Doosan DX210W Wheel Excavator Shop Manual – K1017314AE – Serial 5001-Up

Description

Doosan DX210W Wheel Excavator Shop Manual – K1017314AE – Serial 5001-Up

This Doosan DX210W Wheel Excavator Shop Manual (document K1017314AE, Edition 1) is the factory-structured repair reference for DX210W wheel excavators from serial number 5001 and up. Running well over a thousand pages, this DX210W shop manual walks a technician through the machine section by section, from wheel excavator safety and full machine specifications through hydraulics, electrical systems, engine, transmission, axles, and attachments.

File Details

• Manual Type: Shop Manual
• Brand/Model: Doosan DX210W Wheel Excavator
• Serial Number Range: 5001 and Up
• Document Number: K1017314AE
• Edition: Edition 1
• Copyright: 2007 Doosan
• Language: English
• Page Count: 1,186 pages
• File Format: PDF

Chapters Covered

• Safety
  • Wheel Excavator Safety
• Specifications
  • Specification for DX210W (dimensions, working range, hydraulic cylinders, engine performance)
• General Maintenance
  • General Maintenance Procedures
  • Standard Torques
• Upper Structure
  • Cabin
  • Counterweight
  • Fuel Tank
  • Fuel Transfer Pump
  • Swing Bearing
  • Swing Reduction Gear
• Lower Structure and Chassis
  • Ram Lock Valve
  • Selector Valve
  • Double Pilot Check Valve
  • Solenoid Valve
  • Front Axle
  • Rear Axle
• Engine and Drive Train
  • Transmission
  • Drive Coupling (Main Pump)
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Doosan DX210W Wheel Excavator Shop Manual – K1017314AE – Serial 5001-Up” are as follows:

  DX210W

  Table of Contentsp. 3

  +Safetyp. 5

  +Wheel Excavator Safety SP000956p. 7

  Safety Precautionsp. 11

  Applicable Modelsp. 11

  +To the Operator of a DOOSAN Excavatorp. 12

  Learn the Signal Words Used with the Safety Alert Symbolp. 14

  +General Safety Essentialsp. 16

  Accessory Applicationsp. 16

  Lifting Capacity Rating Configurationp. 16

  Location of Safety Labelsp. 17

  Summary of Safety Precautions for Lifting in Digging Modep. 18

  Unauthorized Modificationsp. 19

  +General Hazard Informationp. 19

  Safety Rulesp. 19

  Safety Featuresp. 19

  Inside Operator's Compartmentp. 20

  Clothing and Personal Protective Itemsp. 20

  Breathing Masks, Ear Protection May Be Requiredp. 21

  Vibration Level Informationp. 21

  Recommendations for Limiting Vibrationsp. 21

  Mounting and Dismountingp. 22

  Fuel, Oil and Hydraulic Fluid Fire Hazardsp. 23

  Precautions When Handling Fluids at High Temperaturep. 23

  Asbestos Dust Hazard Preventionp. 24

  Injury from Work Equipmentp. 24

  Fire Extinguisher and First Aid Kitp. 24

  Protection from Falling or Flying Objectsp. 25

  Attachment Precautionsp. 26

  Accumulatorp. 26

  Indoor Ventilationp. 26

  Emergency Exitp. 27

  +Before Starting Enginep. 28

  Work Site Precautionsp. 28

  Checks Before Starting Enginep. 29

  Engine Startingp. 30

  Before Operating Machinep. 31

  +Machine Operationp. 32

  When Swinging or Changing Direction of Travelp. 32

  Travel Precautionsp. 32

  Traveling on Slopesp. 33

  Prohibited Operationsp. 34

  Precautions for Operationp. 35

  Avoid High Voltage Cablesp. 35

  Protecting Cabin from Falling Object (Optional)p. 36

  Operate Carefully on Snow, Ice and in Very Cold Temperaturesp. 36

  Operations on Slopesp. 37

  Parking Machinep. 37

  Never Let Anyone Ride on Attachmentp. 37

  +Maintenancep. 38

  Warning Tagp. 38

  Clean Before Inspection or Maintenancep. 38

  Proper Toolsp. 39

  Use of Lightingp. 39

  Fire Prevention and Explosion Preventionp. 39

  Burn Preventionp. 40

  +Welding Repairsp. 40

  Treatment for Electrical Welding to the Body Structurep. 41

  Warning for Counterweight and Front Attachment Removalp. 42

  Precautions for Removal, Installation, and Storage of Attachmentsp. 42

  Precautions When Working on Machinep. 43

  Lock Inspection Coversp. 43

  Crushing Prevention and Cutting Preventionp. 43

  Supports and Blocking for Work Equipmentp. 44

  Action When Abnormality Is Found During Inspectionp. 44

  Precautions with Highpressure Lines, Tubes and Hosesp. 44

  Waste Materialsp. 45

  +Batteryp. 46

  Battery Hazard Preventionp. 46

  Boost Starting or Charging Engine Batteriesp. 47

  +Towingp. 48

  Precautions When Towingp. 48

  +Shipping and Transportationp. 49

  Obey State and Local OvertheRoad Regulationsp. 49

  +Specificationsp. 51

  +Specification for DX210W SP000957p. 53

  Safety Precautionsp. 57

  Applicable Modelsp. 57

  General Descriptionp. 59

  Component Locationsp. 60

  +General Dimensionsp. 62

  One-Piece Boomp. 62

  Two-Piece Boomp. 63

  +Working Rangep. 64

  One-Piece Boomp. 65

  Two-Piece Boomp. 66

  Front Pin sizep. 67

  Hydraulic Cylindersp. 68

  General Specificationsp. 69

  Hydraulic System Component Specificationsp. 70

  System Component Specificationsp. 71

  Engine Performance Curves (Per DIN6270 Standard)p. 73

  Approximate Weight of Workload Materialsp. 75

  Performance Tests and Standardsp. 77

  +Excavator Performance Standardsp. 78

  Test Conditionsp. 78

  Travel Speed Testsp. 78

  +Swing Speed and Deceleration Force Testp. 80

  Swing Speed Testp. 80

  Swing Deceleration Force Testp. 81

  Cylinder Performance Testsp. 81

  Boom Cylinders Testp. 81

  Arm Cylinder Testp. 81

  Bucket Cylinder Testp. 82

  Hydraulic Cylinder Natural Drop Testp. 82

  +General Maintenancep. 85

  +General Maintenance Procedures SP000016p. 87

  Safety Precautionsp. 91

  Applicable Modelsp. 91

  Welding Precautions and Guidelinesp. 93

  Hydraulic System – General Precautionsp. 94

  +Maintenance Service and Repair Procedurep. 96

  General Precautionsp. 96

  +Hydraulic System Cleanliness and Oil Leaksp. 97

  Maintenance Precautions for Hydraulic System Servicep. 97

  Oil Leakage Precautionsp. 98

  +Cleaning and Inspectionp. 99

  General Guidelinesp. 99

  +Bearing Inspectionp. 100

  Normal Bearingp. 101

  Bent Cagep. 101

  Gallingp. 102

  Abrasive Step Wearp. 102

  Etchingp. 103

  Misalignmentp. 103

  Indentationsp. 103

  Fatigue Spallingp. 104

  Brinellingp. 104

  Cage Wearp. 104

  Abrasive Roller Wearp. 105

  Cracked Inner Racep. 105

  Smearsp. 105

  Frettagep. 106

  Heat Discolorationp. 106

  Stain Discolorationp. 106

  +Standard Torques SP000813p. 107

  Safety Precautionsp. 111

  Applicable Modelsp. 111

  Torque Values for Standard Metric Fastenersp. 113

  Torque Values for Standard U.S. Fastenersp. 114

  Type 8 Phosphate Coated Hardwarep. 116

  Torque Values for Hose Clampsp. 117

  Torque Values for Split Flangesp. 118

  +Torque Wrench Extension Toolsp. 119

  Torque Multiplicationp. 119

  Other Uses for Torque Wrench Extension Toolsp. 120

  +Tightening Torque Specifications (Metric)p. 121

  I. "Loctite" Fastener Adhesivesp. 122

  II. "Loctite" Pipe Thread Sealantp. 122

  III. "Loctite" gasket/flange sealerp. 122

  IV. "Loctite" retaining compoundsp. 123

  V. "Loctite" Adhesivesp. 123

  +Upper Structurep. 125

  +Cabin SP001231p. 127

  Safety Precautionsp. 131

  Applicable Modelsp. 131

  Removalp. 133

  Installationp. 136

  +Counterweight SP000959p. 139

  Safety Precautionsp. 143

  Applicable Modelsp. 143

  +Generalp. 144

  Warning for Counterweight and Front Attachment Removalp. 144

  Removalp. 146

  Installationp. 148

  +Fuel Tank SP000961p. 149

  Safety Precautionsp. 153

  Applicable Modelsp. 153

  +General Descriptionp. 154

  Parts Listp. 154

  Specificationsp. 155

  Removalp. 156

  Installationp. 160

  Start-up Proceduresp. 163

  +Fuel Transfer Pump SP000021p. 165

  Safety Precautionsp. 169

  Applicable Modelsp. 169

  +General Descriptionp. 171

  Theory of Operationp. 171

  Troubleshootingp. 172

  Replacement of Rotor and Vanep. 172

  Replacement of Rear Coverp. 173

  Replacement of Armaturep. 173

  +Swing Bearing SP001232p. 175

  Safety Precautionsp. 179

  Applicable Modelsp. 179

  +Swing Bearing Maintenancep. 181

  Operating Recommendationp. 181

  Measuring Swing Bearing Axial Playp. 181

  Measuring Bearing Lateral Playp. 181

  Swing Bearing Basic Operationp. 182

  Rebuilding Swing Bearingp. 182

  +Swing Reduction Gear SP001233p. 185

  Safety Precautionsp. 189

  Applicable Modelsp. 189

  +General Descriptionp. 191

  Theory of Operationp. 191

  Parts Listp. 192

  Specificationsp. 193

  Troubleshooting, Testing and Adjustmentp. 194

  Removalp. 195

  Disassemblyp. 196

  Cleaning and Inspection (Wear Limits and Tolerances)p. 202

  +Reassemblyp. 203

  Shaft and S/R Bearing Heatfitp. 203

  +Assembly of Carrier Subassembliesp. 204

  Cleaning Carrierp. 204

  Cleaning Planet Gearp. 204

  Assembly of No. 1 Carrierp. 205

  Assembly of No. 2 Carrierp. 207

  +Assembly of Main Casep. 210

  Cleaning Casing and Other Partsp. 210

  Assembly of Shaft and Pinionp. 211

  Assembly of Seal and Bearingp. 212

  Assembly of Ring Gearp. 217

  Assembly of Carrier.p. 218

  Assembly of the Motorp. 221

  Installationp. 227

  Startup Proceduresp. 227

  +Lower Structure and Chassisp. 229

  +Ram Lock Valve SP000923p. 231

  Safety Precautionsp. 235

  Applicable Modelsp. 235

  Sectional Drawing and Part Namesp. 237

  Hydraulic Circuitp. 237

  +Operational Principlep. 238

  In Case of No Pilot Pressure at PI Portp. 238

  In Case of Pilot Pressure (Approx. 20 kg.cm2) at PI Portp. 238

  +Disassembly and Assemblyp. 238

  General Cautionsp. 238

  Assembly and Disassembly of Chocking Valvep. 239

  +Performance Testp. 240

  Oil Leakage Testp. 240

  Operational Testp. 240

  +Selector Valve SP000926p. 241

  Safety Precautionsp. 245

  Applicable Modelsp. 245

  Sectional Drawing and Part Namesp. 247

  Hydraulic Circuitp. 247

  +Operational Principlep. 248

  Neutral Position : A Æ Bp. 248

  Selective Position : A Æ Cp. 248

  +Disassembly and Assemblyp. 249

  General Cautionsp. 249

  Assembly and Disassembly of Selector Valvep. 249

  +Performance Testp. 251

  Oil Leakage Testp. 251

  Operational Testp. 251

  +Double Pilot Check Valve SP000927p. 253

  Safety Precautionsp. 257

  Applicable Modelsp. 257

  Sectional Drawing & Partsp. 259

  Hydraulic Diagramp. 260

  +Operational Principlep. 261

  A Æ C, D Æ Bp. 261

  B Æ D, C Æ Ap. 261

  +Disassembly and Assemblyp. 262

  General Cautionsp. 262

  Assembly and Disassembly of Double Pilot Check Valvep. 263

  +Performance Testp. 265

  Cracking Pressure Test for Check Cartridge Ass'yp. 265

  Pilot Cracking Pressure Testp. 265

  Oil Leakage Testp. 266

  +Solenoid Valve SP000928p. 267

  Safety Precautionsp. 271

  Applicable Modelsp. 271

  Single Solenoid Valve Diagramp. 273

  Functions of Single Solenoid Valvep. 274

  Disassembly and Reassembly Diagramsp. 275

  Troubleshooting of Each Partp. 276

  Double Solenoid Valve Diagramp. 277

  Functions of Double Solenoid Valvep. 278

  Disassembly and Reassembly Diagramsp. 279

  Troubleshooting of Each Partp. 280

  +Front Axle SP000929p. 281

  Safety Precautionsp. 285

  +Applicable Modelsp. 285

  Examples of Gear-Tooth-Contact Patterns for the Gleason GearTooth Systemp. 287

  +Lubrication and Maintenance Specifications for Axle MS- E 3050/3060/3070p. 290

  Oil Gradep. 290

  Oil Changep. 290

  Oil Change Intervalp. 291

  Oil Level Checkp. 291

  Brakep. 292

  +Brake Wear Measurement on Axles of MT/MS-E 3050/ 3060/3070 Rangep. 293

  Lining Wear Measurement of Multi-disc Brakep. 294

  +Disassemblyp. 295

  Steeringp. 295

  +Outputp. 299

  Planetary Carrierp. 300

  Brake / Hubp. 301

  Knuckle Housingp. 304

  +Differential – Inputp. 307

  Differential Version "D-500" and "D-750"p. 308

  Inputp. 310

  Pivot Bearingp. 312

  +Reassemblyp. 313

  +Inputp. 313

  Determine Shim for Pinion Positioning to Obtain An Optimum Contact Pattern of Crown Wheel/pinion …p. 313

  Adjust Rolling Moment of Drive Pinion Bearing 1.0 ~ 2.0 N•m (Without Seal Ring):p. 315

  Differential Version "D-500" and "D-750"p. 317

  Adjust Backlash of Bevel Gear Set and Bearing Rolling Moment of Differential Bearingp. 320

  Backlash and Contact Pattern Checkp. 322

  Input Flangep. 325

  +Outputp. 326

  Pre-assemble Axle Housimp. 327

  Knuckle Housingp. 328

  Hubp. 333

  Multi-Disc Brakep. 337

  Planetary Carrierp. 343

  Pivot Bearingp. 345

  +Steeringp. 346

  Steering Setting and Checkingp. 352

  Oil Drain-Oil Filler and Oil Control Plugs and Grease Lubrication Pointsp. 355

  +Rear Axle SP000930p. 357

  Safety Precautionsp. 361

  +Applicable Modelsp. 361

  Examples of Gear-Tooth-Contact Patterns for the Gleason GearTooth Systemp. 363

  +Lubrication and Maintenance Specifications for Axle MT- E 3050/3060/3070p. 366

  Oil Gradep. 366

  Oil Changep. 366

  Oil Change Intervalp. 367

  Oil Level Checkp. 367

  Brakep. 368

  +Brake Wear Measurement on Axles of MT/MS-E 3050/ 3060/3070 Rangep. 369

  Lining Wear Measurement of Multi-Disc Brakep. 370

  Disassemblyp. 371

  +Reassemblyp. 377

  Hub Carrier / Hubp. 377

  +Multi Disc Brakep. 381

  Make Leakage Test of Multi-Disc Brakep. 384

  Adjust and Check Disc Clearance/Piston Strokep. 385

  Planetary Carrierp. 386

  Assembly of An Output Ass’y (Figure 78)p. 388

  +Disassemblyp. 389

  Differential / Inputp. 389

  Input – HL Transmissionp. 390

  Differential Type "D 500" and "D-750"p. 392

  +Reassemblyp. 394

  +Differential / Inputp. 394

  Differential – Type "D-500" and "D-750"p. 394

  Determine Shim for Backlash (Crown Wheel/Drive Pinion)p. 397

  Check Backlash and Contact Patternp. 401

  Reassembly of Output Ass’y (Figure 123 ~ 125)p. 403

  +Engine and Drive Trainp. 405

  +Transmission SP000962p. 407

  Safety Precautionsp. 411

  Applicable Modelsp. 411

  Layout 2 HL 250/270/290 Axle Attachmentp. 413

  Layout 2 HL 250/270/290 Separate Installationp. 414

  Measuring Points and Connections or Installation View 2 HL 250/ 270/290 Layout "Axle Attachment"p. 415

  Measuring Points and Connections on the 2 HL 250/270/290 Transmission – Version "Separate Install…p. 417

  +Notes to the Required Oil Quality and Oil Filling Capacityp. 418

  Oil Quality / Oil Gradep. 418

  Oil Filling Capacity for Power Shift Transmissions (2 HL- 250/270/290)p. 418

  For the Version "Axle Attachment"p. 418

  Separate the HL- Transmission from the Axle Casingp. 419

  +Disassembly – Brake / Clutch / Planet Carrierp. 420

  +Lube Oil Pump/Downshift Interlockp. 420

  Version "Lube Oil Pump"p. 420

  Speed Transmitterp. 421

  Emergency Release (Parking Brake)p. 421

  Input Housing and Modulation Valvep. 422

  Brake / Clutchp. 423

  Planet Carrierp. 429

  +Disassembly – Outputp. 433

  Version – Axle Attachmentp. 433

  Version – "Separate Installation"p. 437

  +Reassembly – Outputp. 441

  +Version – Axle Attachmentp. 441

  Determine Adjusting Shim for Pinion Gapp. 443

  Determine the Adjusting Ring for Rolling Moment/Pinion Bearingp. 448

  Check the Rolling Moment of the Pinion Bearingp. 449

  Shaft Seal/Output Flangep. 450

  Check the Pinion Gapp. 451

  Version Separate Installationp. 453

  Shaft Seal/Output Flangep. 457

  +Reassembly – Brake / Clutch / Planet Carrierp. 460

  Planet Carrierp. 460

  +Brake/Clutchp. 466

  Disc Components Brake and Clutchp. 468

  Adjust and check the Disc Clearance/Piston Stroke of Brake and Clutchp. 470

  Modulation Valve and Input Housingp. 479

  +Emergency Release (Parking Brake)p. 481

  Check the Emergency Release for Leak Tightnessp. 483

  Check the Multi-Disc Brake and Multi-Disc Clutch for Leak Tightness as well as Closing Pressurep. 485

  Speed Transmitterp. 486

  Lube Oil Pump/Downshift Interlockp. 487

  +Disassembly – Lube Oil Pump/Downshift Interlockp. 488

  Version "with" Lube Oil Pumpp. 488

  Version "with" hydr. Downshift Interlockp. 491

  Version "with" electr. Downshift Interlock- mounted to Transmissionp. 494

  +Reassembly – Lube Oil Pump/Downshift Interlockp. 495

  Version "with" Lube Oil Pumpp. 495

  Version "with" hydr. Downshift Interlockp. 501

  Version "with" electr. Downshift Interlock – mounted to the Transmissionp. 508

  Attach the HL- Transmission to the Axlep. 509

  +Drive Coupling (Main Pump) SP000963p. 511

  Safety Precautionsp. 515

  Applicable Modelsp. 515

  Drive Couplingp. 517

  Special Tools

  +Drive Coupling Installation

  Installation Procedure

  +Hydraulicsp. 523

  +Hydraulic System Troubleshooting, Testing and Adjustment SP001097p. 525

  Safety Precautionsp. 529

  Applicable Modelsp. 529

  Hydraulic System – General Notesp. 531

  +Hydraulic Schematicp. 532

  General Notesp. 532

  +Operation of Working Componentsp. 534

  Boom Operating Circuitp. 534

  Boom Up Circuitp. 534

  Boom Down Circuitp. 535

  Arm Operating Circuitp. 535

  Arm Crowd Circuitp. 536

  Arm Dump Circuitp. 536

  Bucket Operating Circuitp. 536

  Bucket Crowd Circuitp. 537

  Bucket Dump Circuitp. 537

  Swing Operating Circuitp. 537

  Right Swing Operating Circuitp. 537

  Left Swing Operating Circuitp. 538

  Swing Relief Valve and Makeup Valvep. 538

  +Procedural Troubleshooting Baseline Recommendationsp. 539

  +Initial Checks and Tests to Establish Operating Condition of the Excavatorp. 539

  Triage Summaryp. 539

  +Pilot Pressurep. 541

  Adjustment and Testingp. 541

  +Power Mode Valvep. 542

  Current Signal and Hydraulic Pressure Adjustmentsp. 542

  +Swing Priority Valvep. 543

  Control Valve Pressure and Current Adjustmentsp. 543

  +Pressure Up Valvep. 544

  Checks and Adjustmentsp. 544

  +Pump Input Power Controlp. 546

  Pump Regulator Adjustmentp. 546

  +Flow Meter and Flow Meter Kit Installation and Testingp. 549

  Installation and Testing Procedurep. 549

  +Swing System Troubleshootingp. 551

  Precautions/Initial Checksp. 551

  Swing Relief Valve Checking and Adjustmentp. 552

  Troubleshooting – Swing Gearboxp. 554

  Troubleshooting – Hydraulic Problemsp. 555

  Troubleshooting – Control Valvep. 557

  Troubleshooting – Travel Control Valvep. 558

  Troubleshooting – Joystick Control Valvep. 559

  +Accumulator SP000984p. 561

  Safety Precautionsp. 565

  Applicable Modelsp. 565

  +General Descriptionp. 567

  Specificationsp. 569

  +Center Joint (Swivel) SP000919p. 571

  Safety Precautionsp. 575

  Applicable Modelsp. 575

  +General Descriptionp. 577

  Parts Listp. 578

  +Troubleshooting, Testing and Adjustmentp. 579

  Inspectionp. 579

  Testingp. 579

  Disassemblyp. 580

  Reassemblyp. 584

  +Cylinders SP001098p. 585

  Safety Precautionsp. 589

  Applicable Modelsp. 589

  +General Descriptionp. 591

  Theory of Operationp. 591

  +Parts Listp. 593

  Arm Cylinderp. 593

  Boom and Bucket Cylinderp. 593

  Dozer Cylinderp. 595

  Outrigger Cylinderp. 596

  Ram Cylinderp. 597

  +Special Tools and Materialsp. 598

  Piston Nutp. 598

  Piston Jigp. 600

  Steel Bushing Jigp. 602

  Dust Wiper Jigp. 604

  Slipper Seal Jigp. 606

  Slipper Seal Straightening Jigp. 608

  Disassemblyp. 610

  Reassemblyp. 615

  +Main Control Valve SP000966p. 619

  Safety Precautionsp. 623

  Applicable Modelsp. 623

  +Control Valve Operationp. 624

  Arm Priority Circuitp. 625

  Bucket (Junction) Circuitp. 626

  Main Relief Valvep. 627

  Overload Relief Valvep. 628

  Arm Load Holding Valvep. 630

  Boom Load Holding Valvep. 633

  Arm Regenerationp. 635

  Boom Regenerationp. 637

  Foot Relief Valvep. 638

  +Parts Listp. 639

  Main Plunger Elementp. 639

  Main Relief Valvep. 640

  Overload Relief Valvep. 641

  Bucket Unity Checkp. 642

  Boom Load Holding Valvep. 642

  Boom Unity Checkp. 643

  Arm Regeneration Valvep. 643

  Foot Relief Valvep. 643

  Check Valve [Am-2]p. 644

  Check Valve [Opt, Bkt, Bm-1, Bm-2, Am-1]p. 644

  Check Valvep. 645

  Capp. 645

  Capp. 645

  Check Valve [Sw]p. 645

  Center Bypass Valve [Cb Valve]p. 646

  Arm Load Holding Valvep. 646

  Specificationsp. 647

  Control Valve Drawing and Hydraulic Circuitp. 648

  +Disassembly and Reassemblyp. 652

  General Disassemblyp. 652

  General Reassemblyp. 652

  Plunger Replacementp. 652

  Main Plunger Element – Disassembly and Assemblyp. 653

  Toolp. 653

  +Main Relief Valvep. 656

  Disassemblyp. 656

  Reassemblyp. 656

  Main Relief Valve Adjustmentp. 657

  High Pressure Adjustmentp. 657

  Low Pressure Adjustmentp. 657

  Overload Relief Valvep. 658

  +Arm Load Holding Valvep. 660

  Check Valve Main Bodyp. 660

  Cover Assemblyp. 661

  Boom Load Holding Valvep. 662

  Arm Regeneration Valvep. 663

  Bucket Unity Checkp. 664

  Foot Relief Valvep. 665

  Center Bypass Valve (CB Valve)p. 666

  +Boom Parallel Switch Valvep. 667

  Special Toolp. 667

  Boom Unity Check Valvep. 668

  Check Valve – Locationsp. 669

  +Check Valvep. 670

  A: Check Valve (Main Relief Valve)p. 670

  B: Check Valve (P2)p. 671

  C: Check Valve [AM-2]p. 671

  D: Check Valve [OPT, BKT, BM-1, BM-2, AM-1]p. 672

  E: Check Valve [TL]p. 672

  F: Check Valve [SW]p. 673

  +Swing Motor SP000985p. 675

  Safety Precautionsp. 679

  Applicable Modelsp. 679

  +Instruction Manualp. 681

  Indication of Typep. 681

  Specificationsp. 682

  +Construction & Principles of Workingp. 683

  Constructionp. 683

  Principles of Workingp. 685

  +Precaution in Usep. 690

  Inspectionp. 690

  Rotation Directionp. 690

  External Load of Shaftp. 691

  Hydraulic Fluids & Range of Temperaturep. 691

  Filterp. 692

  Installation & Pipingp. 692

  Oil Filling & Air Bleederp. 694

  Precaution in Starting Operationsp. 694

  +Troubleshootingp. 695

  General Cautionsp. 695

  Investigation Manner of the Motor Bodyp. 695

  Condition & Countermeasures of Troublesp. 696

  +Maintenance Manualp. 698

  +Disassembling & Assemblingp. 698

  Tightening Torque of Boltsp. 698

  Necessary Toolsp. 699

  Procedures for Disassemblyp. 701

  Procedures for Assemblyp. 705

  +Maintenance Standardsp. 711

  Standards for Replacement of Worn Partsp. 711

  Standard for Correcting Sliding Surfacesp. 711

  +Travel Motor SP001110p. 713

  Safety Precautionsp. 717

  Applicable Modelsp. 717

  General Repair Guidelinesp. 719

  +Seal Kits and Sub- assembliesp. 720

  Replace Seal Nutp. 722

  +Disassemblyp. 723

  Sealing the Drive Shaftp. 723

  Seal of the Control Partsp. 724

  Seal of the Relief Valve / Counter-balance Valvep. 726

  +Spare Parts Listp. 728

  Counter-balance Valvep. 728

  Brake Release Valve (Pos.50)p. 729

  Shuttle Valve (Pos.25)p. 729

  Diassembly of the Port Platep. 730

  Remove of the Positioning Pistonp. 731

  Remove Rotary Groupp. 733

  Exchanging of the Rotary Groupp. 734

  Inspection Notesp. 735

  +Assemblyp. 738

  Rotary Group Assemblyp. 738

  Rotary Group Adjustment (See Service Information)p. 740

  Assembly of the Port Platep. 742

  +Tightening Torquesp. 744

  Shaft Boltsp. 744

  Locking Screws VSTIp. 744

  Seal-Lock Nutsp. 745

  Cross-slotted Lens Head Screws DIN 7985p. 745

  +Test Procedurep. 746

  Hydraulics Schematicp. 748

  +Counterbalance Valve SP000991p. 749

  Safety Precautionsp. 753

  Applicable Modelsp. 753

  +General Descriptionp. 755

  While Operating to Run Forwardp. 755

  While Operating to Stopp. 755

  While Operating to Backp. 756

  Adjustment of Relief Valvep. 757

  Troubleshootingp. 758

  +Counterbalance Valvep. 759

  Recommended Toolsp. 759

  Disassemblyp. 759

  Order of Disassembly and Torque Valuesp. 760

  Reassemblyp. 761

  +Main Pump & PTO SP000988p. 767

  Safety Precautionsp. 771

  Applicable Modelsp. 771

  Sectionp. 773

  General Repair Guidelinesp. 774

  Seal Kits and Sub- assembliesp. 775

  +Disassemblyp. 779

  Sealing the Drive Shaftp. 779

  Gear Pump Sealingp. 781

  Control Housingp. 782

  Control Module LRp. 785

  Control Module Hp. 786

  Controllerp. 787

  Rotary Groupsp. 789

  Intermediate Wheelp. 792

  Auxiliary Drivep. 794

  Inspection Hintsp. 797

  +Assemblyp. 802

  Rotary Groupp. 802

  +Pumpp. 803

  Assembly Guidelinep. 805

  Hydraulic Component – Measurement "D"p. 806

  Control Housingp. 809

  Intermediate Wheelp. 812

  Gear Pumpp. 813

  Cover / Auxiliary Drivep. 814

  +Assembly Guidelines for Tightening Torquesp. 815

  Bolts (to N 08.001)p. 815

  Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)p. 816

  Seal-Lock – Sealing Nuts (to N 02.100)p. 816

  +Gear Pump SP000989p. 817

  Safety Precautionsp. 821

  Applicable Modelsp. 821

  +Single Gear Pumpp. 823

  Disassemblyp. 823

  Reassemblyp. 825

  +Double Gear Pumpp. 829

  Disassemblyp. 829

  Reassemblyp. 831

  +Service Brake Supply Valve SP000990p. 835

  Safety Precautionsp. 839

  +Applicable Modelsp. 839

  Diagram of Brake Supply Valve Assembly Packagep. 841

  +Functions of Brake Supply Valve Assembly Packagep. 842

  Functionsp. 842

  Functions of Each Valvep. 842

  Detailed Functions and Application of Brake Supply Valve Assembly Packagep. 842

  Exploded View and Toolsp. 844

  Cautions for Disassembly and Re-assemblyp. 845

  Troubleshooting Guidep. 846

  How to Check Brake Pressurep. 847

  +Dozer Control Valve SP000992p. 849

  Safety Precautionsp. 853

  Applicable Modelsp. 853

  Structurep. 855

  Parts Listp. 856

  Performance Curvep. 857

  Hydraulics Symbolp. 857

  Disassembly & Assembly Toolsp. 857

  Disassemblyp. 858

  Assemblyp. 861

  +Steering Valve SP000993p. 867

  Safety Precautionsp. 871

  Applicable Modelsp. 871

  +General Descriptionp. 873

  Theory of Operationp. 874

  OSPC / OSPFp. 875

  TOOLSp. 877

  +Disassemblyp. 879

  Dismantling the Shock Valves for OSPC/ OSPC LSp. 883

  Dismantling the Pressure Relief Valve for OSPCp. 884

  Dismantling the Pressure Relief Valve (cartridge) for OSPC LS/OSPC LSRp. 885

  Cleaningp. 886

  Inspection and Replacementp. 886

  Lubricationp. 886

  +Assemblyp. 887

  Assembly Pattern for Standard Bearingp. 889

  Assembly Pattern for Double Bearingp. 890

  Installation Instructions for O-ring/Kin-ring /Roto Glydp. 890

  Installation Instructions for Lip Sealp. 891

  Assembly of the Pressure Relief Valve for OSPCp. 896

  Assembly of the Shock Valves for OSPC/ OSPC LS/OSPC LSRp. 897

  Hydraulic Connectionsp. 899

  +Accelerator Pedal Valve (Hydraulic) SP000964p. 901

  Safety Precautionsp. 905

  Applicable Modelsp. 905

  STructurep. 907

  Parts Listp. 907

  Performance Curvep. 908

  Hydraulics Symbolp. 908

  Disassembly & Assembly Toolsp. 908

  Disassemblyp. 909

  Assemblyp. 910

  +One Spool Valve SP000996p. 913

  Safety Precautionsp. 917

  Applicable Modelsp. 917

  Outside Drawingp. 919

  Hydraulic Circuitp. 919

  +Operational Principlep. 920

  In the Neutral Conditionp. 920

  Spool Operationp. 920

  +Disassembly and Assemblyp. 921

  General Cautionsp. 921

  Replacement of Spool Ass'y (Pilot Type)p. 922

  Replacement of Main Relief Valvep. 924

  Replacement of Overload Relief Valvep. 925

  Replacement of Sub-Block Ass'yp. 926

  +Remote Control Valve (Work Lever / Joystick) SP000069p. 929

  Safety Precautionsp. 933

  Applicable Modelsp. 933

  +General Descriptionp. 935

  +Theory of Operationp. 935

  Structurep. 935

  Functionp. 935

  Parts Listp. 936

  +Specificationsp. 938

  Performancep. 938

  Torquesp. 938

  Tools and Materialsp. 938

  Disassemblyp. 939

  Cleaning and Inspection (Wear Limits and Tolerances)p. 943

  Reassemblyp. 943

  Start-up Proceduresp. 949

  +Breaker EPPR Valve (Opt) SP000192p. 951

  Safety Precautionsp. 955

  Applicable Modelsp. 955

  +Structurep. 957

  Numbers and Names of Partsp. 957

  Functions and Operationp. 958

  Cautions for Operationp. 958

  +Maintenance Instructionsp. 959

  +Maintenancep. 959

  Bolt Tightening Torquep. 959

  Tools Used for Disassembly and Assemblyp. 959

  Disassemblyp. 960

  Assemblyp. 961

  +Service Brake Pedal Valve SP001006p. 963

  Safety Precautionsp. 967

  Applicable Modelsp. 967

  Functions of Brake Pedalp. 969

  +Internal Structure and Operation Principlesp. 970

  Internal Structurep. 970

  Operation Principlesp. 972

  Disassemblyp. 973

  +Reassemblyp. 973

  Reassembly of the Lower Partp. 973

  Reassembly of the Upper Partp. 975

  Assembly of Pedal Platep. 978

  +Solenoid Valve Assembly SP000997p. 985

  Safety Precautionsp. 989

  Applicable Modelsp. 989

  +2-Solenoid Valvep. 991

  Diagram of 2-Solenoid Valve Assembly Packagep. 991

  +Exploded View and Toolsp. 992

  Assembly, Re-assembly of Solenoid Valve Package, and Necessary Toolsp. 992

  +Cautions for Disassembly and Re- assemblyp. 993

  Solenoid Valve Diagramp. 994

  Troubleshooting Guidep. 994

  +6-Solenoid Valvep. 995

  Diagram of 6-Solenoid Valve Assembly Packagep. 995

  +Functions of 6-Solenoid Valve Assembly Packagep. 996

  Functionsp. 996

  Application by Function of Each Solenoid Valvep. 996

  Detailed Functions and Application of Each Solenoid Valvep. 996

  +Exploded View and Toolsp. 998

  Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Toolsp. 998

  +Cautions for Disassembly and Re- assemblyp. 999

  Solenoid Valve Diagramp. 1000

  +Troubleshooting Guidep. 1000

  Partsp. 1000

  How to Check Pilot Pressurep. 1001

  +4-Solenoid Valvep. 1002

  Diagram of 4-Solenoid Valve Assembly Packagep. 1002

  +Functions of 4 Solenoid Valve Assembly Packagep. 1003

  Functionsp. 1003

  Application by Function of Each Solenoid Valvep. 1003

  Detailed Function and Application Descriptions by Solenoid Valvep. 1003

  +Exploded View and Toolsp. 1005

  Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Toolsp. 1005

  +Cautions for Disassembly and Re- assemblyp. 1006

  Solenoid Valve Diagramp. 1007

  +Troubleshooting Guidep. 1008

  Partsp. 1008

  How to Check Pilot Pressurep. 1008

  +3-Solenoidp. 1009

  Diagram of 3-Solenoid Valve Assembly Packagep. 1009

  +Functions of 3 Solenoid Valve Assembly Packagep. 1010

  Functionsp. 1010

  Application by Function of Each Solenoid Valvep. 1010

  Detailed Function and Application Descriptions by Solenoid Valvep. 1010

  +Exploded View and Toolsp. 1012

  Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Toolsp. 1012

  +Cautions for Disassembly and Re- Assemblyp. 1013

  Solenoid Valve Diagramp. 1014

  +Troubleshooting Guidep. 1015

  Partsp. 1015

  How to Check Pilot Pressurep. 1015

  +Hydraulic Schematic SP001107p. 1017

  Safety Precautionsp. 1021

  Applicable Modelsp. 1021

  +Electrical Systemp. 1027

  +Electrical System SP001108p. 1029

  Safety Precautionsp. 1035

  Applicable Modelsp. 1035

  +Introductionp. 1037

  Electric Wire Colorp. 1037

  Electrical Supply Systemp. 1038

  +Engine Starting Circuitp. 1040

  Start Operationp. 1040

  +After Startp. 1042

  Operation of the Start Circuit (2)  Immediately After Startp. 1043

  Engine Preheating Systemp. 1044

  Engine Stopp. 1046

  Charging Systemp. 1048

  +Monitoring Systemp. 1049

  Instrument Panelp. 1050

  Monitoring System Schematicp. 1051

  +Operationp. 1053

  +Instrumentsp. 1053

  DX210Wp. 1053

  DX190Wp. 1054

  +Warning and Indicator Lightsp. 1056

  Indication of Warning Lightsp. 1056

  Indication of Multifunction Gauge and Letter Information Areap. 1057

  Initial Operationp. 1059

  +Mode Selector Switchp. 1060

  Power Modep. 1060

  Trenching Mode Switchp. 1060

  Auto Idle Switchp. 1060

  +Graphic Information Area Displayp. 1061

  Overviewp. 1061

  Main Menus for the Graphic Display Areap. 1062

  Menu Selector Buttonsp. 1062

  Menu Selector Buttonsp. 1062

  +Main Menup. 1063

  Languagep. 1063

  Set Clockp. 1064

  +Filter/Oil Infop. 1064

  Menu Display Order and Icon Explanationp. 1065

  Adjust Displayp. 1065

  Set Passwordp. 1066

  +Special Menup. 1067

  +Entering/Accessing and Exiting/Escaping Menusp. 1067

  Entering/Accessing Menusp. 1067

  Exiting/Escaping Menusp. 1068

  +Special Menu Selectionsp. 1068

  Information of Machine Statusp. 1068

  Failure Informationp. 1072

  Information of Machine Operationp. 1081

  Machine Operation Info Screenp. 1084

  +Electronic Hydraulic Control System (eEPOS)p. 1086

  Control System Schematicp. 1086

  +Power Mode Controlp. 1088

  +Operationp. 1090

  1. Power Modep. 1090

  2. Standard Modep. 1092

  3) Operation in case of failure in the control system (Aux mode operation)p. 1092

  Power Mode Control  Circuit Diagramp. 1094

  +Work Mode Controlp. 1096

  +Operationp. 1097

  1. Digging Modep. 1097

  2. Trenching Modep. 1097

  Work Mode Control  Circuit Diagramp. 1098

  Engine Control Systemp. 1099

  Engine Control Dialp. 1100

  Acceleration pedalp. 1102

  Engine Control Circuit Diagramp. 1103

  Automatic Deceleration Control (Auto Idle Control)p. 1106

  Engine Overheat Protection Systemp. 1108

  +Power Boost Modep. 1110

  Operationp. 1110

  Power Boost Control  Circuit Diagramp. 1112

  +cruise controlp. 1114

  Operationp. 1114

  Cruise Control Circuitp. 1116

  +Automatic Travel Speed Controlp. 1118

  Automatic Travel Speed Control  Circuit Diagramp. 1120

  +Selfdiagnostic Functionp. 1121

  eEPOS Controllerp. 1121

  +Wiper Systemp. 1123

  Wiper Circuitp. 1123

  +Wiper operationp. 1124

  Continuous operationp. 1124

  Intermittent operationp. 1124

  +Lighting Systemp. 1126

  Lighting System Circuit Diagramp. 1126

  Typep. 1127

  Operationp. 1127

  +Overload Warning Devicep. 1129

  Overload Warning Device Circuit Diagramp. 1129

  +Audio Controllerp. 1130

  +Audio Controller Circuit Diagramp. 1130

  Operations Via Audio Control Panelp. 1131

  +ram lock devicep. 1132

  Ram Lock Control Circuitp. 1132

  Operationp. 1133

  +Air Conditioner Systemp. 1134

  Outlinep. 1134

  +Internal and External Filtersp. 1135

  How to check Indoor air filterp. 1135

  How to check outdoor air filterp. 1135

  Air-Conditioning System Layoutp. 1137

  Air Conditioner/Heater Circuit Diagramp. 1138

  +Air Conditioner/Heater Unitp. 1139

  Air Flow Diagramp. 1139

  Door Open by Vent Modesp. 1140

  Main Componentsp. 1140

  Actuator – Internal/external air exchangep. 1142

  Air Flow Control Modulep. 1142

  Relay – Blowerp. 1143

  Relay – A/Cp. 1143

  Duct Sensorp. 1143

  Water Temp Sensorp. 1144

  Internal Air Temp Sensorp. 1144

  Ambient Air Temperature Sensorp. 1144

  Sun Sensorp. 1145

  +Control Panelp. 1145

  Appearance and Terminal Arrangementp. 1145

  Terminal Termsp. 1146

  Control Logicp. 1146

  Self Diagnosisp. 1150

  Ambient Temp Displayp. 1151

  Compressorp. 1152

  Receiver Dryerp. 1152

  +Electrical Schematic SP001256p. 1153

  Safety Precautionsp. 1157

  Applicable Modelsp. 1157

  +Attachmentsp. 1161

  +Boom and Arm SP001255p. 1163

  Safety Precautionsp. 1167

  Applicable Modelsp. 1167

  Front Attachment Pin Specificationsp. 1169

  +Front Attachment – Removal and Installationp. 1170

  Arm Removal Procedurep. 1170

  Boom Removal Procedurep. 1172

  +Installationp. 1173

  Arm Installation Procedurep. 1173

  Boom Installation Procedurep. 1173

  Start-up Proceduresp. 1173

  +Bucket SP001001p. 1175

  Safety Precautionsp. 1179

  Applicable Modelsp. 1179

  Bucket Tooth Inspection and Replacementp. 1181

  Bucket O-ring Replacementp. 1182

  +Bucket Attachment, Removal and Reversalp. 1184

  Detaching the Bucketp. 1184

  Attaching the Bucketp. 1184

  Reversing the Bucketp. 1185

• Hydraulics
  • Hydraulic System Troubleshooting, Testing and Adjustment
  • Accumulator
  • Center Joint (Swivel)
  • Cylinders
  • Main Control Valve
  • Swing Motor
  • Travel Motor
  • Counterbalance Valve
  • Main Pump and PTO
  • Gear Pump
  • Service Brake Supply Valve
  • Dozer Control Valve
  • Steering Valve
  • Accelerator Pedal Valve (Hydraulic)
  • One Spool Valve
  • Remote Control Valve (Work Lever/Joystick)
  • Breaker EPPR Valve (Opt)
  • Service Brake Pedal Valve
  • Solenoid Valve Assembly
  • Hydraulic Schematic
• Electrical System
  • Electrical System
  • Electrical Schematic
• Attachments
  • Boom and Arm
  • Bucket

Together these sections give a technician everything needed to service the upper turntable, undercarriage/chassis, and front-end attachment of the DX210W as one connected machine, rather than treating hydraulics, electrical, and structural components as separate guesswork.

What This Doosan DX210W Shop Manual Covers

Inside the DX210W Wheel Excavator Shop Manual you’ll find the DIN 6270 engine performance curves for the DL06 engine (164 ps @ 2,000 rpm, 72 kg-m max torque @ 1,400 rpm), full hydraulic system component specifications (main relief valve settings, spool configurations, accumulator charges), swing mechanism and swing bearing data, brake system pressures, steering cylinder dimensions, and general dimensions/working range tables for both one-piece and two-piece boom configurations with multiple arm lengths.

IMAGES PREVIEW

Because this DX210W shop manual documents both boom configurations and several arm-length options side by side, it’s built to support a shop that services more than one DX210W configuration, not just a single fixed spec.

Why Technicians Choose This DX210W Shop Manual

With this Doosan DX210W Wheel Excavator Shop Manual on hand, a technician can diagnose and repair hydraulic circuits using the actual factory relief valve and pressure settings, rebuild or replace swing bearings, reduction gears, cylinders and control valves to spec, verify engine performance against the factory DIN 6270 curves, and trace electrical faults using the included electrical schematic. Working from the correct torque values, pressures, and clearances documented for the DX210W – rather than guessing or borrowing numbers from a different excavator – protects the machine from avoidable damage and keeps repairs consistent with how Doosan engineered it. This DX210W Shop Manual (K1017314AE) downloads instantly as a PDF after purchase, works on any computer, tablet, or phone, and can be printed as needed – no shipping and no waiting.