Part of the Doosan Repair Manuals.
Every one of the 648 pages in this Doosan DX19 Shop Manual PDF (OEM #7278164EN) covers a single machine: your DX19 compact excavator. Inside: step-by-step teardown and reassembly for the boom, arm, swing, bucket, and blade cylinders, plus control valve disassembly, piston and gear pump service, and travel and swing motor repair. You also get a full engine section (cylinder head, crankshaft, camshaft and timing gears), electrical coverage from battery to starter, undercarriage maintenance, and a dedicated specifications chapter. Set the hydraulic pump plug between 30 and 34 N-m, then pull the track roller bolts down to 190 to 210 N-m (140 to 155 ft-lb). Your excavator is dead in the yard and the forums are guessing. Bookmarked chapters and a real text layer let you jump straight to the right spec and get wrenching.
What's Inside This Doosan DX19 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety & Maintenance | 3-88 | Maintenance Safety, Lifting and Blocking the Excavator, Operator Cab |
| Hydraulic System Information and Cylinders (Boom, Arm, Boom Swing) | 89-120 | Hydraulic Symbols, Troubleshooting, Boom Cylinder, Arm Cylinder, Boom Swing Cylinder |
| Cylinders (Bucket, Blade, Track Frame Expansion) and Valves | 121-162 | Bucket Cylinder, Blade Cylinder, Track Frame Expansion Cylinder, Main Relief Valve, Port Relief Valve |
| Hydraulic Control Valve and Hydraulic Pump | 163-254 | Control Valve Disassembly, Control Valve Assembly, Piston Pump, Gear Pump, Torque Adjustment |
| Manifold, Accumulator, Travel Motors, and Swivel Joint | 255-320 | Manifold Assembly, Accumulator, Single Speed Travel Motor, Two Speed Travel Motor, Swivel Joint |
| Swing Motor, Control Levers, and Hydraulic Components | 321-366 | Swing Motor, Joystick Controls, Hydraulic Filter Mount, Hydraulic Reservoir, Oil Cooler |
| Undercarriage | 367-396 | Blade, Track Undercarriage Components, Track Maintenance |
| Upperstructure & Swing | 397-484 | Upperstructure, Cab, Left Console, Engine Speed Control |
| Electrical System | 485-528 | Battery, Alternator, Starter, Lights |
| Engine | 529-604 | Engine Information, Cylinder Head, Crankshaft and Pistons, Camshaft and Timing Gears |
| Heating and Ventilation | 605-620 | Heater System, Regular Maintenance, Heater Unit, Heater Coil |
| Specifications | 621-646 | Excavator Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel filter storage limit | 3 months | p. 49 |
| Hydraulic pump plug torque | 30 - 34 N•m (22 - 25 ft-lb) | p. 60 |
| Nut torque | 1152 N•m (850 ft-lb) | p. 110 |
| Head torque | 373 N•m (275 ft-lb) | p. 110 |
| Track roller bolt torque | 190 - 210 N•m (140 - 155 ft-lb) | p. 380 |
| Drive sprocket bolt torque | 108 N•m (80 ft-lb) | p. 380 |
| Track clearance | 8,3 - 13,5 mm (0.33 - 0.53 in) | p. 374 |
| Rubber track sag | 8 - 13 mm (0.33 - 0.53 in) | p. 375 |
| Terminal clamp nut torque | 7 N•m (5 ft-lb) | p. 494 |
| Electrolyte level | 13 mm (0.50 in) | p. 493 |
| O-ring Face Seal Tightening Torque (1/4" Tubeline) | 18 N•m (13 ft-lb) | p. 635 |
| O-ring Face Seal Tightening Torque (3/8" Tubeline) | 30 N•m (22 ft-lb) | p. 635 |
Doosan DX19 Common Problems This Manual Covers
Doosan DX19 hydraulic system loses power, bucket and arm cycle slow under load
Check hydraulic oil level first; the system holds 19.0 L including the reservoir. Test the main relief valve at the manifold, then test boom and arm cylinders for internal leakage. If the pump is worn, replace it and torque the mounting bolts to 105-115 N•m (78-85 ft-lb) per page 217.
Manual Section: Hydraulic Control Valve and Hydraulic Pump p. 217Engine overheats within an hour in dusty conditions, temperature gauge climbing into the red
Shut down and let the engine cool, then blow compressed air through the radiator core from the fan side to clear silica dust. Drain and refill the cooling system with 3.3 L of fresh coolant if contaminated. Inspect the water pump for shaft play and seal weeping; engine service coverage starts on page 529.
Manual Section: Engine p. 529Starter clicks but the engine won't crank, battery terminals covered in white corrosion
Remove both cables, clean the terminals with a wire brush and baking soda solution, then reinstall and torque the clamp nuts to 7 N•m (5 ft-lb) as shown on page 494. Check electrolyte level; it should sit 13 mm above the plates. Load test the battery against its 530 CCA rating and replace if weak.
Manual Section: Electrical System p. 494Rubber tracks derail on side slopes and tension adjuster bolts keep backing off
Measure track sag midway along the top run and adjust the tensioner until sag falls within 8-13 mm per page 375. Inspect track rollers and idlers for flat spots and wobble. Retorque the track roller bolts to 190-210 N•m (140-155 ft-lb) and add thread locker if they loosened before.
Manual Section: Undercarriage p. 375Hydraulic hoses weep at the fittings after a year, oil misting on the boom
Wipe the fitting dry and trace the leak with a piece of cardboard, never your bare hand. Replace the hose if the crimp is leaking; if the fitting itself weeps, retorque O-ring face seals to spec, 18 N•m for 1/4 inch tubelines and 54 N•m for 1/2 inch, using the chart on page 635.
Manual Section: Specifications p. 635Frequently Asked Questions
What are the torque specifications for the boom pivot bolt on the Doosan DX19?
The boom pivot bolt and nut assembly is secured to the pin boss. After the lock nut is installed, the bolt should be free to spin, and the assembly is not tightened to a specific torque value against the pin boss. p. 75
What is the correct valve clearance for the intake and exhaust valves on the DX19 engine?
The valve clearance for both intake and exhaust valves must be checked and adjusted when the engine is cold. The correct clearance is 0,145 - 0,185 mm (0.0057 - 0.0073 inch). p. 572
What is the engine oil pressure specification at rated rpm for the DX19?
The engine oil pressure at rated rpm should be between 200 and 400 kPa (2 - 4 bar) (28 - 64 psi). If the pressure is less than the allowable limit of 100 kPa (1 bar) (21 psi), you should check for issues such as an insufficient oil level or a defective oil pump. p. 559
What is the correct fuel tank capacity for the DX19?
The fuel tank capacity for the DX19 is 19,0 L (5.0 U.S. gal). p. 629
What is the procedure for checking the track tension on the DX19?
To check track tension, raise the side of the machine approximately 102 mm (4 in) using the boom and arm. Measure the clearance at the middle track roller; the correct track clearance is 8,3 - 13,5 mm (0.33 - 0.53 in). p. 374
What do I get after purchasing this Doosan DX19 manual?
Instant PDF download. You get the full 648-page searchable Shop Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Are there any print restrictions on this Doosan DX19 manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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