PDF Shop Manual Doosan DX190W Excavator - 3 MB
Unlock the full potential of your Doosan DX190W Excavator with this official shop manual.
This guide is packed with detailed procedures for complete disassembly, inspection, and reassembly of your machine.
It is an essential resource for any professional technician aiming to perform complex repairs and diagnostics.
Keep your excavator operating at peak performance with the manufacturer's recommended service information.
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Doosan Infracore
DX190W
Serial Number 5001 thru 5408
Shop
Manual
K1024513E-1
--- Page 3 ---
MEMO
Wheel Excavator Safety SP000956
Page 2
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UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not taking
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition in which the safety
of critical assemblies is dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgement in
emergencies and may cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and use
them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
Wheel Excavator Safety SP000956
Page 13
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Engine Starting
Walk around your machine before getting in the operator's
cabin. Look for evidence of leaking fluid, loose fasteners,
misaligned assemblies or any other indications of possible
equipment hazard.
All equipment covers and machinery safety guards must be in
place, to protect against injury while the machine is being
operated.
Look around the work site area for potential hazards, people or
properly that could be at risk while operation is in progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning tag is
attached to controls in the cabin.
A machine that has not been used recently, or is being operated
in extremely cold temperatures, could require a warm-up or
maintenance service before start-up.
Check gauges and monitor displays for normal operation before
starting the engine. Listen for unusual noises and remain alert
for other potentially hazardous conditions at the start of the work
cycle.
Do not short circuit the starting motor to start the engine. This is
not only dangerous, but may also damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Wheel Excavator Safety SP000956
Page 24
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When carrying out welding repairs, carry out the welding in a
properly equipped place. The welding should be performed by a
qualified worker. During welding operations, there is the danger
of, generation of gas, fire, or electric shock, so never let an
unqualified worker do welding.
The qualified welder must do the following;
• To prevent explosion of the battery, disconnect the
battery terminals and remove batteries.
• To prevent generation of gas, remove the paint from
the location of the weld.
• If hydraulic equipment, piping or places close to them
are heated, a flammable gas or mist will be generated
and there is danger of it catching fire. To avoid this,
never subject these places to heat.
• Do not weld on pipes or on tubes that contain
flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you weld
on pipes or on tubes or before you flame cut on pipes
or on tubes, clean the pipes or tubes thoroughly with
a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping
under pressure, they may suddenly break so cover
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire
extinguisher.
Treatment for Electrical Welding to the Body Structure
To prevent damage to ECU by electrical welding, please
observe the following procedures:
1. Open the door of the battery cover.
2. Detach the cover after loosening the bolts on the battery.
3. Detach the positive and negative terminal cables from the
battery.
4. Detach the undercover, and after that detach the connector
(1) from the ECU that are installed at the engine. FG000312
Figure 35
5. Proceed with welding.
Wheel Excavator Safety SP000956
Page 35
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Two-Piece Boom
A
I
E
B
D
H
G
F
L J
FG008700
Figure 3
Dimension
Referance Description 5.36 m (17' 7") Two-Piece Boom
2.3 m (7' 7") Arm 2.6 m (8' 6") Arm
A Shipping Length 8,860 mm 29' 1" 8,610 mm 28' 3"
B Shipping Width 2,496 mm 8' 2" 2,496 mm 8' 2"
C Shipping Height (Boom) 3,140 mm 10' 4" 3,360 mm 11'
D Height Over Cab 3,135 mm 10' 3" 3,135 mm 10' 3"
Counter Weight Swing
E 2,450 mm 8' 2,450 mm 8'
Clearance
F Ground Clearance 350 mm 1' 1" 350 mm 1' 1"
CounterWeight
G 1,249 mm 4' 1" 1,249 mm 4' 1"
Clearance
H Engine Cover Height 2,530 mm 8' 3" 2,530 mm 8' 3"
I Upper Housing Width 2,494 mm 8' 2" 2,494 mm 8' 2"
J Wheel Base 2,700 mm 8' 10" 2,700 mm 8' 10"
K,L Tread Width 1,944 mm 6' 5" 1,944 mm 6' 5"
Specification for DX190W SP001143
Page 11
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ENGINE PERFORMANCE
CURVES (PER DIN 6271
STANDARD)
70
TORQUE (kg.m)
60
150
POWER OUTPUT (ps)
100
FUEL CONSUMPTION (g/ps.h)
50
160
150
140
1000 1500 2000
REVOLUTION (rpm)
FG009226
Figure 8
Specification for DX190W SP001143
Page 22
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MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other type of maintenance service or repair is being
performed.
NOTE: If the unit is being used in an extreme temperature
environment (in sub-freezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should 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
filter elements 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 as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
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 the 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.
General Maintenance Procedures SP000016
Page 10
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SP000813
STANDARD TORQUESSP000813
Standard
Torques
Edition 1
Standard Torques SP000813
Page 1
--- Page 13 ---
TORQUE VALUES FOR SPLIT
FLANGES
The following chart provides the tightening torques for split
flange connections used in hydraulic systems. Split flanges and
fitting shoulders should fit squarely. Install all bolts, finger tight
and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or
bolts, which may cause leakage.
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(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.
Standard Torques SP000813
Page 12
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Table of Contents
Cabin
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Removal ............................................................... 7
Installation .......................................................... 10
Cabin SP001231
Page 3
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MEMO
Counterweight SP001145
Page 2
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Table of Contents
Fuel Tank
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Parts List ......................................................................... 6
Specifications .................................................................. 7
Removal ............................................................... 8
Installation .......................................................... 12
Start-up Procedures ........................................... 15
Fuel Tank SP001146
Page 3
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10. Connect as tagged, fuel supply line (21, Figure 20) and fuel
return line (19) to fuel tank (1). 1
11. Install clamp (20, Figure 20) to hold fuel return line (19) to
tank (1).
19
20
21
FG007184
Figure 20
12. Make sure fuel tank drain valve (6, Figure 21) on bottom of
tank is closed.
13. Fill fuel tank and check for signs of leaks. Correct any
problems found.
14. Connect negative (-) battery cable to battery.
6
FG007183
Figure 21
Fuel Tank SP001146
Page 14
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Insert vane, with the circled edge of vane facing in the
counterclockwise direction. (Detail A)
IN OUT
Insert a new O-ring during reassembly of pump cover.
A
FG003883
Figure 6
REPLACEMENT OF REAR
COVER
Brush assembly and a thermal limiter are installed in the rear
cover. If you find any damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95) from the rear
cover.
Remove cover.
At reassembly of rear cover, widen the space of the brush and
insert it to the armature. Then fit the hole of screw in the Figure 7
housing.
Be careful when installing the screw. The cover screw may be
attracted by the motor magnet.
REPLACEMENT OF ARMATURE
Rear Cover
Pump Side
You can replace only the armature in case motor was damaged Side
by a short circuit.
Remove the switch cover and rear cover, than remove the
armature from the housing.
Remove the pump cover and remove the rotor and vane.
Insert a new armature into the housing. Commutator
Refer to “Replacement of Rear Cover” on page 1-9, for FG001146
installation of the rear cover. Figure 8
Fit the rotor into the shaft flute of the armature. Insert vane to the
rotor being careful of the direction. Refer to “Replacement of
Rotor and Vane” on page 1-8.
Fuel Transfer Pump SP000021
Page 9
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Swing Bearing SP001253
Page 10
--- Page 20 ---
REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
WARNING
WARNING!
DON’T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE
FG007179
If engine must be running while performing Figure 2
maintenance, always use extreme caution. Always
have one person in cab at all times. Never leave cab
with engine running.
6. Fully stroke work levers (joysticks) in all directions to
relieve any pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang a maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from
battery.
11. Tag and disconnect hoses from swing motor (1, Figure 3).
Plug and cap hoses and ports to prevent contamination 1
from entering hydraulic system or component.
12. Assemble drain hose (3, Figure 3) to drain valve (8) and
drain oil from reduction gearbox (5, Figure 3).
13. Remove drain hose (3, Figure 3) from drain valve (8) and
disconnect hose (2, Figure 3) from reduction gearbox (5). 4
5
14. Disconnect grease lubrication line (7, Figure 3) from
reduction gearbox (5). 6 8
2
15. Remove eleven bolts and washers (4, Figure 3) holding
swing reduction gearbox (5) to frame.
16. Using a suitable lifting device, sling swing motor (1, Figure
3) and remove swing motor and reduction gearbox (5) as 3
an assembly from unit. 7
FG007055
NOTE: There is a alignment pin (6, Figure 3), on
reduction gearbox flange. Figure 3
Swing Reduction Gear SP001233
Page 11
--- Page 21 ---
Figure 33
3. Put the jig, while keeping the pin assembly 1
perpendicular, and push it with a press.
4. After its pressure insert, check the state of the pressure
insert visually.
Figure 34
5. Insert the 2 remaining parts with pressure in the same way.
Figure 35
Swing Reduction Gear SP001233
Page 22
--- Page 22 ---
Assembly of Ring Gear
1. Insertion of lock pin.
Insert four lock pins in four reamed holes of case flange.
Tap them into place, by gently hitting them with a soft-face
hammer.
FG000936
Figure 75
FG000937
Figure 76
2. Apply liquid gasket (Three Bond #1104) evenly to ring gear
assembly of casing.
FG000938
Figure 77
3. Lift ring gear with hoist, wipe its mating surface clean with
Aim at holes.
cloth, match and align holes after checking its assembling
direction, and press assembled parts firmly by tightening
special bolts (M12x150) on which no Loctite has been
applied.
FG001353
Figure 78
Swing Reduction Gear SP001233
Page 33
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Swing Reduction Gear SP001233
Page 44
--- Page 24 ---
Assembly and Disassembly of Chocking
Valve
1. Assemble the main poppet, the pilot poppet, the spring and
the spring seat in order. Insert the sub-assembly to the
block and fasten the hexa-head plug.
Hexa-head (41 mm) plug fastening torque : 7.0 kg•m
Figure 3
2. Insert each of the two plungers to each of the holes of the
block.
Figure 4
3. Mount the O-rings to the block and fasten the plate with
bolts.
A. O-ring: 1B-P24
B. Wrench bolt (5 mm) fastening torque : 1.2 kg•m
Figure 5
NOTE: Follow the reverse procedure for disassembly.
Ram Lock Valve SP000923
Page 9
--- Page 25 ---
2. Assemble the spool ass'y to the body.
A. Insert the assembly to the hole of the C port direction.
B. Insert the spool ass'y to the spool hole of the body
precisely and be careful not to allow intrusion of
foreign material. Do not apply excessive force for
assembly.
Figure 5
3. Assemble the return spring #1 and #2 to the body, insert
the O-ring into the cover #1 and fasten the cover to the
body with bolts.
A. Fastening O-RING: 1B-P41
B. Bolt Fastening Torque : 0.8 kg•m - 1.2 kg•m
Figure 6
Figure 7
4. Insert the O-ring into the cover #2 for the opposite side and
fasten the cover #2 to the body with bolts.
A. Bolt Fastening Torque : 0.8 kg•m - 1.2 kg•m
Figure 8
NOTE: Follow the reverse procedure for disassembly.
Selector Valve SP000926
Page 10
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OPERATIONAL PRINCIPLE
Figure 3
A → C, D → B
The pressured oil, flowed in through the A port, is to be flowed
out to the C port through oil passage of the side of the nipple (3)
while pressing the poppet (7) and the sleeve (8) simultaneously.
The pressure of the hydraulic oil, flowed in through the A port,
pushes the plunger (2) of the center to the left side. And if the
pressure is greater than the spring (10) force, the poppet is to be
pushed back to make a gap between the sleeve (8) and the
plunger (2) and it discharges the hydraulic oil, flowed in from the
D port, to the B port.
B → D, C → A
The same principle of 3.1 is to be applied to case of the
hydraulic oil, flowed in through the port B.
Double Pilot Check Valve SP000927
Page 9
--- Page 27 ---
Solenoid Valve SP000928
Page 6
--- Page 28 ---
Table of Contents
Front Axle
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Examples of Gear-Tooth-Contact Patterns
for the Gleason Gear-Tooth System ............................... 7
Lubrication and Maintenance Specifications for
Axle MS-E 3050/3060/3070................................ 10
Brake Wear Measurement on Axles of
MT/MS-E 3050/3060/3070 Range ...................... 13
Disassembly ....................................................... 15
Steering ......................................................................... 15
Output............................................................................ 19
Differential - Input .......................................................... 27
Pivot Bearing ................................................................. 32
Reassembly ........................................................ 33
Input .............................................................................. 33
Input Flange .................................................................. 45
Output............................................................................ 46
Pivot Bearing ................................................................. 65
Steering ......................................................................... 66
Oil Drain-Oil Filler and Oil Control Plugs and
Grease Lubrication Points ............................................. 75
Front Axle SP000929
Page 3
--- Page 29 ---
X
FG002282
Figure 12
Lining Wear Measurement of Multi-disc Brake
With unapplied brake, piston is in contact with ring gear by
compression spring return. see Figure 11
• 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 12) by means of dial indicator
• Take limit value of piston stroke (at max. wear) from
the chart below
Limit value of piston stroke (X) at
Axle type Lined discs Piston stroke with new discs
max. wear
MT-E 3050 8 pcs. 1.2 ... 1.8 mm 7.0 mm
MT-E 3060 6 pcs. 0.7 ... 1.3 mm 6.0 mm
MT-E 3070 7 pcs. 0.7 ... 1.3 mm 6.5 mm
MS-E 3050 8 pcs. 1.2 ... 1.8 mm 7.0 mm
MS-E 3060 6 pcs. 1.2 ... 1.8 mm 6.0 mm
MS-E 3070 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.
Tightening torque(M36x1.5) ....................................MA = 50 N•m
Front Axle SP000929
Page 14
--- Page 30 ---
3. Secure knuckle housing by means of lifting device and
dismantle lower bearing pin.
CAUTION!
Pay attention to releasing shim.
Figure 51
4. Remove bearing inner ring (7), O-ring (5), sealing cap (6)
and brake connection screw neck (8) from bearing pin (1).
Figure 52
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 53
6. Pull out double u-joint shaft from knuckle housing.
WARNING!
Pay attention to seal ring in the axle housing - risk of
damage
Figure 54
Front Axle SP000929
Page 25
--- Page 31 ---
2. Insert the preas sembled drive pinion, mount the heated
bearing inner ring until contact is obtained.
Figure 88
3. Mount flange, fix with washer and hex. nut.
Tightening torque (M27x1.5) ........................MA = 600 N•m
Figure 89
4. Check rolling moment of pinion bearing.
Bearing rolling moment (without seal ring) 1.0 ~ 2.0 N•m
Try to achieve upper value.
CAUTION!
If the rolling moment differs from the required value,
correct it with a suitable spacer ring (See Figure 21 on
page -17).
Figure 90
CAUTION!
Reassemble seal ring - as shown in page -45~74 (after
completed differential assembly and positive contact
pattern check).
Front Axle SP000929
Page 36
--- Page 32 ---
Pre-assemble Axle Housim
1. Legend on Figure 124 ~ Figure 128
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 124
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 125
Detailed sketch - 90° offset: