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Contents

Engine - 10

Engine and crankcase - 001

TECHNICAL DATA

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine horse power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

48144035_EN 03/07/2017

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Summary of Contents for W190D

Page 1: ...SERVICE MANUAL W190D Stage IV Wheel Loader Part number 48144035 English June 2017 2017 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL 1 2 Part number 48144035 W190D Wheel Loader ...

Page 2: ...SERVICE MANUAL W190D XR EH NEW CAB Tier 4B W190D ZBAR EH NEW CAB Tier 4B 48144035_EN 03 07 2017 EN Find manuals at https best manuals com ...

Page 3: ...roduct Engine Product Market Product Engine W190D ZBAR EH NEW CAB Tier 4B Europe F4HFE613S B004 W190D XR EH NEW CAB Tier 4B Europe F4HFE613S B004 48144035_EN 03 07 2017 Find manuals at https best manuals com ...

Page 4: ... internal components 21 2 21 700 Torque converter 21 3 Four Wheel Drive 4WD system 23 23 314 Drive shaft 23 1 Front axle system 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 108 Final drive hub steering knuckles and shafts 25 3 Rear axle system 27 27 100 Powered rear axle 27 1 27 106 Rear bevel gear set and differential 27 2 27 120 Planetary and final drive...

Page 5: ... coupler hydraulic system 35 9 Frames and ballasting 39 39 100 Frame 39 1 Steering 41 41 101 Steering control 41 1 41 200 Hydraulic control components 41 2 41 216 Cylinders 41 3 41 910 Auxiliary steering 41 4 Wheels 44 44 511 Front wheels 44 1 44 520 Rear wheels 44 2 Cab climate control 50 50 200 Air conditioning 50 1 Electrical systems 55 55 100 Harnesses and connectors 55 1 55 301 Alternator 55 ...

Page 6: ... controls 55 6 55 530 Camera 55 7 55 DTC FAULT CODES 55 8 Front loader and bucket 82 82 100 Arm 82 1 82 300 Bucket 82 2 Platform cab bodywork and decals 90 90 150 Cab 90 1 90 105 Machine shields and guards 90 2 48144035_EN 03 07 2017 Find manuals at https best manuals com ...

Page 7: ...48144035_EN 03 07 2017 Find manuals at https best manuals com ...

Page 8: ...INTRODUCTION 48144035_EN 03 07 2017 1 Find manuals at https best manuals com ...

Page 9: ...use the maintenance standard and precautions 14 Basic instructions Precaution for disassembly and assembly 16 Basic instructions Electrical equipment precautions 18 Consumables 19 Consumables Biodiesel Fuel 20 Hydraulic contamination 21 Product identification 22 Product identification 23 48144035_EN 03 07 2017 2 Find manuals at https best manuals com ...

Page 10: ...CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Machine safety NOTICE Notice indicates a situation that if not avoided could result in machine or property damage Throughout this manual you will find the signal word Notice followed by special instruction...

Page 11: ...rom any other position than the operator s seat TULI12WEX2004AA 1 Never carry out any operation on the machine when the engine is running except when specifically indicated Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps covers valves etc All repair and maintenance operations should be carried out with the greatest care and attention Service st...

Page 12: ...otections Goggles with lateral shield or masks for eye protection Do not wear rings wristwatches jewelry unbuttoned or flapping clothing such as ties torn clothes scarves open jackets or shirts with open zips which could get caught into moving parts TULI12WEX2008AA 4 Engine Radiator Never leave the engine running in enclosed spaces with out proper ventilation which is able to evacuate toxic ex hau...

Page 13: ...e cap while engine is hot wear safety clothes and equipment then loosen the cap slowly to relieve the pressure gradually When checking the fuel oil and coolant levels use lights and lamps explicitly designated as explosion proof If these types of lamps are not used fires or explosions may occur TULI12WEX2011AA 7 Hydraulic systems Jets of fluids under pressure can penetrate the skin caus ing seriou...

Page 14: ...entally be pierced when the heat expands beyond the area immediately heated Arrange for temporary fire resistant shields to protect hoses or other components during welding or torch use Have any visible leakage repaired immediately Discharged oil pollutes the environment Soak up any oil that has spilled with a proper binding agent Sweep up binding agent and dispose of it separately from other wast...

Page 15: ...d outer sheath will allow water penetra tion Concealed corrosion of the wire reinforcement could subsequently occur along the hose length with resultant hose failure Ballooning of the hose indicates an internal leakage due to structural failure This condition rapidly deteriorates and total hose failure soon occurs Kinked crushed stretched or deformed hoses generally suffer internal structural dama...

Page 16: ...id vomiting Drink water to rinse your mouth Consult a doctor EYES Rinse abundantly with water for 15 min and con sult a doctor When the electrolyte of a battery is frozen it can ex plode if you attempt to charge the battery or if you try to start the engine using a booster battery Always keep the battery charged to prevent the electrolyte freezing Provide good ventilation when changing a battery o...

Page 17: ...il or fuel Fuel or oil spills can cause slipping hazards thoroughly contain and clean affected areas Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly Never use fuel to clean machine parts that will be exposed to dirt or debris Use a non flammable product for cleaning parts Always perform fuel or oil refilling in well aired and venti lated areas TULI12WEX2018AA 15 During r...

Page 18: ...y means of an inflation pistol complete with extension and pressure control valve Use an inflation cage TULI12WEX2020AA 17 Cleaning Clean the exterior of all components before carrying out any form of repair Dirt and dust can reduce the efficient working life of a component and lead to costly replace ment Solvents should be checked that they are suitable for the cleaning of components and also tha...

Page 19: ...nd pure an tifreeze Fuel Filter elements oil and fuel filters Filter elements air filters Battery Also polluted rags paper sawdust and gloves must be disposed in compliance with the same procedures Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping int...

Page 20: ...ility for damages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and or components not approved by the manufacturer The informat...

Page 21: ...e at which reconditioning is impossible without replacement of parts If the value is expected to exceed the service limit before next inspection and correction are performed replace the parts immediately The operation over the specified values causes increase of damage and requires the down time of machine and also causes safety problems Cautions to be exercised at judgment EVALUATION OF MEASURED ...

Page 22: ... P and recommend that they should be replaced regularly INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance it is necessary for the user to familiarize themselves with the machine and handle safely Use caution when inspecting and replacing oils and grease Refer to the Operators Manuals as well 48144035_EN 03 07 2017 15 ...

Page 23: ...sassembling and assembling hydraulic equipment Before removing lines release the pressure of hydraulic oil tank or open the cover on the return side to tank and take out the filter Drain the oil in removed lines into an appropriate container to prevent oil contamination Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system Thoroughly clean...

Page 24: ...emoved o rings back up rings and oil seals with new ones Apply gear oil on them before reassembling Thoroughly clean and dry surfaces on which liquid sealant must be reapplied Before assembling remove rust preventives on new parts Use special tools to fit bearings bushing and oil seal Assemble parts matching to the marks After completion check that there is no omission of parts 48144035_EN 03 07 2...

Page 25: ...e equipment with care so as not to drop it or bump it Connector should be removed by unlocking while hold ing the connector Never disconnect electrical plugs by pulling on the wires Always use only the electrical connectors to make the disconnection Check that connector is connected and locked com pletely Engine key off before removing and connecting connec tor Engine key off before touching termi...

Page 26: ...HOLLAND AMBRA MULTI G 134 HYDRAULIC TRANSMISSION OIL Technical specifications SAE 10W 30 API GL 4 ISO VG 32 46 NEW HOLLAND CONSTRUCTION specifications MAT 3525 Service capacity with filter change 34 1 L 36 US qt Axles Type of oil NEW HOLLAND AMBRA TRX 80W 140 Technical specifications SAE 80W 140 API GL 4 NEW HOLLAND CONSTRUCTION specifications MAT 3510 Front axle Standard and Heavy Duty 40 L 42 3 ...

Page 27: ... and may cause shortened filter life or filter blockages Blockages are more common in cold weather conditions Consult your dealer for information on cold weather operation and proper maintenance intervals when using any biodiesel fuel blend Biodiesel fuel may degrade natural rubber gaskets and hoses as it is more solvent than petro diesel Frequently inspect hoses and other engine components when u...

Page 28: ...ear rapidly Relief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times or a lack of power If your machine has any of these problems check the hydraulic oil for contamination There are two types of contamination microscopic and visible Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydrauli...

Page 29: ...ification The terms right hand left hand front and rear are used in this manual to indicate the sides as they are seen from the operator s seat 1 Front 2 Right hand 3 Rear 4 Left hand RCPH10WHL003BAH 1 48144035_EN 03 07 2017 22 ...

Page 30: ...entification LEIL17WHL1061FA 1 1 Roll Over Protection System ROPS cab 5 Steps 2 Door handle 6 Bucket 3 Electric disconnect and battery jump post 7 Loader lift arms 4 Battery access 8 Bucket cylinder 48144035_EN 03 07 2017 23 ...

Page 31: ...L17WHL1060FA 2 1 Pre cleaner 5 Bucket 2 Sliding access panel 6 Cab air filters door 3 Cab side window 7 Windshield washer reservoir 4 Driving lights 8 Diesel Exhaust Fluid DEF AdBlue fill tank 48144035_EN 03 07 2017 24 ...

Page 32: ...SERVICE MANUAL Engine W190D XR EH NEW CAB Tier 4B W190D ZBAR EH NEW CAB Tier 4B 48144035_EN 03 07 2017 10 ...

Page 33: ...0 1 10 202 Air cleaners and lines 10 2 10 500 Selective Catalytic Reduction SCR exhaust treatment 10 3 10 400 Engine cooling system 10 4 10 414 Fan and drive 10 5 10 310 Aftercooler 10 6 10 304 Engine lubrication system 10 7 48144035_EN 03 07 2017 10 ...

Page 34: ...Engine 10 Engine and crankcase 001 W190D XR EH NEW CAB Tier 4B W190D ZBAR EH NEW CAB Tier 4B 48144035_EN 03 07 2017 10 1 10 001 1 ...

Page 35: ...Contents Engine 10 Engine and crankcase 001 TECHNICAL DATA Engine General specification 3 Engine horse power 3 SERVICE Engine Remove 5 Install 25 Test 46 48144035_EN 03 07 2017 10 1 10 001 2 ...

Page 36: ...rter Stall 1912 RPM to 2112 RPM D Hydraulic Stall 2070 RPM to 2270 RPM E Converter and Hydraulic Stall 1590 RPM to 1790 RPM Temperature of the torque converter oil 82 104 C 180 219 F Temperature of the hydraulic oil 54 57 C 129 135 F NOTE hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open...

Page 37: ...Engine Engine and crankcase LEIL17WHL0358GA 1 NOTE performances detected at engine test bench NOTE BSFC indicates the Brake Specific Fuel Consumption 48144035_EN 03 07 2017 10 1 10 001 4 ...

Page 38: ... the sensors using extreme caution prior to performing any service procedure 1 Park the machine on a level surface and lower the bucket to the ground Put the articulation lock in LOCKED position and stop the engine LEIL16WHL0048AB 1 2 Actuate the brake pedal several times to discharge the brake accumulators LEIL15WHL0564AA 2 3 Put the key switch in ON position Put the control switch in ON position...

Page 39: ...n the battery box Raise the engine hood and put the timed disconnect switch in the OFF position RCPH10WHL106AAH 5 6 Unhook the rubber T handle 1 and raise the upper panel 2 Make sure that the security levers are blocked LEIL13WHL0137AB 6 7 Raise both side panels 1 Then remove the thumb screws 2 and inner fender panels 3 NOTE right hand side of the machine is shown The op eration is similar for the...

Page 40: ...ng system vol ume LEIL16WHL0198AA 8 9 Place a suitable container below the engine oil drain plug see the arrow in figure Remove the engine oil drain plug and drain oil into container Then reinstall the engine oil drain plug NOTE see machine specifications for engine oil sump vol ume LEIL16WHL0198AA 9 10 Remove the drain hose 1 from the frame bracket 2 LEIL16WHL1250AB 10 11 Double up a nylon liftin...

Page 41: ...rearview camera wire harness 3 Cut the wire ties 2 that hold the rearview camera wire harness 3 to the rear grill LEIL17WHL1268AB 13 14 Cut the wire ties and remove the rearview camera wire harness from the engine hood Place the rearview camera wire harness off to the side in a safe location LEIL13WHL0140AB 14 15 Remove the engine hood wire harness clamp 1 from the cooler housing Tag and remove th...

Page 42: ...mounting bolts see the arrows in figure from the cooler frame NOTE do not remove the engine hood hinge mounting bolts at this time LEIL13WHL0142AB 17 18 Disconnect the wiring harness 5 Put the timed disconnect switch in the ON position Retract the lifting motor cylinder 1 and remove the clevis pin 3 and the cotter pin 4 from the bottom of the lifting motor cylinder 1 Separate the lifting motor cyl...

Page 43: ...re from the cooler frame LEIL13WHL0142AB 20 21 Carefully raise and remove the engine hood from the machine Lower the engine hood onto a suitable plat form and disconnect lifting equipment from the ex haust stack 1 NOTE radiator overflow hose may interfere with left hand hood hinge movement and hood removal LEIL13WHL0552AB 21 22 Tag and disconnect the engine wiring harness con nector from the air f...

Page 44: ... on the crankcase ventilation hose 2 and disconnect the hose LEIL13WHL0144AB 24 25 Loosen the clamps on the turbocharger and air filter housing Remove the intake air hose 1 Cover the turbocharger inlet to prevent debris entry LEIL13WHL0145AB 25 26 Loosen the clamp from the elbow connected to the turbocharger LEIL14WHL0203AB 26 48144035_EN 03 07 2017 10 1 10 001 11 ...

Page 45: ...nlet hose at the air filter housing LEIL13WHL0148AB 28 29 Loosen the clamp 1 on the air inlet hose 2 at the exhaust support bracket Remove the air inlet hose 2 LEIL13WHL0151AB 29 30 Remove the securing bolts 1 with the related wash ers and nuts Remove the bracket 2 with the air filter 3 as an assembly LEIL15WHL0037AB 30 48144035_EN 03 07 2017 10 1 10 001 12 ...

Page 46: ...om the engine LEIL13WHL0155AB 32 33 If machine is equipped with the air conditioning sys tem identify tag and disconnect the engine wiring harness connectors from the air compressor clutch connector 1 and high pressure switch 2 Then re move the three mounting bolts 3 for the compressor and carefully set it on the left battery cover LEIL13WHL0156AB 33 34 Tag and disconnect the wiring from the alter...

Page 47: ...ound cable 2 and ground strap 3 from the starter NOTE move the starter cables away from the engine LEIL16WHL0569AB 36 37 Remove the bolts securing the wiring harness clamps to the engine LEIL16WHL0570AB 37 38 Remove the ground wires from the engine NOTE move the wiring harness away from the engine LEIL16WHL0572AB 38 48144035_EN 03 07 2017 10 1 10 001 14 ...

Page 48: ... aside LEIL15WHL0016AB 39 40 Loosen the clamp see the arrow in figure and dis connect the pipe LEIL15WHL0015AB 40 41 Loosen the clamps and remove the lower coolant hose from the engine RAPH12WEL0629AA 41 42 Remove the radiator hose from the engine LEIL13WHL0159AB 42 48144035_EN 03 07 2017 10 1 10 001 15 ...

Page 49: ...olant vent hose from the top of the radiator LEIL13WHL0141AB 43 44 Remove the overflow tank of the engine coolant LEIL16WHL0574AB 44 45 Remove the bracket of the overflow tank LEIL16WHL0575AB 45 46 Remove the cooling fan guard LEIL13WHL0160AB 46 48144035_EN 03 07 2017 10 1 10 001 16 ...

Page 50: ...hine LEIL13WHL0162AB 48 49 Tag and disconnect the fuel filter heater wire 1 and the water sensor 2 Then drain fuel filter and discon nect the inlet 3 and outlet 4 fuel lines from the fuel filter head Plug the lines and cap the fittings Remove the ground wire and the attachment bolt 5 of the fuel filter head LEIL13WHL0163AB 49 50 Tag and remove the grid heater cable 1 NOTE hold the rear nut with a ...

Page 51: ...es by the sup ply module Disconnect the end of the jumper harness near the supply module from the Diesel Oxidation Catalyst DOC support LEIL15WHL0034AB 52 53 Loosen the clamp 1 on the Diesel Oxidation Catalyst DOC LEIL13WHL0166AB 53 54 Tag and disconnect the connector 1 LEIL13WHL0167AB 54 48144035_EN 03 07 2017 10 1 10 001 18 ...

Page 52: ...t the front 1 and rear 2 part of the structure Use a suitable lifting device and carefully lift the support structure of the Selective Catalytic Reduction muffler SCR from the machine NOTE pay particular attention to the connection between the SCR muffler and the Diesel Oxidation Catalyst DOC LEIL13WHL0169AB 56 57 Tag and disconnect the wire harness from the buzzer Remove the bolts 1 securing the ...

Page 53: ...ag and disconnect the wire harness and DEF ADBLUE supply and return lines from the DEF ADBLUE storage tank Install a protective cap in the supply lines RAPH12WEL0070AA 60 61 Remove the support bracket of the hood lift cylinder RAPH12WEL0071AA 61 62 Remove the heater hose from the engine LEIL15WHL0009AB 62 48144035_EN 03 07 2017 10 1 10 001 20 ...

Page 54: ...ant control valve are also at tached to this support structure LEIL14WHL0212AB 64 65 Loosen the two hexagonal nuts of the sensors 3 and 4 and disconnect the sensors 3 and 4 Loosen the clamp 1 on the Diesel Oxidation Catalyst DOC and disconnect the exhaust pipe 2 from the Diesel Oxidation Catalyst DOC LEIL13WHL0229AA 65 66 Remove the SCR coolant supply line from the engine LEIL15WHL0008AB 66 481440...

Page 55: ...67 68 Disconnect the wiring harness from the ECU con troller NOTE lifting up on the lever will release the connector from the controller LEIL13WHL0175AB 68 69 Remove the fuel line from the top of the primary fuel filter plug the line and cap the fitting NOTE make note on how fuel lines are routed LEIL13WHL0176AB 69 70 Remove the support clamp of the fuel line LEIL13WHL0177AB 70 NOTE make note on h...

Page 56: ...L0017FB 71 71 Remove the upper and lower covers for the drive shaft RAPH12WEL0079AA 72 72 Remove the drive shaft bolts 1 from the flywheel Move the drive shaft clear of the flywheel RAPH12WEL0080AA 73 48144035_EN 03 07 2017 10 1 10 001 23 ...

Page 57: ...fting equipment to engine lifting brackets Take up all slack in lifting equipment Re move the engine mounting bolts RAPH12WEL0080AA 75 LEIL15WHL0036AA 76 75 Slowly raise the engine from the rear chassis Be sure all wire harness connections and hoses have been disconnected and are clear of the engine Guide the oil drain hose from the frame as the engine is lifted Remove the engine from machine 4814...

Page 58: ...rations Use of tools that gen erate extreme vibrations such as impact wrenches and hammers will result in damage to emission sensors Avoid using these tools during any service procedure in close proximity of emission sensors If the use of these tools cannot be avoided remove the sensors using extreme caution prior to performing any service procedure RAIL12WEL0130FA 1 1 Engine mount bolt 5 Washers ...

Page 59: ...s connections and hoses are out of the way or positioned correctly for reconnecting before lowering engine RAPH12WEL0080AA 2 LEIL15WHL0036AA 3 3 Tighten the mounting bolts of the engine to a tighten of 244 298 N m 180 220 lb ft RAPH12WEL0080AA 4 4 Disconnect the lifting equipment from the engine lifting brackets 48144035_EN 03 07 2017 10 1 10 001 26 ...

Page 60: ...ulic reservoir LEIL13WHL0178AB 5 6 Connect the drain hose 1 of the engine oil to the frame bracket 2 LEIL16WHL1250AB 6 7 At front of engine position the drive shaft on engine coupling Install the bolts to secure the drive shaft to the engine coupling Tighten to 85 94 N m 63 69 lb ft RAPH12WEL0080AA 7 8 Install the upper and the lower drive shaft dust covers Tighten to 20 27 N m 15 20 lb ft NOTE at...

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