John Deere Wheeled Excavator 190DW Repair Technical Service Manual (TM10543)
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.
TM10543 - John Deere 190DW Wheeled Excavator Technical Manual - Repair.pdf
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
Section 00: General Information....12
Group 0001: Safety....12
Recognize Safety Information....15
Follow Safety Instructions....16
Operate Only If Qualified....17
Wear Protective Equipment....18
Avoid Unauthorized Machine Modifications....19
Add Cab Guarding for Special Uses....20
Inspect Machine....21
Stay Clear of Moving Parts....22
Avoid High-Pressure Fluids....23
Avoid High-Pressure Oils....24
Beware of Exhaust Fumes....25
Prevent Fires....26
Prevent Battery Explosions....27
Handle Chemical Products Safely....28
Dispose of Waste Properly....29
Prepare for Emergencies....30
Use Steps and Handholds Correctly....31
Start Only From Operator's Seat....32
Use and Maintain Seat Belt....33
Prevent Unintended Machine Movement....34
Avoid Work Site Hazards....35
Keep Riders Off Machine....37
Avoid Backover Accidents....38
Avoid Machine Tip Over....39
Use Special Care When Lifting Objects....40
Add and Operate Attachments Safely....41
Park and Prepare for Service Safely....42
Service Cooling System Safely....43
Remove Paint Before Welding or Heating....44
Service Tires Safely....45
Make Welding Repairs Safely....46
Drive Metal Pins Safely....47
Group 0003: Torque Values....13
Metric Bolt and Cap Screw Torque Values....50
Additional Metric Cap Screw Torque Values....52
Unified Inch Bolt and Cap Screw Torque Values....54
Service Recommendations for 37° Flare and 30° Cone Seat Connectors....56
Service Recommendations for O-Ring Boss Fittings....58
O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators....60
Service Recommendations for Flared Connections—Straight or Tapered Threads....63
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations....65
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations....67
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations....70
Service Recommendations for Metric Series Four Bolt Flange Fitting....73
Service Recommendations For Inch Series Four Bolt Flange Fittings....75
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations....77
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings....79
Service Recommendations For O-Ring Boss Fittings With Shoulder....82
Metric 24° O-Ring Seal DIN 20078 Service Recommendations....85
Section 01: Wheels....89
Group 0110: Wheels and Fasteners....89
Wheel Remove and Install....94
Tire Remove and Install....98
Section 02: Axles, Differentials, and Suspension Systems....101
Group 0201: Drive Axle Housing and Support....101
Front Axle Remove and Install....107
Front Axle Disassemble and Assemble....112
Front Axle Adjustment....128
Rear Axle Remove and Install....129
Rear Axle Disassemble and Assemble....135
Group 0210: Differential or Bevel Drive....101
Differential Disassemble and Assemble....154
Check Gear Tooth Contact Pattern....161
Group 0250: Axle Shaft, Bearings, and Reduction Gears....101
Front Axle Planetary Drive Remove and Install....174
Front Axle Planetary Drive Disassemble and Assemble....183
Rear Axle Planetary Drive Remove and Install....191
Rear Axle Planetary Drive Disassemble and Assemble....196
Group 0260: Axles, Differentials, and Suspension Systems Hydraulics....101
Axle Lock Cylinder Remove and Install....976
Axle Lock Cylinder Disassemble and Assemble....979
Axle Lock Cylinder Check Valve Remove and Install....981
Axle Lock Cylinder Check Valve Disassemble and Assemble....983
Section 03: Transmision....210
Group 0300: Removal and Installation....210
Drive Shaft Remove and Install....214
Transmission Remove and Install....217
Group 0350: Gear, Shafts, and Power Shift Clutches....210
Drive Shaft Disassemble and Assemble....223
Transmission Disassemble....227
Transmission Assemble....249
Group 0360: Hydraulic System....210
Travel Motor Remove and Install....299
Travel Motor Start-Up Procedure....303
Travel Motor Counterbalance Valve Remove and Install....305
Travel Motor Counterbalance Valve Disassemble and Assemble....307
Travel Pilot Valve Remove and Install....314
Travel Pilot Valve Disassemble and Assemble....315
Transmission Control Valve Remove and Install....875
Travel Shockless Valve Remove and Install....318
Travel Shockless Valve Disassemble and Assemble....320
Transmission Shift Interlock Remove and Install....322
Transmission Shift Interlock Disassemble and Assemble....324
Section 04: Engine....336
Group 0400: Removal and Installation....336
Engine Remove and Install....350
Turbocharger Remove and Install....362
Turbocharger Inspection....364
Exhaust Manifold Remove and Install....365
Valve Cover Remove and Install....367
Lower Valve Cover Remove and Install....369
Rocker Arm Shaft Assembly Remove and Install....370
Rocker Arm Shaft Assembly Disassemble and Assemble....372
Rocker Arm Shaft Assembly Inspection....374
Intake Manifold Remove and Install....377
Reed Valve Remove and Install....379
Coolant Pump Remove and Install....381
Coolant Pump Inspection....383
Cylinder Head Remove and Install....384
Cylinder Head Disassemble and Assemble....391
Cylinder Head Inspection....403
Front Cover Remove and Install....408
Cylinder Block Disassemble and Assemble....415
Cylinder Block Inspection....421
Camshaft Remove and Install....425
Camshaft Disassemble and Assemble....428
Camshaft Inspection....430
Flywheel Remove and Install....433
Flywheel Disassemble and Assemble....437
Flywheel Housing Remove and Install....439
Timing Gear Train Remove and Install....444
Engine Oil Pan Remove and Install....451
Crankshaft Remove and Install....454
Crankshaft Disassemble and Assemble....461
Crankshaft Inspection....464
Piston and Connecting Rod Remove and Install....469
Piston and Connecting Rod Disassemble and Assemble....472
Piston and Connecting Rod Inspection....475
Engine Oil Pump Remove and Install....482
Engine Oil Pump Disassemble and Assemble....486
Engine Oil Pump Inspection....488
Engine Oil Cooler Remove and Install....491
Engine Oil Cooler Disassemble and Assemble....495
Thermostat Housing Remove and Install....496
Thermostat Remove and Install....498
Thermostat Inspection....501
Exhaust Gas Recirculation (EGR) Cooler Remove and Install....503
High Pressure Fuel Pump Remove and Install....505
High Pressure Fuel Pump Disassemble and Assemble....511
High Pressure Fuel Rail Remove and Install....513
Fuel Injection Nozzle Remove and Install....515
Starter Remove and Install....517
Alternator Remove and Install....519
Section 05: Engine Auxiliary System....521
Group 0510: Cooling System....521
Radiator Remove and Install....525
Hydraulic Oil Cooler Remove and Install....528
Intercooler Remove and Install....531
Fuel Cooler Remove and Install....534
Fan, Fan Guard, and Fan Shroud Remove and Install....535
Coolant Recovery Tank Remove and Install....538
Group 0520: Intake System....521
Air Cleaner Remove and Install....540
Group 0560: External Fuel Supply System....521
Fuel Tank Remove and Install....545
Primary Fuel Filter (Water Separator) Remove and Install....549
Final Fuel Filter Remove and Install....550
Section 07: Dampener Drive (Flex Coupling)....551
Group 0752: Elements....551
Damper Drive (Flex Coupling) Remove and Install....554
Section 09: Steering System....556
Group 0900: Removal and Installation....556
Steering Wheel Remove and Install....559
Steering Column Remove and Install....561
Steering Valve Remove and Install....566
Group 0960: Steering Hydraulic System....556
Steering Cylinder Disassemble and Assemble....583
Section 10: Service Brakes....594
Group 1011: Service Brake Active Elements....594
Front Axle Brake Disassemble and Assemble....611
Rear Axle Brake Disassemble and Assemble....627
Group 1060: Service Brakes Hydraulic System....594
Brake Valve Remove and Install....646
Brake Valve Disassemble and Assemble....650
Brake Accumulator Remove and Install....654
Brake Accumulator Charge Valve Remove and Install....658
Brake Accumulator Charge Valve Disassemble and Assemble....662
Section 17: Frame or Supporting Structure....665
Group 1740: Frame Installation....665
Welding On Machine....667
Welding Repair of Major Structure....668
Group 1749: Chassis Weights....665
Counterweight Remove and Install....675
Section 18: Operator's Station....680
Group 1800: Removal and Install....680
Cab Remove and Install....689
Group 1810: Operator Enclosure....680
Sliding Windows Remove and Install....699
Windowpanes Remove and Install....701
Windowpanes Dimensions....702
Group 1821: Seat and Seat Belt....680
Seat Remove and Install....708
Seat Belt Remove and Install....710
Mechanical Suspension Seat Disassemble and Assemble....712
Air Suspension Seat Disassemble and Assemble—If Equipped....714
Left and Right Console Covers Remove and Install....716
Group 1830: Heating and Air Conditioning....680
Refrigerant Cautions and Proper Handling....723
Flush and Purge Air Conditioner System....724
R134a Refrigerant Oil Information....728
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure....730
Recover R134a Refrigerant....732
Evacuate R134a System....733
Charge R134a System....735
Compressor Remove and Install....736
Condenser Remove and Install....738
Heater and Air Conditioner Remove and Install....740
Receiver-Dryer Remove and Install....751
Section 33: Excavator....753
Group 3302: Buckets....753
Bucket Remove and Install....758
Bucket Pin-Up Data....760
Group 3340: Frames....753
Bucket Links Remove and Install....764
Arm Remove and Install....766
Monoblock Boom Remove and Install....774
Two Piece Boom Upper Section Remove and Install....780
Two Piece Boom Lower Section Remove and Install....785
Inspect Pins, Bushings and Bosses—Front Attachment....788
Bushings and Seal Remove and Install....791
Outrigger Remove and Install....793
Blade Remove and Install....795
Blade Disassemble and Assemble....798
Group 3360: Hydraulic System....753
Apply Vacuum to Hydraulic Oil Tank....803
Hydraulic Oil Cleanup Procedure Using Super Caddy....805
Pump 1 and 2 Remove and Install....807
Pump 1 and 2 Disassemble and Assemble....811
Pump 1 and 2 Inspection....823
Pump 1 and 2 Start-Up Procedure....828
Pump 1 and 2 Regulator Remove and Install....830
Pump 1 and 2 Regulator Disassemble and Assemble....832
Pilot Pump and Steering Pump Remove and Install....835
Pilot Pump and Steering Pump Disassemble and Assemble....837
Pilot Pump Drive Shaft Remove and Install....839
Pilot Pressure Regulating Valve and Filter Remove and Install....841
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble....843
Pilot Control Shut-Off Valve Remove and Install....844
Pilot Control Shut-Off Valve Disassemble and Assemble....846
Solenoid Valve Manifold Remove and Install....848
Solenoid Valve Manifold Disassemble and Assemble....850
Torque Control and Pump Flow Rate Limit Solenoid Valve Remove and Install....852
Swing Park Brake, Assist, Auxiliary, Positioning, and Blade/Outrigger Solenoid Valves Remove and Install....855
Swing Park Brake, Assist, Auxiliary, Positioning, and Blade/Outrigger Solenoid Valves Disassemble and Assemble....857
Pilot Control Valve (Left and Right) Remove and Install....860
Pilot Control Valve (Left and Right) Disassemble and Assemble....862
Travel Pilot Control Valve Remove and Install....875
Travel Pilot Control Valve Disassemble and Assemble....867
Pilot Signal Manifold Remove and Install....869
Pilot Signal Manifold Disassemble and Assemble....871
Control Valve Remove and Install....875
Control Valve Separation....878
Control Valve (5-Spool) Disassemble and Assemble....879
Control Valve (4-Spool) Disassemble and Assemble....898
Hydraulic Oil Tank Remove and Install....915
Hydraulic Oil Tank Disassemble and Assemble....919
Restriction Valve Remove and Install....922
Hydraulic Oil Cooler Bypass Valve Remove and Install....924
Boom Cylinder Remove and Install....927
Boom Cylinder Disassemble and Assemble....931
Positioning Cylinder Remove and Install—If Equipped....934
Positioning Cylinder Disassemble and Assemble—If Equipped....939
Arm Cylinder Remove and Install....944
Arm Cylinder Disassemble and Assemble....948
Bucket Cylinder Remove and Install....952
Bucket Cylinder Disassemble and Assemble....956
Outrigger Cylinder Remove and Install....959
Outrigger Cylinder Disassemble and Assemble....963
Blade Cylinder Remove and Install....968
Blade Cylinder Disassemble and Assemble....971
Axle Lock Cylinder Remove and Install....976
Axle Lock Cylinder Disassemble and Assemble....979
Axle Lock Cylinder Check Valve Remove and Install....981
Axle Lock Cylinder Check Valve Disassemble and Assemble....983
Hydraulic Cylinder Bleed Procedure....985
Section 43: Swing or Pivoting System....986
Group 4350: Mechanical Drive Elements....986
Swing Gearbox Remove and Install....990
Swing Gearbox Disassemble and Assemble....993
Swing Gearbox Start-Up Procedure....1001
Upperstructure Remove and Install....1002
Swing Bearing Remove and Install....1006
Swing Bearing Disassemble and Assemble....1010
Swing Bearing Upper Seal Install....1016
Swing Bearing Lower Seal Install....1017
Group 4360: Hydraulic System....986
Center Joint Remove and Install....1025
Center Joint Disassemble and Assemble....1032
Center Joint Air Test....1035
Swing Motor and Park Brake Remove and Install....1036
Swing Motor and Park Brake Disassemble and Assemble....1039
Swing Motor and Park Brake Inspection....1046
Swing Motor and Park Brake Start-Up Procedure....1050
Crossover Relief Valve and Make-Up Check Valve Remove and Install....1051
Make-Up Check Valve Disassemble and Assemble....1054
Swing Dampener Valve Remove and Install....1056
Swing Dampener Valve Disassemble and Assemble....1058
Swing Park Brake Release Valve Remove and Install....1060
Section 99: Dealer Fabricated Tools....1061
Group 9900: Dealer Fabricated Tools....1061
DFT1119 Pump Support....1063
DFT1144 Guide Pin....1064
DFT1220 Swing Gearbox Nut Spanner Wrench....1065
DFT1265 Axle Support....1066
DFT1266 Transmission Adapter....1067
John Deere Wheeled Excavator 190DW Repair Technical Service Manual (TM10543)
