John Deere Wheeled Excavator 190DW Repair Technical Service Manual (TM10543)

TM10543 - John Deere 190DW Wheeled Excavator Technical Manual - Repair.pdf

Complete Technical repair manual for John Deere 190DW, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere 190DW Excavator workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,373 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Foreword
   General Information
      Safety
      Torque Values
   Wheels
      Wheels and Fasteners
   Axles, Differentials, and Suspension Systems
      Drive Axle Housing and Support
      Differential or Bevel Drive
      Axle Shaft, Bearings, and Reduction Gears
      Axles, Differentials, and Suspension Systems Hydraulics
   Transmision
      Removal and Installation
      Gear, Shafts, and Power Shift Clutches
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary System
      Cooling System
      Intake System
      External Fuel Supply System
   Dampener Drive (Flex Coupling)
      Elements
   Steering System
      Removal and Installation
      Steering Hydraulic System
   Service Brakes
      Service Brake Active Elements
      Service Brakes Hydraulic System
   Frame or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator`s Station
      Removal and Install
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
   Excavator
      Buckets
      Frames
      Hydraulic System
   Swing or Pivoting System
      Mechanical Drive Elements
      Hydraulic System
   Dealer Fabricated Tools
      Dealer Fabricated Tools

tm10543 - 190DW Wheeled Excavator

Table of Contents

Foreword

Section 00: General Information

Group 0001: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Service Tires Safely

Make Welding Repairs Safely

Drive Metal Pins Safely

Group 0003: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

Service Recommendations for Flared Connections—Straight or Tapered Threads

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Wheels

Group 0110: Wheels and Fasteners

Wheel Remove and Install

Tire Remove and Install

Section 02: Axles, Differentials, and Suspension Systems

Group 0201: Drive Axle Housing and Support

Front Axle Remove and Install

Front Axle Disassemble and Assemble

Front Axle Adjustment

Rear Axle Remove and Install

Rear Axle Disassemble and Assemble

Group 0210: Differential or Bevel Drive

Differential Disassemble and Assemble

Check Gear Tooth Contact Pattern

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Front Axle Planetary Drive Remove and Install

Front Axle Planetary Drive Disassemble and Assemble

Rear Axle Planetary Drive Remove and Install

Rear Axle Planetary Drive Disassemble and Assemble

Group 0260: Axles, Differentials, and Suspension Systems Hydraulics

Axle Lock Cylinder Remove and Install

Axle Lock Cylinder Disassemble and Assemble

Axle Lock Cylinder Check Valve Remove and Install

Axle Lock Cylinder Check Valve Disassemble and Assemble

Section 03: Transmision

Group 0300: Removal and Installation

Drive Shaft Remove and Install

Transmission Remove and Install

Group 0350: Gear, Shafts, and Power Shift Clutches

Drive Shaft Disassemble and Assemble

Transmission Disassemble

Transmission Assemble

Group 0360: Hydraulic System

Travel Motor Remove and Install

Travel Motor Start-Up Procedure

Travel Motor Counterbalance Valve Remove and Install

Travel Motor Counterbalance Valve Disassemble and Assemble

Travel Pilot Valve Remove and Install

Travel Pilot Valve Disassemble and Assemble

Transmission Control Valve Remove and Install

Travel Shockless Valve Remove and Install

Travel Shockless Valve Disassemble and Assemble

Transmission Shift Interlock Remove and Install

Transmission Shift Interlock Disassemble and Assemble

Section 04: Engine

Group 0400: Removal and Installation

Engine Remove and Install

Turbocharger Remove and Install

Turbocharger Inspection

Exhaust Manifold Remove and Install

Valve Cover Remove and Install

Lower Valve Cover Remove and Install

Rocker Arm Shaft Assembly Remove and Install

Rocker Arm Shaft Assembly Disassemble and Assemble

Rocker Arm Shaft Assembly Inspection

Intake Manifold Remove and Install

Reed Valve Remove and Install

Coolant Pump Remove and Install

Coolant Pump Inspection

Cylinder Head Remove and Install

Cylinder Head Disassemble and Assemble

Cylinder Head Inspection

Front Cover Remove and Install

Cylinder Block Disassemble and Assemble

Cylinder Block Inspection

Camshaft Remove and Install

Camshaft Disassemble and Assemble

Camshaft Inspection

Flywheel Remove and Install

Flywheel Disassemble and Assemble

Flywheel Housing Remove and Install

Timing Gear Train Remove and Install

Engine Oil Pan Remove and Install

Crankshaft Remove and Install

Crankshaft Disassemble and Assemble

Crankshaft Inspection

Piston and Connecting Rod Remove and Install

Piston and Connecting Rod Disassemble and Assemble

Piston and Connecting Rod Inspection

Engine Oil Pump Remove and Install

Engine Oil Pump Disassemble and Assemble

Engine Oil Pump Inspection

Engine Oil Cooler Remove and Install

Engine Oil Cooler Disassemble and Assemble

Thermostat Housing Remove and Install

Thermostat Remove and Install

Thermostat Inspection

Exhaust Gas Recirculation (EGR) Cooler Remove and Install

High Pressure Fuel Pump Remove and Install

High Pressure Fuel Pump Disassemble and Assemble

High Pressure Fuel Rail Remove and Install

Fuel Injection Nozzle Remove and Install

Starter Remove and Install

Alternator Remove and Install

Section 05: Engine Auxiliary System

Group 0510: Cooling System

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Intercooler Remove and Install

Fuel Cooler Remove and Install

Fan, Fan Guard, and Fan Shroud Remove and Install

Coolant Recovery Tank Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Group 0560: External Fuel Supply System

Fuel Tank Remove and Install

Primary Fuel Filter (Water Separator) Remove and Install

Final Fuel Filter Remove and Install

Section 07: Dampener Drive (Flex Coupling)

Group 0752: Elements

Damper Drive (Flex Coupling) Remove and Install

Section 09: Steering System

Group 0900: Removal and Installation

Steering Wheel Remove and Install

Steering Column Remove and Install

Steering Valve Remove and Install

Group 0960: Steering Hydraulic System

Steering Cylinder Disassemble and Assemble

Section 10: Service Brakes

Group 1011: Service Brake Active Elements

Front Axle Brake Disassemble and Assemble

Rear Axle Brake Disassemble and Assemble

Group 1060: Service Brakes Hydraulic System

Brake Valve Remove and Install

Brake Valve Disassemble and Assemble

Brake Accumulator Remove and Install

Brake Accumulator Charge Valve Remove and Install

Brake Accumulator Charge Valve Disassemble and Assemble

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding On Machine

Welding Repair of Major Structure

Group 1749: Chassis Weights

Counterweight Remove and Install

Section 18: Operator's Station

Group 1800: Removal and Install

Cab Remove and Install

Group 1810: Operator Enclosure

Sliding Windows Remove and Install

Windowpanes Remove and Install

Windowpanes Dimensions

Group 1821: Seat and Seat Belt

Seat Remove and Install

Seat Belt Remove and Install

Mechanical Suspension Seat Disassemble and Assemble

Air Suspension Seat Disassemble and Assemble—If Equipped

Left and Right Console Covers Remove and Install

Group 1830: Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

Flush and Purge Air Conditioner System

R134a Refrigerant Oil Information

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

Recover R134a Refrigerant

Evacuate R134a System

Charge R134a System

Compressor Remove and Install

Condenser Remove and Install

Heater and Air Conditioner Remove and Install

Receiver-Dryer Remove and Install

Section 33: Excavator

Group 3302: Buckets

Bucket Remove and Install

Bucket Pin-Up Data

Group 3340: Frames

Bucket Links Remove and Install

Arm Remove and Install

Monoblock Boom Remove and Install

Two Piece Boom Upper Section Remove and Install

Two Piece Boom Lower Section Remove and Install

Inspect Pins, Bushings and Bosses—Front Attachment

Bushings and Seal Remove and Install

Outrigger Remove and Install

Blade Remove and Install

Blade Disassemble and Assemble

Group 3360: Hydraulic System

Apply Vacuum to Hydraulic Oil Tank

Hydraulic Oil Cleanup Procedure Using Super Caddy

Pump 1 and 2 Remove and Install

Pump 1 and 2 Disassemble and Assemble

Pump 1 and 2 Inspection

Pump 1 and 2 Start-Up Procedure

Pump 1 and 2 Regulator Remove and Install

Pump 1 and 2 Regulator Disassemble and Assemble

Pilot Pump and Steering Pump Remove and Install

Pilot Pump and Steering Pump Disassemble and Assemble

Pilot Pump Drive Shaft Remove and Install

Pilot Pressure Regulating Valve and Filter Remove and Install

Pilot Pressure Regulating Valve and Filter Disassemble and Assemble

Pilot Control Shut-Off Valve Remove and Install

Pilot Control Shut-Off Valve Disassemble and Assemble

Solenoid Valve Manifold Remove and Install

Solenoid Valve Manifold Disassemble and Assemble

Torque Control and Pump Flow Rate Limit Solenoid Valve Remove and Install

Swing Park Brake, Assist, Auxiliary, Positioning, and Blade/Outrigger Solenoid Valves Remove and Install

Swing Park Brake, Assist, Auxiliary, Positioning, and Blade/Outrigger Solenoid Valves Disassemble and Assemble

Pilot Control Valve (Left and Right) Remove and Install

Pilot Control Valve (Left and Right) Disassemble and Assemble

Travel Pilot Control Valve Remove and Install

Travel Pilot Control Valve Disassemble and Assemble

Pilot Signal Manifold Remove and Install

Pilot Signal Manifold Disassemble and Assemble

Control Valve Remove and Install

Control Valve Separation

Control Valve (5-Spool) Disassemble and Assemble

Control Valve (4-Spool) Disassemble and Assemble

Hydraulic Oil Tank Remove and Install

Hydraulic Oil Tank Disassemble and Assemble

Restriction Valve Remove and Install

Hydraulic Oil Cooler Bypass Valve Remove and Install

Boom Cylinder Remove and Install

Boom Cylinder Disassemble and Assemble

Positioning Cylinder Remove and Install—If Equipped

Positioning Cylinder Disassemble and Assemble—If Equipped

Arm Cylinder Remove and Install

Arm Cylinder Disassemble and Assemble

Bucket Cylinder Remove and Install

Bucket Cylinder Disassemble and Assemble

Outrigger Cylinder Remove and Install

Outrigger Cylinder Disassemble and Assemble

Blade Cylinder Remove and Install

Blade Cylinder Disassemble and Assemble

Axle Lock Cylinder Remove and Install

Axle Lock Cylinder Disassemble and Assemble

Axle Lock Cylinder Check Valve Remove and Install

Axle Lock Cylinder Check Valve Disassemble and Assemble

Hydraulic Cylinder Bleed Procedure

Section 43: Swing or Pivoting System

Group 4350: Mechanical Drive Elements

Swing Gearbox Remove and Install

Swing Gearbox Disassemble and Assemble

Swing Gearbox Start-Up Procedure

Upperstructure Remove and Install

Swing Bearing Remove and Install

Swing Bearing Disassemble and Assemble

Swing Bearing Upper Seal Install

Swing Bearing Lower Seal Install

Group 4360: Hydraulic System

Center Joint Remove and Install

Center Joint Disassemble and Assemble

Center Joint Air Test

Swing Motor and Park Brake Remove and Install

Swing Motor and Park Brake Disassemble and Assemble

Swing Motor and Park Brake Inspection

Swing Motor and Park Brake Start-Up Procedure

Crossover Relief Valve and Make-Up Check Valve Remove and Install

Make-Up Check Valve Disassemble and Assemble

Swing Dampener Valve Remove and Install

Swing Dampener Valve Disassemble and Assemble

Swing Park Brake Release Valve Remove and Install

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DFT1119 Pump Support

DFT1144 Guide Pin

DFT1220 Swing Gearbox Nut Spanner Wrench

DFT1265 Axle Support

DFT1266 Transmission Adapter