spool 18 Clip
2 Pump, Gear 19 Clip, Hose
3 Gear 20 Bolt
4 Bracket 21 Bolt; Set
5 Bracket, Rotating Valve 22 Bolt
9 Hose Assembly, Hydraulic 27 Nut
11 Adapter 29 O-ring
12 Adapter PFO, ORS 3/4 30 O-ring
15 Adapter 33 Bolt
16 Elbow 51 Hose Assembly, Hydraulic
17 Elbow
DX210W-5 Rotating
10-3-11
Pilot Piping - Rotating
FR
ON
T
7 1-1
11 1
13
T 10
9
P 11
A
11 B
2 11
6 5 6
13
13 13
13
8
14 51
52 53
T
2 pa
12
P
PT BLOCK 52
11 51
pb
7 13 3 ONE SPOOL VALVE
53
WE1500499
Figure 6
10-3-12
Reference Reference
Number Number
1 Valve, EPPR; Dual 9 Bolt
1-1 Valve, EPPR 10 Washer, Spring
3 Hose Assembly; Hydraulic 12 O-ring
5 Adapter 14 O-ring
6 Adapter 51 Elbow
7 Elbow 52 O-ring
8 Tee 53 O-ring
DX210W-5 Rotating
10-3-13
Boom Piping - Rotating
FR
15 ON
5 14 11 T
5
11 13
12
14 3
15 11 12
13 11 7
4 6 1113
12
7
6 12
11 12
13 13
11
BOOM 12
2
11
13
1
8 10 9
9
8 10
5
5
WE1500500
Figure 7
10-3-14
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 9 Bolt
2 Pipe Assembly, Hydraulic 10 Washer; Hardened
3 Pipe Assembly, Hydraulic 11 Washer; Spring
4 Pipe Assembly, Hydraulic 12 Clamp; Pipe
5 O-ring 13 Bolt
7 Bolt; Socket M8 x 1.25 x 45 15 Bolt
8 Clamp, Pipe
DX210W-5 Rotating
10-3-15
Arm Piping - Rotating
ONT
FR
BOOM
2 2
5 3
6
4
6
5
1
4
5
6 1
4
ARM
6
5
12
4
12
11
9
8 11
10
7
31
32
31
34 32
33 8 34
7 33
WE1500501
Figure 8
10-3-16
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 9 Valve; Switch
2 Hose Assembly, Hydraulic 10 Valve; Switch
3 O-ring 11 O-ring
4 Clamp; Pipe 12 Bolt; Socket
5 Bolt 31 O-ring
6 Washer; Spring 32 Elbow
7 Bolt 33 Cap
8 Washer, Spring 34 O-ring

attachments.
Air Bleeding
end of stroke.
COMPLETING WORK
• Control valve (rotating) pressure check (main relief): 80 bar
(81.6 kg/cm2)
• Left joystick pilot pressure check: 31 bar (31.6 kg/cm2)
DX210W-5 Rotating
10-3-17
10-3-18
Quick Coupler
Edition 1
DX210W-5 Quick Coupler

10-4-1
MEMO
Quick Coupler DX210W-5

10-4-2
Table of Contents
Quick Coupler
General .........................................................10-4-5
Quick Coupler Operation ..............................10-4-8
Securing Work Tool................................................. 10-4-8
Attaching Quick Coupler to Excavator..................... 10-4-8
Releasing the Work Tool ....................................... 10-4-10
Main Piping - Quick Coupler.................................. 10-4-12
Electric Parts - Quick Coupler ............................... 10-4-13
Boom Piping - Quick Coupler ................................ 10-4-14
Arm Piping - Quick Coupler................................... 10-4-16
Air Bleeding ........................................................... 10-4-17
Completing Work ........................................10-4-17

10-4-3
10-4-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
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
1. LOCK
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 EX1301517
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.
Quick coupler only operate over 280 bar pressure of bucket
crowd.

10-4-5
Hydraulic Circuit
B7 A7 b7 B6 A6 b6
Bucket
Option
a7 a6
Travel Priority or
2 Pump Spool
P2 P0
2 2 1
B A B A
A3 A2
Y3
(Front) X1
245bar 245bar
274bar 274bar
P2 P2
X3
X1
(Rear)
Y3
T P1 T P1 A1
WE1500204
Figure 3
Reference Reference
Number Number
1 Main Pump 3 Bucket Cylinder
2 Quick Coupler Solenoid Valve 4 Control Valve

10-4-6
CAUTION
AVOID INJURY

C. Stop engine.
position.
starter switch.

10-4-7
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

10-4-8
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

10-4-9
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

10-4-10
10-4-11
Main Piping - Quick Coupler
BOOM
FR
ON
T
55
15 MAIN PUMP
51
11 CONTROL VALVE
54 2
53 17
52
B6
18
6
20
4
A2
20 20 23
20 6
18
9 10
18 B 18
A 21
P2 21 7
8 19
T 18
1 3
14
16
P1
18
22 OIL COOLER PIPE
21
1-2
5
1-1
1-3
WE1500514
Figure 12

10-4-12
Reference Reference
Number Number
1 Valve Assembly; Quick-fit 15 Bolt; Socket M12 x 1.75 x 80
1-1 Valve, Solenoid 16 Washer, Spring
1-2 Valve, Reducing 17 O-ring
1-3 Coil 18 O-ring
2 Block, Spacer 19 O-ring
5 Hose Assembly, Hydraulic 22 Adapter
6 Adapter 23 Adapter, Filter
14 Bolt
Electric Parts - Quick Coupler
1
ONT
FR 3
CONTROL STAND(R.H)
Figure 13 WE1401042
Reference Reference
Number Number
1 Switch; Lockout Toggle 3 Name Plate; Quick Clamp
2 Harness; Joint

10-4-13
Boom Piping - Quick Coupler
14 FR
9 ON
6 T
13
8
9 (2)
9
6
4 8
9 (1)
a
# 2
BOOM
a
1
a
12
(2)
9
(1)
3
9 9
3 5
9
11 6
10
WE1500515
Figure 14

10-4-14
Reference Reference
Number Number
1 Hose Assembly, Hydraulic 8 Adapter
3 Adapter 10 Bolt
4 Bracket 11 Washer; Spring
5 Bracket 12 Bolt
6 Nut; Hex 13 Washer; Hardened
7 Clip 14 Bolt

10-4-15
Arm Piping - Quick Coupler
O NT
FR
8
4
BOOM
a
8
3
a
a
7
6
5
1 ARM
2
9 9
8 8 a
WE1500516
Figure 15

10-4-16
Reference Reference
Number Number
1 Pipe Assembly, Hydraulic 6 Washer, Spring
2 Pipe Assembly, Hydraulic 7 Clamp; Pipe
4 Hose Assembly, Hydraulic 9 Plug
5 Bolt

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.

10-4-17
10-4-18
Two Pump
Edition 1
DX210W-5 Two Pump

10-5-1
MEMO
Two Pump DX210W-5

10-5-2
Table of Contents
Two Pump
General .........................................................10-5-5
Installation Procedure ...................................10-5-8
Pilot Piping - Two Pump .......................................... 10-5-8
After Installation Precautions................................... 10-5-9
Air Bleeding ............................................................. 10-5-9
DX210W-5 Two Pump

10-5-3
10-5-4
SAFETY INSTRUCTIONS
WARNING
or serious injury.
GENERAL
General Description
To prevent decreases in operational speed because of an
insufficient flow rate when an attachment such as a crusher is
used, a two-pump system in which an additional valve is
installed and lines drive side and idle side which can be
(optionally) supplied to supplement an insufficient flow rate.
Theory of Operation
When a set flow rate of an attachment is 1 pump (about 224 L/min)
or greater:
The two-pump solenoid valve is moved, and thus the drive side
pump's oil flows through the travel priority spool in main control
valve to join the idle side pump's oil in the OPT spool.
DX210W-5 Two Pump

10-5-5
Hydraulic Circuit
Attachment
B7 A7 b7 P
6
A B
Dozer/
Bucket Boom Outrigger LH-HI RH-HI
T
from Joystick (R) PPC

Shear Select operating
A5 B5 B7 A7
380 ± 5bar
1.1.6 1.1.2
1.1.4
a7 1.1.7 C7
4
Travel Priority or
2 Pump Spool
5
T P2 Po P1
a5 b5 b7 a7
XAb BB XBo1 XAo1
(DN) XBb (OPEN) (CLOSE)
(UP)
1
A3 A2 T
Ram Lock
Operating
Hammer
Inching
Y3 A
Cut-off
(Front)
Pilot
X1 P
SD CH IC PB PS HO
3
C7
X3 C6
C1 C2 C3 C4 C5
P1
X1
(Rear)
Y3 P2 P3 GTS
A1 2 from JOYSTICK(R) BOTTON
WE1500205
Figure 1
Reference Reference
Number Number
1 Main Pump 4 Control Valve
2 Solenoid Valve 5 Shuttle Valve
3 Solenoid Valve (Two Pump) 6 EPPR Valve

10-5-6
CAUTION
AVOID INJURY

C. Stop engine.
position.
starter switch.
DX210W-5 Two Pump

10-5-7
Pilot Piping - Two Pump
OIL TANK
FR
ON
T
26
19
26 12
( 4) 27
Po 26 24
CONTROL VALVE
17
24
26
Pi
Pc2 27
SHUTTLE
11 19
BLOCK VALVE
26
26 26
5
14
21 25
2 22
4 26 P
P2 26
27 C7 27 20 A
25
1 3
26
13 26 P1P T
13 15 25
6 10
LOGIC VALVE 26
8
16 15 1
16-1
15-1
16 16-1 15-2
1-2
23 16-1
1-1
WE1500502
Figure 2

10-5-8
Reference Reference
Number Number
1 Valve, Solenoid 15-1 O-ring
1-1 Spool, Solenoid 15-2 O-ring
1-2 Coil 24V 16 Valve, Shuttle
2 Hose Assembly, Hydraulic 16-1 O-ring
10 Elbow 23 Nut
12 Elbow 25 O-ring
13 Elbow 26 O-ring
14 Elbow 27 O-ring
15 Tee, Shuttle Valve

• When connecting the hoses, make it sure that no foreign
attachments.
Air Bleeding
end of stroke.
DX210W-5 Two Pump

10-5-9
10-5-10
1Schematic
1Hydraulic Schematic
/ Electrical Schematic
Edition 1
DX210W-5 Hydraulic Schematic / Electrical Schematic

11-1-1
MEMO
Hydraulic Schematic / Electrical Schematic DX210W-5

11-1-2
DX210W-5
Hydraulic Schematic
3.5 bar
OPT. PEDAL OPT. PEDAL

63 (ARTI. BOOM) 17 DOZER ARM/SWING 15 BOOM/BUCKET 16 62 (PE3C)
UP DOWN Dump Down RH 11
P1T_SH P1P_SH 26 2 1
(L) 2 (R)
2
Crowd Dump
2
1 3 1 3 A3 1.5 bar
T P
PT_SH 1 2 4
Crowd
4 1 53 OPTION APPLIED PART
Pi_CV 1 T P 2
DOWN 1 P T 2 UP 4 P 2 1 T 3 1 P 3 2 T 4
Up
1 T P 2
LH
59 A
PROPORTIONAL BOOM FLOATING 69
P1 T VALVE
T PI_SH XAo2 XBo2 T-BLOCK A LOCK VALVE(BOOM/ARM) 51 52
C7 (DN) (UP) T
B(#57) A(#57)
P2 R3 ONE/TWO-WAY 53 55 56 57 59 62
P
C1
2 13
BUCKET
SD R1 ROTATING 64 65 66
TRAVEL
P3
DOZER
BOOM
2x0.75 L
ARM
PAR PBR
SWING
30 bar QUICK COUPLER 67 68
C2 CH 19 (#07) (#07)
B4 A4 B3 A3 B1 A1 B2 A2 B6 A6 A5 B5 B7 A7 8 ARTI. BOOM 54 61 63
5 1.1.14
1.1.15
1.1.13 1.1.11
1.1.12
1.1.10
1.1.6 1.1.2
T P1 GP ACC'A
C3 M2 PRESS. SENSOR
IC
4 PT P1(#67) TWO PUMP 60
18
1.1.5 1.1.4
GTS C6 1.1.16
1.1.7 C7 A2 490 Bar Rear
AB
1.1.17
26 bar PB to P2(#20) T BLOCK T Axle BREAKER FILTER 58

TRANS 0.75 L 1.1.8
M
10 bar Y3 P A
MISSION C4
1.1.9
to P(#64) (Front) CLEMSHELL 74

PS PSA
PRESSURE 1.1.18 Vgmax X1 MODULATION VALVE C1
ENGINE FRONT ATTACHMENT 70 71 72 73
WARNING PI 66 DL06P
Vgmin
P3 P2 P1
Travel
C5
b4 a4 b3 a3 P1 b1 AB a1b2 SB a2 P2 P21 b6 a6 a5 b5BB b7 a7 GEAR 7
HO P11
A7(#19) XBd XAd XAt XBt XBa XAa XBs XAs XBo1 XAo1
PUMP
M3 TS M 6 C3
(DN) (UP) (FWD) (REV) (CR) (DU) (R) (L) XBk XAk XAb XBb (OPEN) (CLOSE) 1. MAIN PUMP
(CR) (DU) (DN) (UP) C6
C4 103 bar 2. PILOT FILTER
Vgmax X3 125 bar
Vgmin 3. CHOCKING CYLINDER
T C3 Y(#20) 4. ACCUMULATOR(for PILOT)
PL C4
A X1 P 5. 4-SOLENOID VALVE
REV
B(HIGH)
P (Rear) C2 A3(#19) 160 bar 6. SOLENOID VALVE(for TM)
K(LOW)
Y3 PBR C5 PSD
60 AI/SB 1 M FWD BRAKE
C2 7. 4-SOLENOID VALVE
to P1(#20) C1 B3(#19) 8. STEERING & BRAKE PUMP
A1 PAR T SUPPLY
XAb(#20) 9. STEERING UNIT
M1 PRESS. SENSOR T VALVE 65 bar
R2 S 490 Bar 10. PRIORITY VALVE
to #65 P G1 ACC'B AC LOW
PRESSURE 11. BRAKE FILTER
12 13
WARNING 12. BRAKE SUPPLY VALVE
Front 13. ACCUMULATOR(for BRAKE)
25 2x0.75 L Axle
14. BRAKE PEDAL
30 bar
15. JOYSTICK VALVE(L)
16. JOYSTICK VALVE(R)
STANDARD
0.5 bar 17. JOYSTICK VALVE(DOZER)
57 29 14
P B7(#19) SWING MOTOR SH
27 18. ACCELERATOR PEDAL VALVE
19. SHUTTLE VALVE
A B
28 20. MAIN CONTROL VALVE
BR1 P1
2(#62) LH-HI RH-HI 1(#62) 1.5 bar 21. BOOM CYLINDER
(CLOSE) (OPEN) 24 PG 10u 4.6 bar T1 22. ARM CYLINDER
DB TANK
T BL1 23. BUCKET CYLINDER
20 CRUISE
24. SWING DEVICE
C 177u RELEASE
380±5 bar
BR2 P2 25. P-T BLOCK

from JOYSTICK(R) PPC
A1
Shear Select operating PA PB 30 4.6 bar T2 26. LOGIC VALVE
B1 265 bar
BL2 27. OIL COOLER
CRUISE
b1 a1
65±5 bar RELEASE BRAKE VALVE 28. RETURN FILTER
BUCKET XBa XAa AUTO RAM 80 bar
23 Arm L2
OPERATE 29. AIR BREATHER
A (RH) B (LH) 30. HYDRAULIC TANK
55 31. CENTER JOINT
56 74
T2 T1 T2 T1 A2 Rear Front 32. TRAVEL MOTOR
Axle Axle
33. TRANSMISSION
R.H A T 58 XBs
B2
a2
XAs Left Right 34. FRONT AXLE
P P b2
74 Swing Turn L R Turn 35. REAR AXLE
225 +20
0 bar 36. CHOCKING VALVE
A3 31
L.H a3
Lo : 350±5 bar 9
B3 XAt Hi : 370±5 bar
35 3 3 1 1 3 3 1 1 3 3 1 3 1 CENTER
34
A T XBt
b3
BB 8 8 1 1 2 2 8 8 4 4 8 8 2 4 4 JOINT
Travel 1bar K 4 5 13 14 10 11 8 9 3 15 7 6 1 12 2 51. LOCK VALVE(for ARTI. BOOM)
Y
PL(#07) 52. LOCK VALVE(for BOOM)
55 53. PROPORTIONAL VALVE(for OPT Flow Control)
PC2 P1 from A1(#01)
70 54. SLOW RETURN VALVE(for ARTI. BOOM)
ONE WAY 21 21 P0 GP
3 55. PROPORTIONAL VALVE(for OPT)
BOOM B(HIGH)
L1 P2 K(LOW)
56. STOP VALVE
from C/V A7 from A2(#01)
56 5K 57. PROPORTIONAL VALVE(for PE3C)
55 L.H pi CHOCK 71 58. BREAKER FILTER
T A AB
Dozer/ 3bar T 59. 1-SOLENOID VALVE(for OPT.PEDAL)
52 52 b4
Outrigger
S X(IC) 60. 1-SOLENOID V/V (for OPT TWO PUMP)
B A XBd PC1 G 61. ARTI. BOOM CYLINDER
C2 C2 A4 XAd MB GEXT
R.H a4 U T1
E GP 62. PEDAL VALVE(for OPT)
OPTION
E B4 DOZER J B Pi BL 175 +10
0 bar
GP
M 63. PEDAL VALVE(for ARTI. BOOM)
b5 Boom a5 XAb qmax
(FWD) 36 STEER 64. ROTATING VALVE
XBb c(#69) S
69 L3 CYLINDER 65. PROPORTIONAL V/V(for PERO)
380±5 bar
B A
Pi1 Pi1
A5 a5(#19) 33 qmin Y BR
66. ROTATING PUMP
B5 A P T LS
T T CHOCK 67. QUICK COUPLER VALVE
MA (REV) 3 bar
V2 V2 T2 M3
M2 68. QUICK COUPLER
LOCK VALVE b6 a6 TRAVEL MOTOR
XBk XAk X2 69. BOOM FLOATING VALVE
32
380±5 bar
Bucket GP (TU) CF EF 70. DOZER CYLINDER

A6
REAR AXLE FRONT AXLE 71. OUTRIGGER CYLINDER
C XAb BRAKE
(#20) B6 BRAKE
C 72. 2-SOLENOID VALVE(for FR-OR.)
T1 T2 P1 LS 73. 1-SOLENOID VALVE(for RE-DZ)
7-10 bar
54 XBo1
b7 a7
XAo1 10 P 74. SWITCH VALVE(for CLAMSHELL)
XAb C
380±5 bar
Option Ø0.5
(#19) A7
QUICK COUPLER ROTATING A
B7
61 C/V XBa
67 B6(#20)
68 Ø0.5
ARM a A B T
V2 T Pil E
P2 64
b8 a8 T 275 bar P BLOCK
XBo2 XAo2 Ø0.4 B from #66 Ø0.5
P T
380±5 bar
Arti Boom (gear pump)

V2 T Pil E A8 A2 (#01)
A B 73
C2 P1 A P A
B8
Ø1.0 245 bar 65 78 bar
51 C2 T
T
72
LOCK VALVE
22 from JOYSTICK(L) PPC b 98 bar Serial Number 1001 and Up
ARTI. BOOM
WE1500510

11-1-3
DX210W-5
Electrical Schematic
0.85LgY EPOS
TERMINAL NO CAR STEREO 6-LAMP ASS'Y (OPT) 0.85WL
24D 4 0.85BR 0.85LR
ACC RELAY 87 0.5RG
0.85RG 1.25RG EPOS 0.85LB 48M TRAVEL 2PUMP
0.5RG
206A 13 EPOS 48N
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Vcc(+5V) 15D 5 0.85RL
DA2-2
5
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
64B 0.85RG 1.25WR 1.25WR 1
205A 16
14 0.85RG 64C 451C
MICOM EPOS
(RR) 0.85LgY 451B
LAMP SWITCH
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
204A 15 24C UNIFIED GP DISPLAY 0.85B 0.5WR 0.85B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
68A 63C 340C CN17-2
0.5WR
COMMON ANTENNA GPS ANT.
COLOR LCD GAUGE PANEL
(REAR)
TURN SIGNAL (R)
L2
2
80AA 3 I
0
2 1.25RW PILOT CUT-OFF SW 2 T/M & PILOT VALVE
0.85RG 64D
DA3-1
RADIO ANT. REAR WORKING LAMP 1 2
DA3-2
DMS ANT. 5 TURN SIGNAL (L) 1 338C CN17-1 PILOT CUT OFF SW 1
Vcc(+5V) ( ) 3 4 L1 87a 1.25WR II 327A 4
ECU (CN1) (RL) 17CC NC 327C 0.85Y 3 325C 0.85YG 0.85YG 325A DOZER STAB
0.85BrB
0.85B 30 67C 0.85YG
370B 18 CN7-13(29) 370A LineR CN17 AMP SEAL 12P 184A 87 0 0.85RW COM 325B
66A 66B 0.85WY 0.85WY 2 1 5 (C1)
1.25RG
371B 8 CN7-14(30) 371A 1.25B 0.85RG I 5 0.85RW 328A N0 DA2-1
9 5 1 7 1 LineL 0.5RB REAR CABIN LAMP 1
65B 0.85RG 0.85GY 0.5B 85 86 440B 440A 6 II 310B
17DD
8 2
10 6 2 9 3 372B 6 CN7-15(31) 372A GND
1.25WR PARKING BRAKE SWITCH (OPT)
0.5WR 0.5GrW 0.85WL 310A
0.5RW
11 7 3
(FR) ARM POSITION LAMP(L) FRONT FRONT ARM POSITION LAMP(R) 0.5WR 8 7 0.5B WORK/TRAVEL SWITCH
10 4
11 5
374A 11 CN6-3(3) 374B Ext_Mute Off Control 0.85B HEAD LAMP(L) HEAD LAMP(R) COBO AA1 O(P) 1 315C 0.85BrW 0.85BrB DA6-4
RAM LOCK SW
12 8 4
SPEAKER 87a (OPT) T/S LAMP(L) T/S LAMP(R) (OPT) 1 0.5B 0.85RB 2 0 (T) 3 313B CN17-9 313A 1 5 312C 0.85YG 311A
12 6
HANDSFREE 30 17J 3W 75/70W 75/70W 3W 2 335B 80GG 314A 0.85YG RAM LOCK
21W 21W 3 314B CN17-10 2
2LR
1.25RW 18Y 0.85WR 19Y HEAD LAMP RELAY I
ECU JOINT UREA SUPPLY MODULE 1 24H 65C 0.85RG 80AB 87 0.85WL 0.85LY 339A 3 CN17-7 81B PST Release LOCK 6 311B
(C2)
(LH) IGN+
CABIN LAMP SWITCH 8 I(W) 1 328C CN17-8 328B 312B DA1-3
TML AUTO
3 7
0.85GY 7 0.5B
0.85WY
- + 2
0.85RG
0.85GY
0.5GrR 9 17 406A (FMR) 0.85RW RAM LOCK PRESS. SW
TEL MUTE GND SPEAKER 0.85B 0.5B 85 86 66C 80YY 4
5 340A CN17-11 8 80AA 7 99 0.85B
0.85L
DA9-3 NC 6,12,15,16
0.85OrR
209B 208B 1 6 407A 339D 339C 80HH 311H
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 7 208A
TEL MUTE
0 62B 338D 340E CN17-12 317A 0.85Br 317B
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 210A' 210B (RH)
2B 339B 6 335A 3
4 5
210A 210B' 3 0.5WR 63A 3 2
0.85WL
F L AUDIO+ (FRONT) I 0.5RL 0.5B
0.85RW
0.85RW
0.85WR
312A
0.85WL
0.85GR
0.5BY 17
0.85GL
SIDE T/S LAMP (LH) 1 2 L
DA9-2
209A CN17-6
DA9-1
- + SIDE T/S LAMP (RH)
2RG
COMBINATION SWITCH (LH)
0.85R
0.85R
0.85B
0.85B
0.85B
0.85B
0.85B
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44
0.85B
3
211A 10 211A' 211B' 4 211B F L AUDIO- 65D 0.85RG II 7 8 14
0.5WR 0.85YG
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63
20P
HOMOLOGATION RELAY 338E 0.85GL 0.85GR 340D
3 4 311G 0.85Y
1 2
409A' 409B 408B
80I 3
0.5LW (FML) 0.85B 0 62C 0.5B 340B 0.85B E 13
EPOS (CN1) 0.5GrL 409B' 87a 5 0.85B 0.85B 338B 340B SW TURN SIGNAL HEAD LAMP 0.85OrR 0.85OrR 314N
I 1.25RL 11 INCHING
(turn sig)
HAZARD SWITCH
(turn sig)
408A 12 408B'
0.85GR
F L SPK+
30 62D 80BF
0.85GL
1.25RG 64A 6 18Z 342B 341C 342C 341B 19Z
(clearanc)
(clearanc)
2RL II TML N 314L 8 314M
409A 13 2RG 65A 87 10 DA1-2 (C3)
F L SPK- 65E 0.85RG 8 0.85WR 0.85GY 335C CN16-7 17F B 0.5B 3
(high)
(high)
7 0.5WR
(low)
4 0.85G
0.5B 49a DA5-3 0.85G
(low)
106 107 108 109 110 111 112 113 119 120 121
408A' 0.5BW 9
98 99 100 101 102 103 104 105
Signal 411B 1 16 411A SIGNAL(SW) (FL) 0.85B 0.5B 85 86 63B 0.85GR 0.85GR 340A CN16-3 BLINKER UNIT 7
329B
329C
117 118
80B R 322C
90 91 92 93 94 95 96 97
82 83 84 85 86 87 88 89 114 115 116 Signal GND 412B 2 18 412A SIGNAL GND(SW) 0.85GL 0.85GL 338A CN16-1 0.85RW 0.85YG 0.85YG 325A PILOT CUT OFF
2B 2RL L 7 325B
IND+ 413B 6 15 413A IND+ 99 11 FRONT CABIN LAMP (C4)
EPOS (CN2) 0.85WL 0.85WY 184B CN16-4 DA1-1
Mic+ 414B 7 9 414A MIC+ CABIN LAMP RELAY 1 56 3
415B 415A 0.85RW 0.85RW 341A CN16-5 0.85B

Mic- 8 20 MIC- 56b
ELEC. CENTER JOINT
8P
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 ILL+ 80L 4 7 416A 0.85WL 0.85R 0.85R 0.85R 342D CN16-6 FUSE 2 (3) 0.85LB 48Z BREAKER
GND(Jack) 56a 0.85OrR
2019 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 ILL- 99 5 5 417A Cable Tx/S RxD 375B 8' CN6-10(10) 375A TxD 0.85WR 0.5WR 0.85RG 67B CN16-8 DA8-1 3 48Y (C1)
21E 21J 1.25RG 1 30 CAR STEREO 4, COMMON ANTENNA, HANSFREE 1
0.85OrR
8P 19 418A Cable Rx TxD 376B 4' CN6-9(9) 376A RxD Bluetooth 1.25RG 0.85GW 0.85B 0 CN16-9 12V POWER 1
45C
15 0.85B 45B
GAUGE (CN7) GAUGE (CN6) 8 419A Cable Tx GND 377B 6' CN6-11(11) 377A GND 5 DA5-1 OUTRIGGER(FL) SOCKET 2R 25A 2 ACC RELAY
CN16-12
0.85GW
CALL SWITCH 0.85RY 0.85B 0 DC/DC 87a
1 1.25W 2 0.85W 343A 1 0 15/1 30 700B
+
(turn sig)
0.85GW
2 21C
(clearanc)
(clearanc)
3 CONVERTER 1
(stop)
8 7 6 5 4 3 2 1 5 4 3 2 1
0.85BR 199B CN16-11 25B
0.85GW
0.5BR
0.85WR
(back up)
0.85RY
0.85B
0.85RY
0.85B
0.85GL
0.85WL
0.85GR
(turn sig)
(back up)
FRONT L 343D 1 2LR 2LR 87
(stop)
JACK ASS'Y 343F 310C 3 I 53c 0.85OrB
0.85WR
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
AUDIO DIODE 38 0.85G 245Z CN16-2 24B 24A 86 85
1.25RW
0.5B 7 8 80S 0.5WR H - 99 0.85OrB 322F 0.85OrB 322G 322A
4 INDEPENDENT OUTRIGGER (OPT)

A/C PANEL (CN9) A/C PANEL (CN8) CONTROL PANEL 5 419B Cable Tx 378B 4 CN6-5(5) 378A USB VDD 338F 165D 18X 337B 80BB 337C 19X 165E 340F 0.85LR 196B CN16-10 99
J 2B 6 5 322H
6B
0.5WR
6 418B Cable Rx 379B 2 CN6-7(7) 379A USB D+ 21F
21K 1.25RG C A B E F D D F E B A C DA5-2 DA5-1
0.5WG 204B 2 0.85LG 198B CN15-10 53b 0.85GrL 2
0.85GrL 1
0.85GrL HI
EPOS CRUISE STOP

2 1
9 417B Cable Tx/S 380B 3 CN6-6(6) 380A USB D-
0.85G I LOW
DA5-2 OUTRIGGER(FR) 0.85GrR 330C
9 8 7 6 5 4 3 2 1 6
5W 0.85LY 197B CN15-9 53
330B 320B 320C
4 3 20 19 18 17 16 15 14 13 12 11 10
0.5W 205B 3 10 416A GND(Jack) 381B 1 CN6-8(8) 381A USB GND 2 1.25WG 3 0.85WG 1 0
80H 2 21D 0.85BG 0.85GrR II 0.85GrR
1 11 80M ILL+ 99 12 FRONT R 344D 344F 21W 21W 21W 21W 31b
A/C UNIT (CN11) A/C UNIT (CN10)
ILL-
344A 3 I
LICENCE LAMP 0.85GrL III
0.5BL 206B 4 DIODE 39 REAR COMBI LAMP REAR COMBI LAMP TML I 0 JI J II OFF ON OFF ON
12P 8 80T 0.5WR
MOLEX 4P CN14
21G 21L 1.25RG 7
STOP LAMP SWITCH 199A 11 (WASHER) 0.85RB
SW WIPER WASHER HORN AIR COMPRESSOR (OPT)
3 2 1 7 DA5-3
7 6 5 4 1 2 3 4 CCD CAMERA 3 - 200B 2 0.85LW 3 200A 87a
5 (CONT)
+
1 176D 0.5Y 3 1.25RY 4 0.85RY 345A 1 0 (1) M 196A 0.85LR 0.85LR 0.85LR 0.85R L 1.25RW 2.5WR
2 21E 0.85BW 165B 48W 2.5R 31B 30 4
11 10 9 8 AUDIO CONTROL PANEL REAR R 345D 345F 10 (INT-2) 87 299A PURGE V/V
2 177D 0.5YB
0.5RG
14 13 12 201B 4 0.85LB 4 201A 198A 0.85LG 1 193A 0.85G 192B
(CN13) 3 I 0
CN7-8(24) 183A Vedio Sig DIODE 40 165C 48X 8 (INT-1) 192A 2 0.85BrW
3 183B 0.5P 7 8 80U 0.5WR 197A 0.85LY +
AIR COMP. CONTROLLER 298C 86 85 0.85BL
3 22E 0.85L 0.85L B RUN STOP
CAMERA (OPT)
0.85GBr
(2) I
4 182B 0.5PB CN7-18(34) 182A Sig Gnd
REAR VIEW
DIAGNOSTIC CONN. 14P WIPER CUT SW

21H
21M 1.25RG 0.5WR 80F 8 7 0.5B 22C M START INHIBIT RELAY Relay Unit 0.85RW
(CN14) CCD CAMERA 2 OUTRIGGER(RR) 202B 194A 9 0.85Lg 194B 0.85B 87a
1 176C 0.5Y 1 0.85WL 7 202A AIR COMP. MOTOR
SMART POWER CONTROL 2 177C 0.5YB
8
4
DA5-4
1.25YB 5 0.85YB 346A 1 0 203B 5 0.85WB 6 203A LOWER WIPER SW 0.85G S 193B
-
ROTATING BEACON (OPT) 472A 87
30 147G
0.85R 31D 1 6 298A AIR COMP. RELAY 299B 1 +
P
- 2.5B
99 CN7-1(17) 0.5B 2 21F 23B 1 0.85L 0.85BG
REAR L 346D 346F 0.85BY 17G 6 0.5RW 13 17H 0.85B E
5 6 7 8 3 181B 0.5Or CN7-9(25) 181A Vedio Sig 3 I 0.85Or 471B 85 86 PRESSURE S/W
WINDOW WASHER 295B
82NA 0.85R
FUSE BOX 2-13 DIODE 41 8 TELESCOPIC BEACON ROTATING 31C 1 0.85Y 295A 2 5 297A 0.85YW 297B 3
+ 4 180B 0.5OrB CN7-19(35) 180A Sig Gnd 7 80V 0.5WR 1.25B 2 99 0
1.25RW
0.5B 195A 12 0.85RB - + 0.85L BEACON SWITCH 26C 0.85RY STOP
SPC SENSOR(1) 488A 0.85GR WIPER MOTOR ROTATING BEACON 0.5BrR 2 296B 4 0.85B 2.5B 2
1 2 3 4
(ARM CROWD) SIG
EPOS CN 1-46 P LOWER WIPER MOTOR 3 0.85YL 696A 3
195C 23D 0.85Or 1 0
SPEED SENSOR
88NA 0.85W I
- EPOS CN 1-10 21N 1.25RG 0.85B OUTRIGGER(RL) WIPER CONTROLLER 2 21B START 2.5B
DIODE ARRAY CCD CAMERA 1 + 0.5WR 8 7
WHEEL
0.5RB 0.5L 186B 186A 3 I GAUGE PANEL CN7-2/JOG SHUTTLE 1 AIR COMP. ASS'Y
1 176B 0.5Y CN7-7(23) 176A V+ 9V 348A 6 0.85RG
82NB 0.85R SIG 0.5RG 195B 23C 80U
+ REAR VIEW 2 177B 0.5YB CN7-17(33) 177A V- 99 0.85B 0.5B 7 8 80E AIR COMP.SWITCH
SPC SENSOR(2) 489A 0.85GR 99 CN7-4(20) 0.5B 0.5RW DIODE 5
3 4 EPOS CN 1-65 CAMERA -
(BOOM UP) SIG 3 178B 0.5YL CN7-10(26) 178A Vedio Sig 99 CN7-3(19) 0.5B
88NB 0.85W
- (K1045037) 0.5WR
4 179B 0.5YW CN7-20(36) 179A Sig Gnd ILL.
1 2
SPC SWITCH 80K
CN6-4(4) 0.5WR
12V POWER SOCKET(OPT) 2RG
O 1 0.5WR
0.85RB 2 69B
DIODE ARRAY FUSE BOX 1-13 0.85Br CN7-16(32) 7G 6G CN7-2(18) 0.85GBr 0.85R 12V POWER
41C I 3 800B 0.85GrR EPOS CN 1-70 START SW (BR/Key-on) START SW (ACC) 2 27A 2L
2RY 1 DC/DC
8 7 0.5B 17GG CN7-6(22) 0.5RW CONVERTER 2 27B + SOCKET
FUSE BOX 2-16 26B 3
4 5 6 7 8 9
80SP 17G CN7-5(21) 0.5RW
1 2 3
10 11 12 13 14 15 16 17 18 19 20
99 -
2B
ALARM RELAY 1
CN7 CN6 87a ALARM RELAY 2
309A 0.85RL
308B 30 0.5WL 308A 87a 2.0B
21 22 23 24
AMP 040 12P+16P 0.5RG
25 26 2728 HANDSFREE UNIT
ECU 87
0.5WB 83A 87
30
1-68 348B 165A 1-61
AUTO IDLE (1)
SENSOR (TRAVEL)
illumination
INJECTOR 80Zxx 86 0.85LgY 2-118 451A 342A 1-53 (BEAM)
0.5Br
85
SOLENOIDS ENGINE VEHICLE 1-03 99 0.85B 0.5B 85 86
TRAVEL 2 PUMP CONTROLLER 0.85R 82B + FUEL HEATER (OPT)
2-49 CONN CONN 171A 1-14
1
2
1-05 99 0.85B 83B CN6-1(1) 7Z 0.85P 171B SIG Py
6 1 INJECTOR1, BANK1 2-73 0.85BL 362V
0.85BrW
99
1.25RW
1-28 0.85B STARTER CONTROLLER
1.25RG
3
0.85BR
-
1.25RW
1.25W
7 2 CN6-12(12)
95B - 309B 0.5BW
0.85R
0.85L
1.25RB
0.5RG
4
0.5RG
2RG
307B 2-117
2RY
2RY
2RL
99
2RL
2-50 1-29 0.85B 0.85B PILOT BUZZER HORN 1 HORN 2 472B N S 0.85BW
3 5
6 99
96B CN6-13(13) 17xxx 0.5RW 1.25B 20B 1.25W STARTER RELAY 1
8 4 INJECTOR2, BANK1 1-52 99 0.85B BACK UP RELAY 62A 67A 69A 81A 82A 17A 20A 21A 22A 23A 26A 700A 15A 12B
7 2-74 97B 1.25RW +
87a H.F L.F 87a
9 5 8
1-75 99 0.85B 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5A 1.25WR 0.85B E 30 0.85Y S
Px 0.85Y 52E 30 87
AUTO IDLE(2)
82C 0.85R 14B 7D
0.85GBr
2-51 + 87 337A 246B 0.85B 246D 0.85B CIGAR LIGHTER 13A 13B
1-76 99 0.85B COMM. ANT. GPS ANT. 0.85RY
30A 20A 20A 15A 15A 30A 10A 10A 10A 10A 10A 30A 10A 10A
85 86
INJECTOR3, BANK1 84B 0.85V 1-33 84A 1.25WR 2WR B P
SENSOR
MICRO PHONE CALL SWITCH 2-75 OVER LOAD WARNING SWITCH SIG
INTER 0.85Y 52xxx 86 85 307A 17 18 2E 15 16
7F
2 362V 0.85BW 1-28 362A 4E 4C 2C 12A 11B
2-25 CONN 2-1 - 87a
INJECTOR1, BANK2 143A 1-09 0.85Or 143B 1 °t SCR DOWNSTREAM 1 0
2 86B 0.5BrY 2-84
ANALOG GND
0.5Y 95C 8 TMS
246A 87
30 334E 0.85RG
5W 5W
0.85Br
V TEMPERATURE SENSOR 86A STARTER RELAY 2
1.25WG
6 5 4 3 2 1
2-01 7
12 11 10 9 8 7 4 1
0.5B 3 I 0.5YB 96C 9
CONTROLLER 1 15X 0.85RL FUSE BOX 2 5W 5W FUSE BOX 1 6A
ACC 87a 0.85BL
3 2
2-26 136A 1-43 0.85RG 136B 2 7 8 3 9F 0.85RW 245A 85 86 334F 0.5RG 15R 212A B
0.5B 80L 0.5WR C 0.85BY
JACK ASS'Y JOG SWITCH INJECTOR2, BANK2 2-02 142A 1-32 0.85Y 142B
6
1 °t SCR UPSTREAM 0.5G 0.5RG 98C 7
4 41F 4F 80AX 4D STARTER
SWITCH
30
87 11A
5 V TEMPERATURE SENSOR TxD 169A 1-42 0.5GL 0.5GL 169A 5 HORN RELAY 15 16 1.25WR 17 18 2B 2WR 1.25WR 10A 10B
139B 82D 0.85R 2 99 0.5G B 86 85 0.5GB
2-27 139A 1-23 0.85G 1 + RxD 168A 1-41 0.5GW 0.5GW 168B 6 20A 20A 10A 10A 10A 10A 10A 10A 30A 20A 20A 20A 30A 30A 147A
1 PRESSURE SENSOR 1-32 0.85B 5B R1
DOSING 87B 0.85BrW 87A 7E 164B
INJECTOR2, BANK2 2-03 138A 1-96 0.85GB 138B 2 VALVE (OWD) SIG 313C 1-62 (TRAVEL SELECT) 0.5BG R2
2 88B 0.85WB ROOM LAMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14
141B - 45A 2-97 (BREAKER OPERATING) (534-00079 ) BR 7A A
141A 1-18 0.85Gr 2 46A 47A 48A 334A 52A 54A 19A 18A 28A 31A 51A 40A 41A 16A 0.85Br
2-58
FUEL METERING
4
°t DOC UPSTREAM(T4) 82E 0.85R 311C (RAM LOCK) OFF 10W
GAUGE PANEL CN7-16
0.5RG
1-72
0.85WR
2.0RG
0.85GrR 140B
2.0RG
+
0.85WL
0.85BrR
0.85RL
140A 1
0.85LB
1-16
0.85Y
0.85BrR
V
2R
2-83 OVER LOAD 0.5B E DR B+ 0.5WL
1.25RB
1.25LR
1.25RL
1.25RL
3 TEMPERATURE SENSOR 89B 0.85GR 89A
UNIT(ZME)
111A 1-62 0.85L
PRESSURE SENSOR(A) SIG 1-34 315A 1-74 (PARKING) STARTER 60B
WIPER MOTOR
2 111B WARNING (OPT) (FRONT PUMP)
- 88PA 0.85W 1-10 88A 329A 2-89 0.85G (INCHING) ON 5X
0.85Br DIODE 2 1.25WG
60R
TANK HEATING
ANALOG GND 330A 2-88 0.85GrR (LOW SPEED) 7B 8A 0.85BrW FUSIBLE LINK
4 3 2 1
VALVE + 82F 0.85R 320A 0.85GrL (HIGH SPEED)
2-114 2WR 2R
PRESSURE SENSOR(B) 91B 0.85GY 91A 2WR
2-11 1 145P SIG 1-15
9 8 6 5
P 363B 3.0bar 0.85WR 5C 2A 1B
7
2-36 0.85WR JOG SHUTTLE
(REAR PUMP) 88PB 0.85WL 363A 2-100 EMERGENCY STEERING PRESS SW 1
0.5G
WIPER SWITCH PANEL RAIL PRESS. -
9C 3 HOUR 2 0.5B
0.85WL 0.85Br 0.85RW
SENSOR V 2-60 UREA SUPPLY MOUDLE POWER AUTO IDLE WORK 82G 0.85R 147B 1-69 0.5BG (KEY SW 'START')
BATTERY RELAY
0.5BG 0.5BG 2R
137A 1-68 0.85RW 137B 2 HOUR METER CIRCUIT BREAKER
1 2 3
135A 1-07 0.85Y 135B 3
P REDUCTION AGENT
WIF SENSOR 93B 0.85LgR 1-38 93A 164A 2-115 0.5GB (START RELAY) 0.5GB 0.5GB
B
1A
4 5 6 2-31 CAMERA DMB - 362V 0.85LgB 8W 8W A
41E 0.85RL
P& 2-35 134A 1-39 0.85L 134B 4 V PRESSURE SENSOR 1-1
OIL PRESS. 41D 1-3 0.85RL 1.25RL 4B 3B 3A
AIR COMP. CONTROLLER SENSOR t° 2-06
95F 3 4 2 1 6D
0.85GBr
133A 1-50 0.85WR 0.85WR 133B 9 96F 99BH START SW (ACC) 9E 1-2 0.5RW ALT 'I' 0.85RW 0.85RW 0.85RW 0.85BrW 8C BR
(ODFT) 0.5Y 0.5Y 1-39 95A
2-13 0.85G 132B 10
V 132A 1-84
M
REDUCTION
0.5YB 0.5YB 1-40
325H 1-55 0.85YG (PILOT CUT-OFF SWITCH) E
AGENT PUMP 96A CAN 0.85Or 0.85Or
2 3
2-07 131A 1-89 0.85BW 131B 8 99 1-4 0.85B
471A
0.85Br 8B 1.25B
4 1
P& 130B 12
SHIELD SHIELD 1-21 97A
99 1-5 0.85B DA7-4
314P 3
2 353A
SOL-VALVE ASS'Y MASTER SWITCH 60R
BOOST PRESS. 2-86 130A 1-85 0.85W 0.85RL 353B
DIODE 1
98A GND 314Q 1 FORWARD(PAR) 0.85BrR
SENSOR t° 2-90 0.85WR 133D 11
UREA 0.5RG 1-23
4 353C
2R
(LDF 6T) REVERTING VALVE 0.5GW 1-24 100A RxD 349A 2-112 0.85BR (FORWARD) 350C 349B 6 DA4-2 60B 1 2 60B 60R
UREA TANK 6 0.85R 5 354A 354C (Fix) 1
2-37 129A 1-02 0.85B 129B 5 2 0.85BR 354B 2 0.85LB
V SUPPLY MODULE 0.5GL 1-43 101A TxD
Fwd.
3 350B 350A 4
0.85Br (Release) 3
481E HEATER 0.5Br 48B 9B
CHECK CONN FUEL SENSOR RS-232 2 0.85L
0.85Or 314R 9 (PBR) 50A
1 8 355A 50B 1
LAN
2-05 0.5GL 101B 471C 0.85RL 355B 50C CABLE
187B 3 314S 7 REVERSE MIC
1 8 THROTTLE PLATE 128A 1-04 0.85BY 128B 1 2 481D
0.85R 1 110B 0.85YR 1-37 110A 1 352B 355C QUICK CLAMP SW
5 40E AMPLIFIER SPEAKER - + - +
2 7
ACTUATOR 2-29 PRESSURE LINE HEATER 0.5GW 100B Rev. 351B 12 DA1-2
6 DIODE 6
M 2 188B 4 88F 0.85BR DA7-1 1.25LR 8 28T 430A 2 0.5GrL 430B + 12V 150AH 12V 150AH
3 6
127B 1 2 481C 0.85R 11 356A 356C 2 0.85Gr 356B
3P
2-34 127A 1-48 0.85LW 0.5RG 98B SOL-VALVE
AUXILIARY F N R SW 352A 10
2P
4 5
SUCTION LINE HEATER 3 352C 0.85LR 0.85B 1 99FR 431A 6 0.5BW 431B - 2RW
THROTTLE POSITION 2-15
126A 1-72 0.85L 0.85L 126B 1 2 481B 0.85R 0.5Y 95E 4 2 351A 2-105 0.85Gr
AUXILIARY TRAVEL SW
(PL)
RELIEF
QUICK CLAMP(OPT) 0.5WR 8W
INTER CONN 1 FEEDBACK SENSOR 2-40 BACK FLOW LINE HEATER 96E (REVERSE) 0.85RL 41L
0.5YB 5 OIL TEMP SENSOR PRESS UP
2R 0.85LB 1.25WG
A/C CONTROL PANEL
0.85WR
SHIELD 97E 6 DA1-1

5 41K
2-95 112B 0.85LgR 1-36 112A (RELIEF PRESS UP) 48D 48C 2 PUMP SELECT SOL V/V 15R
ENGINE BRAKE ACTUATOR1 133C 481A
AUTO SHUTOFF 0.85GrW 43C
DIODE 3
0.5YW 290B 7 43A 2-96 0.85GrW 43B 1
UREA HEATING 362V (OPTION) 28B
1.25RW
1 12 INTERNAL, ENGINE 2-70 86 30 (TS) 80Q CN9-11 CN11-2 1.25LR

14A 4A 9A
2
3
11
10
DECOMPRESSION VALVE RELAY FUEL PUMP (OPT) 0.5YL 291B 8 0.85RL 41N
41M
CRUISE
49B 49C
334C 334B
ILL 15E CN9-6 0.5RL
0.5LR CN10-8 28C 1.25RB 40B 1.25B SEAT HEATER
P(R) B(B+) R(I)
2-93 SHIELD 292A 9 DA1-3
7
ACCELERATOR ASS'Y
4 9
DA4-3
CN10-18 30B
5 8
BARGWARNER N 2-94 AUTO SHUTOFF UNIT 151E 1-20 151Z 357A 2-113 0.85BrB (CRUISE) 357C 3 0.85BrB 357B 28E CN9-5 1.25LR
A
6 7
TURBINE WHEEL 2 CN15 0.5BW
POSITION
17B 2WAY OPTION PEDAL S/V LED 1~12

SENSOR
358B 1-12 358A 323A 2-116 0.85GW 0.85GW 323B 323C

V 0.85R PT
C B
SPEED SENSOR 2-78 12 0.85LR RECEIVER DRIER 1.25RB 40C 1.25B SEAT AIR
3 187A 0.85LR 153E 153Z (OPTION) P
INTER CONN 2 0.5B
13 1-29 CN8 CN9
28D 30A
BLOWER SUSPENSION SG
CAN H2 2-17 85 87 360B 360A 50D 1-77 0.5Br (QUICK CLAMP) 0.5Br TRAVEL SPEED SELECT SWITCH AMP 12P + 18P
1.25B 1 START STOP 4 188A 0.85BY 0.5B 106A 14 2-93 RELAY
E
VALIDATION
321B 47C SWITCH SWITCH 49A 2-104 0.85YW (2 PUMP SELECT) 0.85YW 473A 3 0.5L 7 473B
CONTROLLER AREA CAN L2 2-18
F
2 1
441B 1-60 0.5YB (INCHING SPEED SELECT) 0.5YB 441A 9 225A CN8-10 0.5LG CN10-16 225B
IDLE
NETWORK2 SHIELD 2-19 1-93 0.85RY 189A 5 6 190B 99 A/C

321A
D
1 81D CN11-4 R
INTER CONN 3 16E 1-01 0.85R FUEL PUMP
442B 1-78 0.5WB (LOW SPEED SELECT) 0.5WB 442A 2 0.85RB A/C THERMO (LOW) 226A CN9-8 0.5LB CN10-5 226B RELAY
F
2RG
P FOOT PEDAL 1-22 106B 443B 1-59 0.5BrY 443A 4 29A

0.85R (HIGE SPEED SELECT) 0.5BrY 227A CN8-11 0.5LY CN10-6 227B E
16D 1-25 2R 189B (+) (-) 190A FET
(PREHEAT LAMP) 0.5LW 2-101 107A 68D 1-79 0.5RG (WORKING LAMP) 5 81H
BAT+ 16F 99 6 1.25B
1-26 0.85R 2R 55A 54C 0.85GBr 8,10 0.85BrR CN11-1 99 - +
(EMERGENCY STOP SIG) 0.5R 2-102 144D 0.85BrB M E
16B 1-49 0.85R AUXILIARY MODE SW
AIRCON UNIT 99 ALTERNATOR
AUXI MODE RESISTOR 0.5G 228A CN8-12 0.5LW CN10-1 228B 8B
0.5GR 359A BLOWER
PARKING BRAKE
CAMSHAFT SPEED SENSOR 2-43 16G 1-73 0.85R 359D 1-19 PUMP
SENSOR
OUTPUT SIGNAL + 59B 2-98 0.85Or 0.85Or 59A 1 0.85Y

CRANKSHAFT SPEED SENSOR 2-44 0.5Y CAN H0 SIG
361B 1-13 361A 5 56A 0.85LgR 56B PROPORTIONAL V/V 229A CN9-13 0.5GrG CN10-2 229B FRE (P1)
95D 1-46 55B 2 P/V-(A) INTAKE
OUTPUT SIGNAL 148C 1-11 148A 145C 212B
CAN L0 230A CN9-12 0.5GrY CN10-20 230B REC (P2) ACTUATOR
ENGINE CONTROL DIAL
96D 1-47 0.5YB - C B

FUEL 2-12 0.5G 58B 2-99 0.85OrB 0.85OrB 58A 3 M
TEMPERATURE
t ° 2-59 97D 1-10 SHIELD SHIELD
1 359C FLOW CONTROL 0.85B 4
6 57B 0.85LgW 57A - +
V LOW 231A CN9-15 0.5OrR CN10-12 231B DEF (P1)
200A
SENSOR 290A 1-71 0.5YW CAN H1 PROPORTIONAL V/V 0.5RG
2 149A 0.5GB 1-31 149A 60A 2-108 0.85LgR 60B P/V-(B) 232A CN9-14 0.5OrW CN10-13 232B VENT (P2)
2-39 291A 1-95 0.5YL CAN L1 JOYSTICK LEVER SWITCH WORKING LAMP RELAY M
COOLANT t° 3 148B 0.5B 8 4 245B 0.5G
87a 233A CN9-16 0.5YB CN10-11 233B Vref MODE
MODE
TEMPERATURE
V SHIELD HIGH CW 0.5G (ON JOYSTICK L.H) (2) (LS1) (1) 46B 30 2RY ACTUATOR
SENSOR BRAKE OIL 61B 2-109 0.85LgW 61A 0.5Y 0.85RG 185B 2RG 185A 87 234A CN9-17 0.5YW CN10-10 234B MODE F/BACK COMPRESSOR
2-69 1-06 0.85LW PREHEAT SIGNAL 452C 0.85V 2-92 452A 150B 7 3 52F (1) (2)
107B PRESS SW 0.85B
150A 1-73 (ONE TOUCH DECELERATION) (4) (LS2) (3) ROTATING 0.85B 68C 86 85 99 CN9-10 1.25B MAGNET D H 213A
7C 1-69 0.85Br KEY-ON 65bar 0.5BrB 0.5BrB + -
1 2-66 0.5B 0.85LW 29C CLUTCH 146A 15L 213B 15B
115B 0.85BW 1-50 115A 151A 1-20 151B SWITCH (OPT) 185C 0.5RG
N INDICATOR 0.85B 0.5GR 0.5GR 1
0.85BL
2 CW CCW 0.85RG
2-65 1 51E 1.25Br 235A CN9-1 0.5LgW CN10-19 235B WARM (P1) 29B PREHEAT RELAY
CRANKSHAFT SPEED SENSOR 152A 1-66 0.5YB 0.5YB 152B 2 0.85B
V
DIODE 4
SHIELD TANK TANK 4 96D2 0.5YB PILOT FILTER SW 0.85B 116B 0.85BG 1-49 116A 153A 1-29 0.5Y (ANALOG GROUND) 0.5Y 153B 5
1 0 46C 2 236A CN9-18 0.5LgB CN10-3 236B COOL (P2)
M AIR HEATER
LEVEL TEMP 3 95D2 0.5Y CW 0.5RY
154A 1-30 68B 3 I 237A CN9-3 0.5YR CN10-7 237B Vref MIX MIX
0.5LB WORKING LAMP
2 2-68 SIGNAL SIGNAL 2 99 0.85B 117B 0.85RB 1-48 117A 7 80XX 8 0.5WR 238A CN9-4 0.5YW CN10-9 238B MIX F/BACK ACTUATOR 0.85B
RETURN FILTER SW
96D1 0.85YB
N
95D1 0.85Y
0.5B
51F 1.25Br
1 2-67
2B 1.5bar 0.5GR 151C 1 CW OPEN 239A CN9-2 1.25BL CN10-4 239B GND
CAMSHAFT SPEED SENSOR 36C 1-81 0.5GY (BREAKER)
V UREA TANK 2B PEDAL BRAEKER 0.85B 118B 0.85GB 2-85 118A 0.5LB 154B 2 WORKING LAMP SWITCH
SHIELD 99 PRESSURE SW 1 (OPT) CRUISE SWITCH 0.5Y 153C 5
240A CN8-2 0.5OrB CN10-15 240B
DUCT
INTER 0 1 CLOSE
8 11 10 9 PEDAL BRAEKER 0.85B 114B 0.85GR 2-103 114A 444A 3 SENSOR
CONN 2-2 444B 1-80 (CRUISE) 0.5GY 36A 8 4 52G 0.5Y
1 PRESSURE SW 2 (OPT) 0.85RG I 2
0.85RG
(RS1) 241A CN8-1 0.5LgR CN10-14 241B
3 0.5WR 80EK 8 7 0.5B 0.5RY 35A 7 WATER
119B 0.85Lg 2-110 119A 3 32C 0.5BrW
+ 306C 0.85RY SENSOR
2
AMP 40P
MASTER 4 TRAVEL 2 PUMP (RS2) BUZZER RELAY

AMP 81P
NOX SENSOR PROPORTIONAL V/V 302B 1-58 0.5LY (FORWARD TRAVEL) 0.5LY 302A 9 10 52H 0.5Y - 0.85B 306B
5 120B 0.85LgB 2-111 120A 4 52B 242A CN8-5 0.5LY CN10-17 242B 1 INCAR
87a
303B 1-76 0.5Or (REVERSE TRAVEL) (F) 30 0.85RB SENSOR
2 TRAVEL 2 SUN LOAD SENSOR
121B 0.85W 1-26 121A 0.5Or 303A 13 10 52I 0.5Y ALARM BUZZER 306A 87 CN10 AMP 20P CN11 KET 4P
ATT. PRESS. CONTROL 301B 1-57 0.5WR (NEUTRAL)
BOSCH 96P
(R)
CN2
1 PROPORTIONAL V/V 0.5LB 305A 85 86 0.5RB

(ONE-WAY) 0.5WR 301A 12 10 52J 0.5Y 243A CN8-3 0.5Lg 2 - + 1
239D
122B 0.85WB 1-27 122A 160B 0.85BL 2
3 160A 1-7 0.85Or P/V-(C) TRAVEL ALARM SWITCH 243B
JOYSTICK LEVER SWITCH (N) 52C
ECU JOINT SECONDARY 4 123B 0.85WR 1-44 123A FLOW CONTROL
1 52D
237C AMBIENT TEMP STARTER SWITCH CONNECTION
CN2
0
254C ATT. PRESS. CONTROL 161A 1-8 0.85OrB 161B PROPORTIONAL V/V (ON JOYSTICK R.H) 2 0.85RB 244A CN8-4 0.85YG 244B 1 SENSOR
3 254A 0.85Br 2-30 NOX SENSOR 5 (JOYSTICK LH-CW)
PEDAL SWITCH TERMINAL
PROPORTIONAL V/V 304A 3
1 TML
CN1
36D 52K I
124B 0.85WL 1-63 124A 162A 2-90 162B B BR R2 C ACC
4 252A 0.85BrY 252C
2
2-38 2 (TWO-WAY) 0.85OrR P/V-(C) 0.5B 7 8 80ZZ 0.5WR PST
AIR FLOW METER 1 253A 0.85BrW 253C 2-54 P/V-(C) 156B 0.85Gr 1-6 156A FLOW CONTROL 0.5OrL
251C
3
FLOW CONTROL 163A 2-91 0.85OrL 163B PROPORTIONAL V/V OFF
2 251A 0.85B
4
2-34
PROPORTIONAL V/V (JOYSTICK LH-CCW) SMART BOOM SWITCH
368C 1-58 0.5BrR Inhibit 0.5BrR E/G EMERGENCY STOP SWITCH 157B 0.85GrB 1-25 157A SMART BOOM RELAY
0.85RL 51B
6
1
BORGWARNER 1-59 0.5BrW Regen 1
(JOYSTICK RH-CLOSE) 304B 1-52 (TRAVEL ALARM SWITCH)
0.5LW 80S 10 9 99 0.5B 87a 0.85LY 33B 34A 0.85LB 34B PILOT S/V
ACC
369C 0.5BrW
2-119 (TRAVEL ALARM RELAY)
3 7
99 2 P/V-(C) 158B 0.85GrR 2-82 158A 305B 0.5LY 0 32A (BOOM FLOAT) 0.85BrW 32B 30
EGR
0.85B 10 144B 1-11 0.85R 0.5R 144A 2 3 145B 0.85W FLOW CONTROL 29D 1-56 0.5LW (AIRCON SIGNAL) 0.5WR
0.85BrR 54E 2
I 3 34D (BREAKER FLOAT)
87 33A
DA7-3 34C 5
DA7-1 ON
145A 1-74 0.85W PROPORTIONAL V/V 35B 86 85 0.5B
1
0.85B 99
159B 0.85GrL 2-83 159A 1-54 0.5LY 0.5WR 80S 8
0.85W 145E 8
4
+ 146C 1-83 0.85BW PREHEAT RELAY
(JOYSTICK RH-OPEN) 34G
0.5WR
0.5BG 7 99 0.5B
99
START
0.85LY 33C SMART MAIN S/V
0.85WB 370B 12
3 1-38 0.85LW A/C REQUIST 0.85Br
- 29XX 2R 6 4 33E 6
DA7-2
0.85WL 125B 5 370A 1-87 0.85WB 2R
7 + FAN 0.85BrW 34H 33D 2
0.85B 99
0.85WR 371B 1 DA7-4
CLUTCH 125A 1-67 0.85WL KEY START 0.5BG 0.5RY
11 SIG
0.85WG 372B 2 371A 1-64 0.85WR 0.85W 0.85W
5 -
372A 1-65 0.85WG 0.85BL 0.85BL
147C 1-63 0.85BG AIRCON SIGNAL
0.5BrR 368C
DeSOx REGEN SWITCH
9 10 80DE 0.5WR
0.85RL (POWER : EGR/VTG)

1 0
2 145C 0.85W
0.5BrW 369C 3 I
WE1401149
7 8 80DD 0.5WR 0.5WR
99

11-1-5
2905 Shawnee Industrial Way
Suite 100
Suwanee, GA 30024

Doosan DX210W 5 Excavator Shop Manual 950106 01052 E 1

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Doosan DX210W 5 Excavator Shop Manual 950106 01052 E 1

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950106-01052 E

Serial Number 1001 and Up

DOOSAN and the DOOSAN logo are registered

Trim Out The Label Along

Pub. No. 950106-01052 E

09/05/2015 1st Edition

3 General Maintenance 1 General Maintenance Instructions

5 Upper Structure 1 Cabin

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

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

Wheel Excavator Maintenance Safety

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

DX210W-5 Wheel Excavator Maintenance Safety

Safe Operation is Operator's Responsibility

Know Your Machine

Wheel Excavator Maintenance Safety DX210W-5

DX210W-5 Wheel Excavator Maintenance Safety

Flying or Falling Objects

Wheel Excavator Maintenance Safety DX210W-5

Correction of Machine Problems

Crushing and Cutting

DX210W-5 Wheel Excavator Maintenance Safety

Hot Coolant and Oils - Burn Prevention

Wheel Excavator Maintenance Safety DX210W-5

• Add fuel, oil, antifreeze and hydraulic fluid to machine only

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

Never Use Ether Starting Aids

Welding and Grinding

DX210W-5 Wheel Excavator Maintenance Safety

Fire Extinguisher and First-Aid Kit

Wheel Excavator Maintenance Safety DX210W-5

Rollover Protective Structure (ROPS)

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

When working in mines, quarries or other work sites where there

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

Obey State and Local Over-the-Road

Loading and Unloading

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

Before Engine Starting

Make sure that the machine is equipped with a lighting system

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

Securely latch door. If you grip handrail inside door when

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

DX210W-5 Wheel Excavator Maintenance Safety

Your machine may be equipped with visual aids such as mirrors

Work Site Rules

Wheel Excavator Maintenance Safety DX210W-5

Boost Starting or Charging Engine

DX210W-5 Wheel Excavator Maintenance Safety

Wheel Excavator Maintenance Safety DX210W-5

DX210W-5 Wheel Excavator Maintenance Safety

Do not operate attachments while traveling.