Daewoo doosan dx190 w excavator service repair manual (serial number 5001 and up)
- 1. K1024513AE Shop Manual Copyright 2007 DOOSAN DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Shop Manual K1024513AE Serial Number 5001 and Up DX190W
- 2. Table of Contents Page I 1Table of Contents Safety Wheel Excavator Safety ....................................................................... SP000956 Specifications Specification for DX190W..................................................................... SP001143 General Maintenance General Maintenance Procedures........................................................ SP000016 Standard Torques................................................................................. SP000813 Upper Structure Cabin .................................................................................................... SP001231 Counterweight....................................................................................... SP001145 Fuel Tank.............................................................................................. SP001146 Fuel Transfer Pump.............................................................................. SP000021 Swing Bearing....................................................................................... SP001253 Swing Reduction Gear.......................................................................... SP001233 Lower Structure and Chassis Ram Lock Valve.................................................................................... SP000923 Selector Valve....................................................................................... SP000926 Double Pilot Check Valve ..................................................................... SP000927 Solenoid Valve...................................................................................... SP000928 Front Axle ............................................................................................. SP000929 Rear Axle.............................................................................................. SP000930 Engine and Drive Train Transmission ........................................................................................ SP000962 Drive Coupling (Main Pump)................................................................. SP000963
- 3. Table of Contents Page II Hydraulics Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001149 Accumulator.......................................................................................... SP000984 Center Joint (Swivel)............................................................................. SP000919 Cylinders............................................................................................... SP001098 Main Control Valve ............................................................................... SP000966 Swing Motor.......................................................................................... SP000985 Travel Motor.......................................................................................... SP001110 Counterbalance Valve .......................................................................... SP000991 Main Pump & PTO................................................................................ SP000988 Gear Pump ........................................................................................... SP000989 Service Brake Supply Valve ................................................................. SP000990 Dozer Control Valve.............................................................................. SP000992 Steering Valve ...................................................................................... SP000993 Accelerator Pedal Valve (Hydraulic)..................................................... SP000964 One Spool Valve................................................................................... SP000996 Remote Control Valve (Work Lever / Joystick)..................................... SP000069 Breaker EPPR Valve (Opt) ................................................................... SP000192 Service Brake Pedal Valve ................................................................... SP001006 Solenoid Valve Assembly ..................................................................... SP000997 Hydraulic Schematic............................................................................. SP001160 Electrical System Electrical System .................................................................................. SP000998 Electrical Schematic ............................................................................. SP001161 Attachments Boom and Arm...................................................................................... SP001162 Bucket................................................................................................... SP001001
- 4. SP000956 Page 1 Wheel Excavator Safety SP000956 WHEEL EXCAVATOR SAFETYSP000956 Wheel Excavator Safety Edition 1
- 5. SP000956 Page 5 Wheel Excavator Safety SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DX140W 5001 and Up DX160W 5001 and Up DX190W 5001 and Up DX210W 5001 and Up
- 6. SP000956Wheel Excavator Safety Page 6 TO THE OPERATOR OF A DOOSAN EXCAVATOR Please respect the importance of taking responsibility for your own safety, and that of other people who may be affected by your actions. The safety information on the following pages is organized into the following sections: 1. “General Safety Essentials” on page 1-10 2. “Location of Safety Labels” on page 1-11 3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 1-12 4. “Unauthorized Modifications” on page 1-13 5. “General Hazard Information” on page 1-13 6. “Before Starting Engine” on page 1-22 7. “Machine Operation” on page 1-26 8. “Maintenance” on page 1-32 9. “Battery” on page 1-40 10. “Towing” on page 1-42 11. “Shipping and Transportation” on page 1-43 DANGER! Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
- 7. SP000956 Page 7 Wheel Excavator Safety WARNING! Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator's seat, and have all personnel involved in working on the machine read the manual periodically. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult DOOSAN or your DOOSAN distributor before operating the machine.
- 8. SP000956Wheel Excavator Safety Page 8 Learn the Signal Words Used with the Safety Alert Symbol The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next to the "Exclamation Point" symbol. SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures. CAUTION! This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice. WARNING! This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice. DANGER! This word is used on safety messages and safety labels and indicates an imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may explode or detonate if handled or treated carelessly.
- 9. SP000956 Page 9 Wheel Excavator Safety Safety precautions are described in SAFETY from page -11 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact a DOOSAN distributor.
- 10. SP001231 Page 5 Cabin SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DX140W 5001 and Up DX160W 5001 and Up DX190W 5001 and Up DX210W 5001 and Up
- 11. SP001231 Page 7 Cabin REMOVAL 1. Park on firm and level ground. 2. Lower front attachment (bucket) to ground. 3. Shut down engine. 4. Set safety lever and stand on "RELEASED" position. 5. Turn starter switch to "I" (ON) position. 6. Fully stroke work levers (joysticks) in all directions to relieve pressure from accumulators. 7. Set safety lever and stand on "LOCK" position. 8. Set paking brake swich to the "I" position 9. Apply the service brake with full stroke several time to relieve pressure from accumulator functioning braking. 10. Turn key to "O" (OFF) position and remove from starter switch. 11. Hang maintenance warning tag on controls. 12. Disconnect the battery cable from the negative (-) battery terminal. 13. Prepare cabin shell for removal by disconnecting wiring connectors for: A. Cabin interior lighting. B. External light wiring. C. Radio antenna and connections. D. Wiper/washer connections. 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 unit is equipped with a cabin protective structure (for forestry, or hazardous working conditions), it must be removed. CAUTION! Avoid disassembling cabin if there are strong wind gusts, which could catch large surface area of cabin shell and push it sideways during lift. WARNING DON’T TOUCH WHEN PERFORMING INSPECTION OR MAINTENANCE FG007179 IO Figure 1 WARNING! If engine must be run while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the engine running.
- 12. SP001231Cabin Page 8 14. Remove floor mat (1, Figure 2) 15. Remove seat (2, Figure 2). NOTE: Be careful not to damage seat covering. 16. Remove cup holder (3, Figure 2). Remove front cover (4, Figure 2) and side covers (5 and 6, Figure 2). Before removing front cover(4), disconnect hour meter connector. NOTE: Don't remove monitor panel (7, Figure 2) and switch panel (8, Figure 2) 17. After removing rear mat (1, Figure 3), remove rear center cover (2. Figure 3), cassette cover (3) and rear side covers (4 and 5, Figure 3) 18. Remove fuse box bracket (1, Figure 4) from left side wall without disassembly harness connector. 19. Disconnect cabin ground cable near fuse box bracket. 20. Remove cassette bracket (2, Figure 4) and disconnet antenna and speaker wire. 21. Remove electric box (4, Figure 4) without disassembly harness connectors. 1 4 6 7 3 5 8 2 FG009223 Figure 2 Figure 3 Figure 4
- 13. SP001231 Page 9 Cabin 22. Remove air ducts (1,2,3 and 4, Figure 5) from cabin rear panel. 23. Remove across bar (5, Figure 5) between left and right side of cabin. 24. Remove air ducts (1,2,3 and 4, Figure 6) at the right side of cabin sequently from the front duct. 25. Disconnect washer hose at floor plate bottom. 26. Disconnect cabin wiring connectors from main harness. 27. Remove four mounting nuts from four corners of cabin floor (1, Figure 7). 28. Remove four M12 hex bolts(2, Figure 7) and two M10 hex bolts (3, Figure 7). Figure 5 Figure 6 Figure 7
- 14. SP001231Cabin Page 10 29. Using a suitable lifting device, attatch slings to four lift points on top of cab (Figure 8). NOTE: Cabin weight is approximately 315kg (700lb). 30. Lift cab from 25 ~50mm (1" ~2") above deck height. Check that all electrical connections have been disconnected and all other items unbolted. 31. Continue lifting with the assist crane to remove the cabin shell. Lower the shell to a prepared safe blocking support. INSTALLATION Install in reverse order of removal. 1. Install four mounting nuts from four corners of cabin floor (1, Figure 9) • Mounting nut torque 21kg•m (205N.m, 150 lbf-ft) 2. Install four M12 hex bolts (2, Figure 9) • Mounting bolt torque 11kg•m (108 N.m, 80 lbf-ft) 3. Install four M10 hex bolts (3, Figure 9) • Mounting bolt torque 6.5kg•m (64 N.m, 47 lbf-ft) 4. Connect cabin wiring connectors from main harness. 5. Connect washer hose at floor plate bottom. 6. Install air ducts (1,2,3 and 4, Figure 10) at the right side of cabin sequently from the front duct. Figure 8 Figure 9 Figure 10
- 15. SP001231 Page 11 Cabin 7. Install cross bar (5, Figure 11) between left and right side of cabin. 8. Install air ducts (1,2,3 and 4, Figure 11) to cabin rear panel. 9. Install electric box (4, Figure 12). 10. Install cassette bracket (2, Figure 12) and connect antenna and speaker wire. 11. Connect cabin ground cable located near fuse box bracket. 12. Install fuse box bracket (1, Figure 12) from left side wall. 13. Install rear side covers (4 and 5, Figure 13) and install cassette cover (3, Figure 13). 14. Install rear center cover (2, Figure 13) and install rear mat (1, Figure 13) sequently. Figure 11 Figure 12 Figure 13
- 16. SP001231Cabin Page 12 15. Install front cover (4, Figure 14) and side covers (5 and 6, Figure 14). Before installing front cover (4), connect hour meter connector. 16. Install cup holder (3, Figure 14). 17. Install seat (2, Figure 14) on the seat plate. NOTE: Be careful not to damage seat covering. 18. Install floor mat (1, Figure 14). 1 4 6 7 3 5 8 2 FG009223 Figure 14
- 17. SP001145Counterweight Page 6 GENERAL Warning for Counterweight and Front Attachment Removal 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. Responsibility should 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. FG007176 Figure 1 DANGER! DOOSAN warns any user, that the 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. DOOSAN is not liable for any misuse. Never remove the 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. 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. Model Weight of Counterweight DX190W 3,200 kg (7,054 lb)
- 18. SP001145 Page 7 Counterweight To maintain stability the counterweight should be removed whenever the front attachment is taken off the machine. 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. The counterweight end of the deck has to get on the trailer first, while the cabin is still going up the ramp (Figure 2). WARNING! If the turntable deck has been unbalanced by removal of weight from one end only, traveling the excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could cause loss of control and possible accidents or injuries. FG00717715 90 ~ 110 Figure 2 FG007178 15 Figure 3
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- 20. SP001145Counterweight Page 8 REMOVAL 1. Park on firm and level ground. 2. Lower front attachment (bucket) to the ground. 3. Shut down engine. 4. Set safety lever on "RELEASED" position. 5. Turn starter switch to "I" (ON) position. 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 maintenance warning tag on controls. 10. Disconnect the battery cable from the negative (-) battery terminal. 11. Remove engine compartment cover. WARNING DON’T TOUCH WHEN PERFORMING INSPECTION OR MAINTENANCE FG007179 IO Figure 4 WARNING! If engine must be run while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the engine running.
- 21. SP001145 Page 9 Counterweight 12. Remove two caps (1, Figure 5) from counterweight (2). 13. Install two lifting eyes in lifting holes (3, Figure 5). 14. Using a suitable lifting device capable of handling a heavy load, partially support counterweight (2, Figure 5) before loosening four bolts (4). Stop lifting with assist crane as soon as lifting slings are taut. 15. Remove four bolts (4, Figure 5) and washers (5) from counterweight (2). NOTE: Heat bolts if necessary, to free them. 16. When bolts (4, Figure 5) and washers (5) have been removed, lift counterweight (2) a very short distance above support frame (6) and stop. Check slings and make sure counterweight is being supported evenly. 3 3 4 5 6 2 1 FG007180 Figure 5 Model Lifting Eye Size DX190W M36 x 4.0
- 22. SP001145Counterweight Page 10 INSTALLATION 1. Using suitable lifting device capable of handling a heavy load, raise counterweight (2, Figure 6) into position just above support frame (6) leaving counterweight suspended. Verify that counterweight is level and even. NOTE: Leave counterweight (2, Figure 6) suspended 3 mm (0.125") above support frame (6) until all four mounting bolts (4) are started in counterweight mounting holes. 2. Slide washers (5, Figure 6) onto bolts (4). Apply Loctite #242 to mounting bolt threads. 3. Install four bolts (4, Figure 6) with washers (5) into counterweight until washers contact support frame. Fully lower counterweight onto support frame and finish tightening bolts. NOTE: Torque bolts (4, Figure 6) to values shown in following table. 4. Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 6). 5. Install two caps (1, Figure 6) in lifting holes (3). 6. Install engine compartment cover. 7. Connect negative (-) battery cable to battery. Figure 6 3 3 4 5 6 2 1 FG007180 Model Bolt Torque DX190W 140 kg•m (1,012 ft lb)