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Copyright New Holland

W190
Workshop Manual

Workshop
Manual

Print No. 604.13.502.01


English - Printed in Italy

W190

PROVEN PERFORMANCE

Copyright New Holland

W190
WHEEL LOADER

Workshop Manual
Print N 604.13.502.01 English
IX - 2005

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.


Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:

WARNING - Cautions directed to avoid improper repair interventions involving potential consequences
for the operators safety.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.

IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the
Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever
necessary, the recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own,
for the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national,
regional or local distributors, are responsible for any liability arising from any damage resulting from defects
caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products
manufactured or merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandized by the Factory, when failures are caused by the use of parts and/or components not approved
by the Factory.

Copyright New Holland

AVOID ACCIDENTS
Most accidents and injuries occurring in industry, on the
farm, at home or on the road, are caused by the failure
of some individual to follow simple and fundamental
safety rules or precautions. For this reason, MOST
ACCIDENTS CAN BE PREVENTED by recognizing
the real cause and taking the necessary precautions,
before the accident occurs.
Regardless of the care used in design and construction
of any type of equipment, there may be conditions that
cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation.
A careful operator is the best insurance against accidents. The complete observance of one simple rule
would prevent many thousands serious injuries each
year.
This rule is: Never attempt to clean, lubricate or adjust
a machine while it is in motion.

WARNING
On machines having hydraulically, mechanically
and/or cable controlled equipment (such as
showels, loaders, dozers, scrapers etc.) be certain
the equipment is lowered to the ground before
servicing, adjusting and/or repairing.
If it is necessary to have the equipment partially or
fully raised to gain access to certain items, be sure
the equipment is suitably supported by means
other than the hydraulic lift cylinders, cable and/or
mechanical device used for controlling the equipment.

Copyright New Holland

SUMMARY

SAFETY RULES .............................................................................................. page 1


SPECIFICATIONS - WHEEL LOADER ............................................................ page 8
TABLE OF FLUID CAPACITIES ...................................................................... page 11
UNITS OF MEASURE ..................................................................................... page 12
TORQUE TABLES ........................................................................................... page 13

ENGINE ................................................................ Section 1


TRANSMISSION .................................................. Section 2
BRAKE SYSTEM ................................................. Section 3
STEERING SYSTEM ........................................... Section 4
BUCKET BOOMS AND FRAME ........................ Section 5
EQUIPMENT HYDRAULIC SYSTEM ................. Section 6
ELECTRICAL SYSTEM ...................................... Section 7
CAB ...................................................................... Section 8

Copyright New Holland

Copyright New Holland

W190

0-1

SAFETY RULES
GENERALITIES
Read this Manual carefully before starting, operating,
maintaining, fuelling or servicing the machine.
Read and comply with all safety precautions before any
intervention.
Do not allow unauthorised personnel to operate or service
this machine.

Ensure that nobody is in the machine operating range


before moving off or operating the attachment. WALK
COMPLETELY AROUND the machine before mounting.
Sound the horn.
Before starting machine, check, adjust and lock the driver's
seat for maximum comfort and control of the machine.
Fasten your seat belts(when fitted).

Do not wear rings, wrist watches, jewellery, loose or


hanging garments, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can get caught in
moving parts. Wear certified safety clothes such as: hard
hat, no-slip footwear, heavy gloves, ear protection, safety
glasses, reflector vests, respirators. Ask your employer
about specific safety equipment requirements.

Obey all flag signals and signs.

Keep the operators compartment, step plates, grab-rails


and handles clean and clear of foreign objects, oil, grease,
mud or snow to minimize the danger of slipping or stumbling. Remove mud or grease from your shoes before
attempting to mount or operate the machine.

DO NOT PUNCTURE OR BURN CONTAINERS.

Do not jump on or off the machine. Always keep both hands


and one foot, or both feet and one hand in contact with
steps and grab rails.

Never use these products near fires, open flames, or


sparks.

Do not use controls or hoses as hand holds when climbing


on or off the machine. Hoses and controls are movable
parts and do not provide solid support. Besides, controls
may be inadvertently moved and cause unexpected
movement of the machine or its attachments.
Never operate the machine or its attachments from any
position other than sitting in the drivers seat.
Keep head, body, limbs, hands and feet inside the operators compartment at all times to reduce exposure to
external hazards .
Be careful of possible slippery conditions of the steps and
hand rails as well as of the ground around the machine.
Do not leave the machine until it is has come to a complete
stop.
Check the seat safety belt at least twice per year and
replace it if it shows signs of wear, fraying or other
weakness that could lead to failure.

Due to the presence of flammable fluids on the machine,


never check or fill fuel tanks or accumulator batteries near
fires, open flames, or sparks.
REMEMBER THAT SPECIAL STARTING FLUIDS ARE
FLAMMABLE. Scrupolously follow recommendations
printed on the containers and in this Manual.
Containers must be stored in fresh, well ventilated places
and out of the reach of unauthorised persons. Strictly
follow the instructions provided by the Manufacturer.

OPERATING
Check wheel and rim retainers before each working shift.
If necessary, tighten to the torque specified.
Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
exhaust gases.
Roll Over Protective Structures (ROPS) are required on
wheel or crawler loaders, dozers, or graders. NEVER
OPERATE the machine if such protective structure is
removed.
Keep the operators compartment free of foreign objects,
especially if not firmly secured. Never use the machine to
transport objects, unless proper securing points are provided.
DO NOT CARRY RIDERS ON THE MACHINE
Study and familiarize with escape routes alternate to
normal exit routes.

STARTING
NEVER START OR OPERATE A FAILED MACHINE. Before operating the machine, always ensure that any unsafe
condition has been satisfactorily corrected.
Check brakes, steering and attachment controls before
moving off. Report any malfuctioning part or system to the
maintenance managers for proper action.
Ensure all protective guards and panels as well as all
safety devices provided are in place and in good operating
condition.

According to law provisions, seat belts must be fitted with


Roll Over Protection Structures or cabs. Keep safety belts
fastened during operation.
For your personal safety, do not climb on or off the machine
while it is in motion.
Make sure that bystanders are clear of the machine operating range before starting the engine and operating the
attachment. Sound the horn. Obey all indications provided
by flags, signs and signals.
DO NOT COAST OR FREEWHEEL down hills. Engage the
most suitable gear speed to keep the machine under control.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

0-2

W190
SAFETY RULES

Do not operate the machine if you are extremely tired or feel


ill. Be especially careful towards the end of the working shift.
Do not operate a machine with misadjusted brakes.
Operate the machine at low speed which can ensure
complete control at all times.
Travel slowly over very rough terrain, slopes or near dropoffs, in congested areas or on frozen or slippery surfaces.
When backing, always look to where the machine is to be
moved. Be alert of the position of bystanders. Should
someone enter the work area, STOP THE MACHINE.
Maintain a safe distance from other machines or obstacles
to ensure required visibility conditions. Give way to loaded
machines.
Maintain a clear vision of the surroundings of the travel or
work area at all times. Keep cab windows clean and
repaired.
When machines are operating in tandem, the pusher (rear)
must be equipped with the appropriate deflectors to protect
the front unit driver against the air stream coming from the
blower fan.

When working on slopes or near sudden level drops in the


terrain, avoid areas where ground is loose or soft since
overturn or loss of machine control could result.
If noise level is high and continuosly exceeds 90 dBA over
8 hours at the operator's ear, wear approved ear protection
in compliance with local regulations.
Where counterweights are provided, do not operate the
machine if they have been removed.
When transporting a loaded bucket, keept it as rolled-back
and low as possible for maximum visibility, stability and
safety of there machine. Ground speed should be adequate to the load and ground conditions.
The load must always be properly arranged in the bucket;
move with extreme care when transporting oversize loads.
Use only the type of bucket recommended for the machine
and the materials to be handled. Follow the recommendations concerning loading capacity, arrangement of the
materials, characteristics of the ground and job to be
performed.

When pulling or towing through a cable or chain, do not


start suddenly at full throttle. Take-up slack carefully.

Do not lift and move loads overhead where persons are


standing or working, nor downhill when working crosswise
on slopes. In this case, the bucket should be unloaded on
the uphill side, whenever possible.

Carefuly inspect the towing items for flaws or problems


before proceedig.

Start and stop the machine carefully when the bucket is full.
Do not move off without first reducing engine speed.

Avoid kinking or twisting chains or cables. Do not pull


through a kinked chain or cable as the high stresses
existing in this condition may induce failures. Always wear
heavy gloves when handling chains or cables.
Chains and cables should be securely anchored. Anchor
points should be strong enough to withstand the expected
load. Keep anyone clear of anchor points and cables or
chains.
DO NOT PULL UNLESS THE OPERATORS COMPARTMENTS OF THE MACHINES INVOLVED ARE PROPERLY PROTECTED AGAINST POSSIBLE BACKLAS IN
CASE OF CABLE OR CHAIN FAILURE OR DETACHMENT.
Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may
cause the wall to collapse.
In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided. Do not
move into low visibility areas.
If the engine tends to stall for whatever reason under load
or at idle, immediately report this problem to the maintenance managers for proper action. Do not operate the
machine until this condition has been corrected.
On machines fitted with suction radiator fans, regularly
check the engine exhaust system for leaks, as exhaust
fumes expelled towards the operator are toxic.
Operators must know thoroughly the performances of the
machine they are driving.

Overtaking manoeuvres should be performed only when


absolutely necessary and unavoidable. Beware possible
uneven terrains, poor visibility, presence of other machinery or persons out of sight.
Operate the machine at a speed adequate to the working
site conditions and in any case slow enough to ensure
complete control at all times.
Check instruments at start-up and frequently during
operation. Stop the machine immediately should any
malfunction be signalled.
Never use the bucket as a man lift or to carry riders.
Never use the machine as a work platform or scaffolding,
nor for other improper use (such as pushing railway cars,
trucks or other machines).
Pay attetion to people within the machine operating range.
Load trucks from the drivers side whenever possible.
Prior to operating the machine, check which obstacles
and/or difficulties you will encounter, such as narrow
streets, overhead doors, cables, piping, as well as ground,
bridges, paving and ramps bearing load limitations.
In case of road transfers, find out beforehand what conditions are likely to be encountered, such as size restrictions,
heavy traffic, paving type, etc. . Beware fog, smoke or dust
that obscure visibility.
When crossing gullies or ditches, move at an angle with
reduced speed after ensuring ground conditions will permit a safe traverse.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

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SAFETY RULES

Always inspect the working area to identify potential risks


such as: inclines, overhangs, trees, demolition rubble,
fires, ravines, steep slopes, rough terrain, ditches, crowns,
ridge trenches, heavy traffic, crowded parking and service
areas, closed ambients. In such conditions, proceed with
extreme care.
Whenever possible, avoid going over obstacles such as
very rough terrain, rocks, logs, steps, ditches, railroad
tracks. When obstructions must be crossed, do so with
extreme care and at an angle, if possible. Slow down and
select a lower gear. Ease up to the break-over point, pass
the balance point slowly and ease down the other side.
In steep down-hill operation, do not allow the engine to
over-speed. Select the proper gear before starting down
grade.
Avoid crosswise hill travel, whenever possible. Drive up
and down the slope. Should the machine start slipping
sideways when going uphill, steer and turn machine front
immediately downhill.
The gradient you may attempt to overcome is limited by
factors such as ground conditions, load being handled,
machine type and speed, and visibility.

Always remember to move the gearshift lever to the neutral


position and engage the control lever lock for safety
purposes.
Apply the parking brake (if fitted).
NEVER LEAVE THE MACHINE UNATTENDED with the
engine running.
Prior to leaving the operators seat,and after making sure
that all people are clear of the machine, always slowly
lower the attachment until resting it safely to the ground
Park the machine in a non-operating and no-traffic area.
Park on firm level ground. If this is not possible, position the
machine at a right angle to the slope, making sure there is
no danger of uncontrolled sliding. Apply the parking brake.
If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and signals as required
to adequately warn the oncoming drivers.
Keep head, body, limbs, hands and feet clear of the dozer,
arms, bucket or ripper when raised.

There is no substitute for good judgement and experience


when working on slopes.

Always switch off the battery isolator switch before servicing the machine in whatever manner (i.e., cleaning,
repairing, maintaining, etc.). Do the same when the
machine is to remain parked for prolonged periods of time
to avoid accidental or unauthorized starting.

Avoid operating the attachment too close to an overhang


or high wall, either above or below the machine. Beware
of caving edges, falling objects and landslips. Remember
that such hazards are likely to be concealed by bushes,
undergrowth and such.

Never lower the attachments other than sitting in the


operators seat. Sound the horn. Make sure that nobody is
within the machine operating range. Lower the attachment
slowly. DO NOT USE FLOAT POSITION in case of hydraulic controls.

When pushing-over trees, the machine must be equipped


with proper overhead guards. Never drive a machine up
the roots, particularly while the tree is being felled. Use
extreme care when pushing over any tree with dead
branches.

Securely block the machine and lock it every time you


leave it unattended. Return keys to authorized security.
Perform all necessary operations as detailed in the Operation and Maintenance Instruction Manual. Apply the parking brake (if fitted) every time you leave the machine.

Avoid faggots, bushes, logs and rocks.


NEVER DRIVE OVER THEM, nor over any other surface
irregularities that discontinue adherence or traction with
the ground, especially near slopes or drop-offs.

MAINTENANCE

Be alert to avoid changes in traction conditions that could


cause loss of control. AVOID driving on ice or frozen
ground when working on steep slopes or near drop-offs.

GENERALITIES

Working in virgin rough terrains is characterized by the


presence of all the perils and risks listed above. In these
conditions, it is emphasised the danger represented by
large tree limbs (possibly falling on the machine), large
roots (which may act as a leverage under the machine
when up-rooted and cause the unit to overturn), etc.

- carefully read all the norms contained in this Manual;

Before operating or performing any intervention on the


machine:
- read and observe all safety plates and instructions
located on the machine.
Do not allow unauthorized personnel to service the machine. Do not carry out any maintenance work without prior
authorization. Follow all recommended maintenance and
service procedures.

STOPPING

Keep the operators compartment free of loose objects that


are not properly secured.

When the machine is to be stopped for whatever reason,


do so following the instructions given in chapters Stopping the machine and Shutting off the engine" in the
Operation and Maintenance Instruction Manual.

Do not wear rings, wrist watches, jewellery, loose or


hanging garments, such as ties, torn clothing,
scarves,unbuttoned or unzipped jackets that can get
caught in moving parts.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

0-4

W190
SAFETY RULES

Wear certified safety clothes such as: hard hat, no-slip


footwear, heavy gloves, ear protection, safety glasses,
reflector vests, respirators. Ask your employer about specific safety equipment requirements.

The fuel filler pipe nozzle must be constantly kept in contact


with the filler neck. Keep this contact from the beginning to
the end of the fuelling operation to avoid possible generation of sparks due to static electricity.

Never service the machine with someone sitting in the


driver's seat, unless this person is an authorized operator
assisting in the maintenance being carried out.

Tow the machine only from the attaching points provided.


Use care in making connections and ensure pins and/or
bolt are firmly secured before pulling. Stay clear of drawbars, cables or chains under load.

Keep the operators compartment, step plates, grab rails


and handles clear of foreign objects, oil, grease, mud or
snow to minimize the danger of slipping or stumbling.
Clean mud or grease from your shoes before climbing on
the machine or driving it.
Never attempt to operate the machine or its attachments
from any position other than sitting in the operators seat.
Never stand under the boom.
Should it be necessary to move the attachment through the
hydraulic controls for maintenance purposes, remember
that this should be done while sitting in the operators seat.
Before starting the machine or moving its attachment,
apply the brakes, sound the horn and call that you are
about to manoeuvre. Raise the attachment slowly.
Always lock machine arms or any other parts that must be
lifted for maintenance purposes using adequate external
means. Do not allow anyone to pass near or even below
a raised yet unlocked attachment. If you are not absolutely
sure about your safety, do not stay under a raised attachment, even if it is locked.
Do not place body, limbs, or fingers near articulated cutting
edges of uncontrolled machine parts or deprived of the
necessary guards, unless they are suitably and safely
locked.
Never perform any work on the machine with the engine
running, except when this is specifically required. Do not
wear loose clothing, jewellery or such near moving parts.

To move a failed machine, use a trailer or a low platform


truck, if available. In case towing is needed, use all necessary signals required by local regulations, and follow
directions provided in this Manual.
Load/unload the machine from transporter on firm level
ground providing safe support to the wheels of the truck or
trailer. Use strong access ramps, with adequate height and
angle. Keep the loading platform free of mud, oil or slippery
materials.
Tie the machine securely to the platform of the truck or
trailer and opportunely wedge machine wheels or tracks
as required.
Never align holes or slots using your fingers; always use
appropriate aligning tools.
Remove all sharp edges and burrs from re-worked parts.
Use only approved and effectively grounded auxiliary
power sources for heaters, battery chargers, pumps and
similar equipment to reduce electrical shock hazard.
Lift and handle heavy components using hoisting devices
of appropriate capacity. Ensure the sling has been correctly applied. Use lifting eyes if provided. Pay attention to
bystanders.
Never pour gasoline or diesel fuel into open, wide and low
containers. Never use gasoline, solvents or other flammable fluids to clean parts. Use proprietary certified nonflammable, non-toxic solvents only.

When service or maintenance require access to areas that


cannot be reached from the ground, use a ladder or step
platform conforming to regulations in force. If such means
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with the
greatest care and attention.

When using compressed air to clean parts, wear safety


glasses with side shields. Limit pressure to max 2 bars, in
accordance with local safety regulations in force.

Shop and/or field service platforms or ladders should be


manufactured in accordance with safety regulations in
force.

Do not smoke, use open flames or produce sparks nearby


while refuelling the unit or handling highly flammable
materials.

Disconnect batteries and label all controls to warn that


service work is in progress. Block the machine and all
attachments to be raised.

Do not use any flame as a light source during maintenance


work or to look for leaks anywhere on the machine.

Do not check or fill fuel tanks, batteries and accumulators,


nor use the starting liquid if you are smoking or near open
flames. These fluids are flammable!
BRAKES ARE INOPERATIVE when manually released for
servicing. Provisions must be made to maintain control of
the machine using suitable blocks or other means.

Do not run the engine in closed buildings without proper


ventilation capable to remove lethal fumes.

Make sure that all tools provided are in good condition at


all times. NEVER USE tools with mushroomed or damaged heads. Always wear eye protections.
Move with extreme care when working under the machine,
its attachments, and even on or near them. Always wear
protective safety equipment as required, such as hard hat,
goggles, safety shoes, and ear plugs.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

0-5
SAFETY RULES

In case tests during which the engine should be kept


runinng, a qualified operator must sit in the drivers seat
with the mechanic in sight at all times. Place the transmission in neutral, apply and lock the brakes. KEEP HANDS
OFF MOVING PARTS.
In case of field service, move machine to level ground, if
possible, and block it. If work on an incline cannot be
advised, block the machine and its attachments securely.
Move damaged to level ground as soon as possible.
Do not trust worn and/or kinked chains and cables. Never
use them for lifting or pulling. Always wear heavy gloves
to handle chains or cables.
Be sure chains and cables are firmly fastened and that
anchor points are strong enough to withstand the expected
load. Nobody should stay near the anchor points, cables
or chains. DO NOT PULL OR TOW UNLESS THE OPERATORS COMPARTMENTS OF THE MACHINES INVOLVED ARE FITTED WITH THE PROPER GUARDS
AGAINST BACKLASH IN CASE OF CABLE OR CHAIN
FAILURE OR DETACHMENT.
Keep the area where maintenance is carried out CLEAN
and DRY at all times. Clean immediately all water and oil
spillages.

Metal cables get frayed after prolonged use. Always wear


appropriate protections (heavy gloves, goggles, etc.)
while handling them.
Handle all parts carefully. Keep hands and fingers away
from gaps, gears, and similar. Always use and wear the
appropriate protections.
Water can build up in pneumatic systems from condensate
moisture due to changes in atmospheric conditions. If
necessary, drain such deposits following instructions.
Before carrying out any maintenance work or service, lock
the machine articulated frame modules using the appropriate safety device. Remember to remove and store it
properly at the end of work.
If the machine is equipped with hydraulic brakes, make
sure that the reservoir is always filled up to the correct level.
Always block all wheels, front and rear, before bleeding
the braking system or disconnecting control hoses and/or
cylinders.

STARTING

Do not pile up oily or greasy rags as they represent a major


fire hazard. Always store them in closed metal containers.

Do not run the engine in closed buildings without proper


ventilation capable to remove lethal exhaust fumes.

Before starting the machine or its attachment, check, adjust


and lock the operators seat. Also ensure that nobody is
within the machine operating range. Sound the horn.

Do not place head, body, limbs, feet, hands or fingers near


rotating fans or belts.
Be especially careful near blower fans.

Rust inhibitors are volatile and flammable. Use them only


in well ventilated areas. Keep open flames away - DO NOT
SMOKE - Store containers in a cool well ventilatedplace
where they could not be reached by unauthorised people.
Do not carry loose objects in your pockets that might fall
unnoticed into open compartments.

REMEMBER THAT THE STARTING FLUID IS HIGHLY


FLAMMABLE. Follow recommendations provided in this
Manual and printed on the containers. Containers must be
stored in a cool, well ventilated place out of the reach of
unauthorised persons.
DO NOT PUNCTURE OR BURN CONTAINERS.

Wear safety glasses with side shields, hard hat, safety


shoes, heavy gloves when metal particles or similar may
be ejected and hit you.
Wear appropriate protective equipment such as dark
safety glasses, hard hat, protective clothing, special
gloves and footwear while welding. Nearby persons
should also wear dark safety glasses even if they are not
welding. DO NOT LOOK THE WELDING ARC WITHOUT
PROPER EYE PROTECTION.
Become acquainted with all your jacking equipment and
its capacity. Remember that the jacking point on the
machine should be appropriate for the load applied. Also,
be sure the support area of the jack at the machine and on
the ground is appropriate and stable.
Any load supported by a jack represents a possible hazard. Always transfer the load onto appropriate support
means according to local or national safety requirements
before proceeding with service or maintenance work.

ENGINE
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant level
with the engine off.
Avoid that flammable materials could touch exhaust parts.
If not possible, provide necessary protections.
Do not refuel with the engine running, especially if hot, as
this increases fire hazard.
Never attempt to check or adjust fan belt tensions when the
engine is running.
Do not adjust the fuel pump when the machine is motion.
Do not lubricate the machine with the engine running.
Do not run the engine with air intakes, door or guards open.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

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W190
SAFETY RULES

ELECTRICAL SYSTEM
Always disconnect the batteries prior to any intervention
on the machine or its electrical system (cleaning, repair,
maintenance).
Should booster batteries be used, remember to connect
ends of the booster cables in the proper manner: (+) to (+)
and (-) to (-). Do not short-circuit terminals. Thoroughly
follow instructions given in this Manual.

Do not use the machine to transport loose objects, unless


proper devices to this purpose are provided.
Clutches and brakes of this machine as well as auxiliary
devices and attachments (such as drive cylinder or winch
control valves) should always be properly adjusted in
accordance with the instructions provided by the Manufacturer. Never perform adjustments with the engine running,
except when this is specifically required by the relevant
procedures.

Before any intervention, make sure that the battery isolator


switch is off.
BATTERY GAS IS HIGHLY FLAMMABLE. Leave the battery compartment open during recharging to improve
ventilation. Never check battery charge by placing metal
objects across the posts. Keep sparks or open flames away
from batteries. Do not smoke near the battery to prevent
explosion hazard.
Before any intervention, make sure that there are no fuel
or electrolyte leakages. If any, correct prior to proceeding
with further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to avoid
accidental explosions due to build-up of gas released
during charging.

TYRES AND WHEELS


Make sure that the tyre inflation pressure corresponds to
specifications issued by the Manufacturer. Regularly
check inflation pressure.
Should pressure be changed, do this while staying on the
tyre side and at a safe distance.
Pressure checks should always be carried out with the
machine unloaded and cold tyres.
Never use reconditioned tyre rims, since possible
weldings, incorrect heat-treatments or repairs can
weaken the wheels and cause damages or failures.
Do not cut, nor weld rims with inflated tyres installed.

HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to penetrate
the skin. Always check any suspected pressure leaks
using a piece of cardboard or wood. DO NOT USE HANDS.
If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop.
Stop the engine and relieve all system pressure before
removing panels, housings, caps, plugs or covers.
Always use gauges of adequate capacity (end-of-scale
reading) and follow recommended procedures.

The spare tyre should be inflated only enough to keep the


rim components assembled. Remember that when not
installed on the disc, a tyre inflated to maximum pressure
can explode.
Therefore, maximum care must be taken when handling a
fully inflated tyre.
Before servicing tyres, block all wheels, front and rear. After
jacking up the machine, block it in the raised position using
suitable stands conforming to current safety regulations.
Deflate the tyre before removing objects from the tyre tread.
Never inflate tyres with flammable gas: explosions and
severe bodily injuries may result.
When starting your work shift, check for loose wheel or rim
bolts and brackets and retighten to correct torque as
necessary.

TOOLS
Always keep head, body, limbs, feet, or hands away from
bucket, blade, or ripper when in the raised position. Prior
to any intervention, install all safety devices according to
current regulations. In case the attachment is to be operated through the machine hydraulic system for maintenance purposes, remember to do so only while sitting in the
driver's seat. Make sure that nobody is within the machine
operating range. Before operating the attachment, alert
people by sounding the horn and by voice. Raise the
attachment slowly.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

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SAFETY RULES

DECOMMISSIONING THE MACHINE


For the decommissioning of the machine, the availability
of particular tooling (hoists, hydraulic presses. containers for liquids etc.) is required as well as specific tools
listed in the Repair Manuals, available from FIAT
KOBELCO Dealers.
This has the purpose of avoiding that during disassembly operations, dangerous situations may arise both for
the personnel involved and the environment.
In the machine are present:
Fluids under pressure (hydraulic system, cooling
system etc.)
Gases (air conditioning system and accumulator, if
installed)
Mechanical devices mounted under pressure (track
tensioner etc.)
Heavy machine components (frames, blades, buckets etc.)

WARNING
The decommissioning of the machine must be
performed exclusively by personnel trained,
qualified and authorised to perform such operation.
Start the disassembly of hydraulic components
only after the same, the hydraulic oil and lubricants have fully cooled-off and after all residual
pressures have been released, as described by
the Repair Instruction Manual.
Prior to proceeding with disassembly operations, comply with the GENERAL SAFETY RULES
and drain each components of the machine filled
with fluids, both in the reservoirs and the relevant systems.

WARNING
Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing
machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators,
loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically,
mechanically, or cable controlled attachment to gain access to certain items, make sure the attachment
is adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or
mechanical devices used for controlling it.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

0-8

W190

SPECIFICATIONS - WHEEL LOADER W190


IDENTIFICATION - 530.130.190
MARKING: ZEF00W19100940XXX
ENGINE
Make and model ................... IVECO NEF-TEKTOR
Net power at the flywheel .......... (ISO 9249) 151 kW
Max power speed ...................................... 2175 rpm
Max torque .................................................. 860 Nm
Max torque speed ..................................... 1500 rpm
Diesel type, 4 stroke, direct injection, turbocharged
Number of cylinders .............................................. 6
Bore x stroke .................................... 102 x 120 mm
Total displacement ................................ 5880 cu cm
Valve/rocker operation lash:
- intake .......................................... 0.25 0.05 mm
- exhaust ....................................... 0.50 0.05 mm
Firing order .............................................. 1-5-3-6-2-4
Minimum starting temperature: ........... - 20 C (-4 F)
Engine coolant high temperature sender setting
...................................... 107 + 2 C (224 + 35.6 F)
Pressure, engine oil at low idle ................. 1.2 bar
Thermostat: starts opening ............ (177.8 F) 81 C
max, opening ............. (204.8 F) 96 C

ENGINE SPEEDS
Minimum idle speed (no load) ...................... 850 rpm
Maximum idle speed (no load) ................... 2300 rpm
Converter stall speed ........................ 2110 50 rpm
Steering stall at idle speed > .......................840 rpm
Attachment stall ................................ 2190 50 rpm
Full stall .......................................... 1900 100 rpm

TORQUE CONVERTER
Type ... : single stage, single phase, three elements
Torque converter pressure ........................... 4.3 bar
Conversion ratio at stall ............................... 2.813:1

TRANSMISSION
Maximum ground speeds (forward/reverse) in kph
(with 23.5 R25 tyres):
Forward
speed

km/h
(Mp/h)

Reverse
speed

km/h
(Mp/h)

1
2
3
4

7.4 (4.5)
12.9 (8)
23.8 (14.7)
36.6 (22.7)

1
2
3

7.8 (4.8)
13.7 (8.5)
25.2 (15.6)

Main pressure on the control valve .......... 16 + 2 bar


Transmission disengagement sensor ...... 15 1 bar
Transmission induction sensors to gear teeth adjust
clearance ........................................... 0,5 0,8 mm
Transmission oil high temperature sensor setting ....
...................................... 119 3 C (246 37.4 F)
AXLES
Axles complete w/ oil-bath disc brakes.
Self-locking differentials.
Limited slip differential (as alternative).
Planetary final drives.
Stiff front axle, support structure type
- reduction ratio ........................................ 1 : 24.05
Oscillating rear axle, support structure type
- reduction ratio ........................................ 1 : 24.05

TYRES
Type ................................... 23.5 R25 XHA tubeless
Inflating pressure
- Work:
front = 3.25 bar
rear = 2.00 bar
- Transfer:
front = 2.00 bar
rear = 2.00 bar
Wheel tightening torque ............................... 788 Nm
BRAKES
Delivery brakes pump
at nominal speed ............... 32 lt/min (7.03 USG/min)
Accumulator recharge start pressure ....... 90 5 bar
Accumulator recharge end pressure ...... 130 5 bar
Pre-charge pressure, service brake accumulator
(1.4 lt) ............................................................ 45 bar
Pre-charge pressure, parking brake accumulator
(1.4 lt) ........................................................... 70 bar
Setting of pressure switch, transmission cut-off . 15 bar
Setting of sensor, brake oil low pressure ...... 73 bar
Setting of pressure switch, stop lights ........ 1.8 bar
Setting of pressure switch, parking brake ...... 82 bar
STEERING SYSTEM
Type ..................... Orbitrol, hydraulically controlled
with integrated priority valve
Pump ....................it uses one body of the hydraulic
system pump
Max. flow ...................... 162 lt/min (35.63 USG/min)
Max. operating pressure ............................... 210 bar
Cylinders ........................................ 2, double stroke
bore x stroke .................................... 80 x 422 mm
Emergency steering w/ bi-directional gear pump actuated by the transmission.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

0-9

EQUIPMENT HYDRAULIC SYSTEM


Type ................ sealed w/ anti-cavitation and safety
valve
Pumps ............. gear, steel made w/ wear automatic
compensation
A sequence valve cuts-off the pump when the pressure exceeds 175 bar.
- max. flow ..... 325 lt/min between (71.49 USG/min)
175 and 210 bar
- max. operating pressure ............................ 210 bar
Control valve ................................................ 2-spool
3-spool
Control ......................................... piloted, dual lever
piloted, single lever
Hydraulic cylinders, double stroke
boom control ...................................................... 2
bore x stroke .................................... 140x960 mm
bucket control .................................................... 1
bore x stroke .................................... 190x505 mm
Times of equipment manoeuvres
lifting ........................................................ 6.2 sec.
lowering .................................................... 3.1 sec.
dumping ................................................... 1.4 sec.
Pipes and connecting flanges are equipped with
O-Ring seals.
L.T.S. device
Electronic Load Travel Stabiliser device. Ideal during
loading applications and travel over rough ground.
- Setting of accumulator safety valve ............ 120 bar

ELECTRICAL SYSTEM
Operating voltage ........................................ 24 Volt
Batteries in series ............................. 2 - 160 Amph
- Maintenance-free
Starter motor ............................................... 24 Volt
Alternator w/ voltage regulator ...... 24 Volt - 70 Amp

WEIGHT
Weight of machine with tyres 23.5 R25 and 3.1 cu m
bucket, supplied and w/operator 17,200 kg (37,920
lbs).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

0 - 10

W190

DIMENSIONS AND WEIGHT

40

3350

45

1230

49
445
322

1600

95

2065

2160
2760

3200

Dimensions in mm (in)
Operating weight: 17.200 kg (37919 lbs)
Note Machine equipped with tyres 23.5R25XHA, fluids and operator.
* Please refer to the table

Type of bucket
With teeth and
segments
3.2

3.5

With suppl. cutting


edge
3.2

3.5

With teeth

Bucket capacity

cu cm

3.1

3.4

Bucket weight

kg (lbs) 1520 (3351) 1605 (3538) 1465 (3229) 1550 (3417) 1425 (3141) 1510 (3328)

Bucket width

mm (in) 2960 (116.5) 2960 (116.5) 2920 (114.9) 2920 (114.9) 2960 (116.5) 2960 (116.5)

Dumping height at 45 mm (in) 2890 (113.7) 2810 (110.6) 2980 (117.3) 2895 (113.9) 2890 (113.7) 2810 (110.6)
Dumping reach at 45

mm (in) 1135 (44.6)

Max. length
(w/ bucket on ground)

mm (in) 8030 (316.1) 8110 (319.3) 7920 (311.8) 8000 (314.9) 8030 (316.1) 8110 (319.3)

Max. height
(w/ bucket raised)

mm (in) 5380 (211.8) 5435 (213.9) 5380 (211.81) 5435 (213.9) 5380 (211.8) 5435 (213.9)

Turning radius (in


transportation position) m (ft)

6.5 (21.3)

1200 (47.2)

6.5 (21.3)

1060 (47.7)

6.5 (21.3)

1125 (44.2)

6.4 (21)

1135 (44.6)

6.5 (21.3)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1200 (47.2)

6.5 (21.3)

0.2 (0.05)

AIR CONDITIONER
COMPRESSOR

L BAR 134

Ambra-MG-2

QFH 585 GR, NLG12

85W-90

40 To 50 C (-40 To 122 F)

20 To 50 C (-4 To 122 F)

20 To 50 C (-4 To 122 F)

30 To 20 C (-22 To 68 F)

35 To 50 C (-31 To 122 F)

10 To 50 C (14 To 122 F)

10 To 50 C (14 To 122 F)
30 To 20 C (-22 To 68 F)

OUT DOOR TEMPERAT.


OF REFERENCE (C)

W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Oil quantities indicated are those required for periodical changes following the draining and filling procedures indicated in detail for each group.
* In the event engine oil with "CH4" classification is used, the change interval can be prolonged to 500 hours providing that the outer temperature of operation
does not exceed 38 C (100 F) and that the percentage of sulphur in the fuel does not exceed 0.5 %.
In the event of really heavy duty conditions, reduce the greasing intervals.

GREASE FITTINGS

252 (66.57)

FUEL
TANK

API GL5
QFH 584 TR

Ambra-TX Fluid

front 31 (8.2)
rear 31 (8.2)

AXLES

ISO VG 46, DIN 51524


Part. 1 and 2, QFH583/HD

Ambra-Hydrosystem
or
Ambra Hi-Tech 46

135 (35.7)

HYDRAULIC SYSTEM

10W-30

Ambra-Super Gold

22 (5.8)

TRANSMISSION

15W-40

API CH-4
ACEA E3

API CF-4/SG
MIL-L-2104E
ACEA E2

Ambra-Agriflu (50%)

15W-40
10W-30

VISCOSITY
(SAE)

API CF-4/SG
MIL-L-2104E
ACEA E2

CLASSIFICATION
SPECIFICATIONS

27 (7.1)

RADIATOR

Ambra-Super Gold HSP*

or
Ambra Master Gold

Ambra Super Gold

FLUIDS OR LUBRICANT

NH-900A

1 (3)

16 (4.2)

QUANTITY
LITRES (USG)

OIL FILTER

ENGINE

ITEM

TABLE OF FLUID CAPACITIES

Copyright New Holland

0 - 11

Copyright New Holland

0 - 12

W190

UNITS OF MEASURE
Units of measure used in this manual are those
adopted by the International System which replace the
units previously used by the M.K.S. system.
Force:

newton (N)

Pressure:

bar

Torque:

newton x meter (Nm)

CLASSIFICATION OF STANDARD COMPONENTS TO DETERMINE THE TIGHTENING TORQUES

Note - In case, in the different sections, the tightening


torque is not listed, refer to the table TIGHTENING TORQUES, only after identifying exactly the component.

The latter is identified by a coded eight digit number,


allowing a complete description of the item.

Example.
I / a

d e / f

I - Standard index digit


It is always represented by the digit 1. This number
indicates that the item can be fabricated in a number
of versions differing for material and coating.

a - b - c - d - e - Standard base digits


It is a number always composed of five digits identifying dimensional specifications of the item.

f - Material index digit


This digit indicates the material used for a defined
item. Its meaning is indicated in the table that follows.

g - Coating index digit


It indicates the coating applied to a defined item.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

0 - 13
Resistance class and material
Material
index (f)

FIAT

R40

R50

R80

R100

Brass

Aluminium

Copper

UNI

DIN

SAE

BSI

42

56

80

10K

100

Messing

Brass

Brass

Laiton

Aluminium

Aluminium

Aluminium

Copper

Copper

Cuivre

4D - 4S - 4A
5S - 6S
8G
100
Brass

Aluminium Aluminium
Copper

Kupfer

BNA

Blank for other metallic materials

WARNING

TORQUE TABLES

- Lubricate all hardware until 24 dia., with engine oil.


Use grease for larger diameters.

If correct torque is not specifically indicated in the


relevant pages, refer to the following tables.

- Tolerance on torque: 5%
- Resistance classes R80, R100, R120 must be
understood as follows:

10.9 replaces R100


for screws
12.9
10

"

R120

replaces R80
for nuts

12

"

R100

CDT= cadmed; FOSF= phosphated; ZNT= galvanised.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

0 - 14

W190

NUTS (ZNT)

SCREWS (ZNT/DEIDR)

Strength grade: 10 (R80)

Strength grade: 10.9 (R100)

normal

Diameter
and pitch

low type

with polyamide ring

Diameter
and pitch
mm

normal
ZNT
Nm

self-locking
ZNT
Nm

M6 x 1

13

Nm

normal
Nm

low type
Nm

13

12

M8 x 1.25

32

26

39

32

M8 x 1.25

13

35

M10 x 1.25

72

52

82

62

M10 x 1.25

71

79

M10 x 1.5

65

50

77

60

M10 x 1.5

65

70

M12 x 1.25

130

87

145

102

M12 x 1.25

127

139

M12 x 1.75

110

81

129

96

M12 x 1.75

110

120

M14 x 1.5

195

130

216

150

M14 x 1.5

200

220

M14 x 2

180

125

200

146

M14 x 2

180

190

M16 x 1.5

300

170

340

200

M16 x 1.5

300

330

M18 x 1.5

450

250

500

290

M18 x 1.5

450

480

M18 x 2.5

M18 x 2.5

M20 x 1.5

600

305

645

350

M20 x 1.5

600

650

M20 x 2.5

M20 x 2.5

M22 x 1.5

800

410

M22 x 1.5

800

900

M22 x 2.5

M22 x 2.5

M24 x 2

1000

470

1080

525

M24 x 2

1000

1100

M24 x 3

M24 x 3

M27 x 2

950

401

M27 x 2

1000

M30 x 2

1300

494

M30 x 2

1400

M33 x 2

1700

M33 x 2

1900

M36 x 3

2200

M36 x 3

2400

mm

Nm

M6 x 1

M16 x 2

M16 x 2

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

SECTION 1

ENGINE
INDEX

PARAGRAPH

SUBJECT

1.1

ENGINE IDENTIFICATION ..................................................................................... 1-1

1.2

GENERAL FEATURES ........................................................................................... 1-5

1.3

DESCRIPTION OF ENGINE OPERATION ............................................................. 1-14

1.4
1.4.1
1.4.2
1.4.3
1.4.4

DESCRIPTION OF MAIN GROUPS .......................................................................


Lubrication ..............................................................................................................
Cooling ....................................................................................................................
Fan Drive System ...................................................................................................
High pressure electronic fuel injection system (Common Rail) ................................

1-16
1-17
1-18
1-19
1-21

1.5
1.5.1
1.5.2
1.5.3

TROUBLESHOOTING GUIDE ................................................................................


Troubleshooting with PT-01 instrument ...................................................................
Troubleshooting with blink code ..............................................................................
Diagnosis of main malfunctions ..............................................................................

1-33
1-34
1-35
1-37

1.6

ENGINE SUPPORTS ............................................................................................. 1-46

1.7
1.7.1

1.7.2

ENGINE OVERHAUL ..............................................................................................


Repair interventions ................................................................................................
Cylinder group ....................................................................................................
Timing ................................................................................................................
Bushes ..............................................................................................................
Crankshaft .........................................................................................................
Conrod-Piston assemgly ....................................................................................
Pistons ..............................................................................................................
Flywheel ............................................................................................................
Cylinder head .....................................................................................................
Valves ...............................................................................................................
Guide valves ......................................................................................................
Valve seats ........................................................................................................
Valve seats in cylinder head ..............................................................................
Valve springs .....................................................................................................
Assembly of the cylinder head ...........................................................................
Rods ..................................................................................................................
Tightening torques ..................................................................................................

1.8

TOOLING ................................................................................................................ 1-107

PAGE

1-47
1-59
1-59
1-61
1-62
1-65
1-69
1-70
1-80
1-86
1-87
1-88
1-88
1-89
1-91
1-91
1-93
1-104

Copyright New Holland

Copyright New Holland

W190

ENGINE

1.1 ENGINE IDENTIFICATION


Engine data plate
The engine data plant provides specific information
about your engine.
Note The engine plate must not be replaced without the
authorisation by the manufacturer.

TYPE - SERIAL NUMBER - APPROVAL

IVECO N. V.
ENGINE
TYPE
ENGINE
FAMILY
EEC
APPR. N

F4AE0684F*D101
F4AE43B00A

E3

SERIAL
NUMBER

000000

e3*97/68EA*0005*00
e3*85R02*1507
e3*24R03*1503

Fig. 1-1

ENGINE DATA

Fig. 1-2

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1-1

Copyright New Holland

1-2

W190

ENGINE

ENGINE DIAGRAMS
The illustrations here below provide information about
the components of the engine, the location of filters,
draining points and the access location for the instrumentation and controls of the engine.

The illustrations and the configuration of components


described in these diagrams are of a general nature.
the locations of some components can change, depending upon the arrangement.

Engine oil
dipstick

Air intake (from after-cooler)


Common rail

Engine oil
filler neck
High pressure
pump

Engine flywheel
cover

VIEW INJECTION
PUMP SIDE
Turbine exhaust
(silencer)

Exhaust
manifold

Electronic
controller (EDC)

Fuel filter
Turbocharger
Pressure relief
valve

Alternator

Engine oil
filter

VIEW TURBOCHARGER
SIDE
Fig. 1-3

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

1-3

ENGINE

Flex-disc
mounting holes

Flywheel

Fig. 1-4 Rear view

Water pump
pulley

Alternator pulley

Belt tensioner

Drive belt

Fig. 1-5 Front view

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

1-4

W190

ENGINE

Engine coolant
by-pass seat

Tappet cover

Injector

Fig. 1-6 Top view

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

GENERAL FEATURES

Type

IVECO NEF F4AE0684F

Cycle

Diesel 4-stroke

Air intake

Turbocharged w/aftercooler

Injection

Direct

Number of cylinders

6 in-line

Bore

mm

102

Stroke

mm

120

+.. = Total displacement

5900

cu cm

1.2

1-5

ENGINE

Compression ratio
Max. power

17 : 1
kW
(CV)

155
211

rpm

2175

Nm
(kgm)

860
87.6

rpm

1500

rpm

850

rpm

2300

Torque converter stall rpm

2110

Equipment stall

rpm

2190

Total stall

rpm

1960

Max. torque

Engine speed at
low idle

Engine speed at
high idle

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

1-6

W190

ENGINE

TURBOCHARGING

w/after-cooler

Turbocharger type
Radial play of turbocharger shaft
Axial play of turbocharger shaft
Minimum stroke of pressure
relief valve:
Maximum stroke of pressure
relief valve:
Pressure corresponding to minimum stroke:
Pressure corresponding to maximum stroke:

HOLSET HY 35 W

mm

mm
bar
bar

LUBRICATION

Forced by gear pump, pressure relief valve,


oil filter

bar

Oil pressure
w/hot engine:
at low idle
at high idle

bar
bar

COOLING

1.2
3.8
By centrifugal pump, regulating
thermostat, radiator,
heat exchanger, after-cooler

Water pump drive


Thermostat
begins to open at:
max. opening at

Belt driven
81 C (177 F)
96 C (204.8 F)

CAPACITY
Total capacity
of first filling:
litres (USG)
kg (lbs)

23 (6.07)

Ambra Super Gold or


Ambra Master Gold
15W40 10W30

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

1-7

ENGINE

TIMING
beginning BTDC
end ATDC

A
B

8.5
8.5

beginning BBDC
end ABDC

D
C

51
12.5

For timing check


X
X

mm

mm

Operational

mm

0.25 0.05

mm

0.50 0.005

FUEL
Injection
Type:

Bosch CP3.3

high pressure, common rail


EDC7 controller

Nozzle type

Electric injectors

Firing order

1-5-3-6-2-4

bar

Injection pressure
Setting of injector

bar
bar

1350

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

1-8

W190

ENGINE

DATA - MOUNTING PLAYS


(1 mm = 0.03937 in)
CYL. GROUP & CRANKING COMPONENTS

mm

Cylinder sleeves

102.009 102.031

2
L

Cylinder sleeves - seats in


cylinder block (interference)

Outer diameter

Cylinder sleeves:
L

outer diameter
length

3
X Cylinder sleeves:

1
X

inner diameter

Spare pistons type:


Dimension
for measurement
Outer diameter
Pin seat

X
1
2

Piston - cylinder sleeve

Piston diameter

12
101.883 101.897
40.008 40.014
0.116 0.134

0.5

X
Position of pistons
from cylinder block

Piston pin

Piston pin - pin seat

0.28 0.52

39.996 40.003

0.005 0.018

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

1-9

ENGINE

(1 mm = 0.03937 in)
CYL. GROUP & CRANKING COMPONENTS
X 1 Piston ring seat
X2
X3

S1
S2
S3

mm
X 1*
X 2*
X 3*

* measured on 99 mm
Piston rings

S 1*
S 2*
S 3*

1
2
3

Piston rings

X3

0.100 0.175
0.040 0.90
0.020 0.065
0.5

Gap of tips piston


rings in cyl. sleeves:

X3

2.560 2.605
2.350 2.380
3.975 4.000

* measured on 99 mm
Piston rings - seats

X3

2.705 2.735
2.420 2.440
4.020 4.040

X1
X2
X3
Seat of conrod small
end bush
1
Seat of conrod bearing
2

0.20 0.32
0.60 0.80
0.25 0.45

42.987 43.553
72.987 73.013

4
3
S

Diameter of conrod small


end bush
Outer
4
Inner
3
Spare conrod half
bearing
S

43.279 43.553
40.019 40.033
1.955 1.968

Conrod small end bush seat

0.266 0.566

Piston pin - bush

0.037 0.016

Conrod half-bearings

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

1 - 10

W190

ENGINE

(1 mm = 0.03937 in)
CYL. GROUP & CRANKING COMPONENTS
X
Measuring dimension

Max. out-of-line
of parallelism
of conrod centre lines

1
2

82.99 83.01
68.99 69.01

S1

2.456 2.464

S2

1.955 1.968

S1

S2

Crankshaft journals
Conrod journals

mm

Crankshaft half
bearings
Conrod half
bearings
* supplied as spare part

Crankshaft journal supports


3 Nos. 1 - 5
3
nos. 2 - 3 - 4
3

87.982 88.008
87.977 88.013

Crankshaft journal half


bearings - journals
Nos. 1 - 5
nos. 2 - 3 - 4

0.041 0.119
0.041 0.103

Half bearings conrod journals

0.033 0.041

Crankshaft half bearings


Conrod half bearings

Thrust crankshaft
journal

X1

37.475 37.545

X1

Thrust crankshaft journal


support
X2

25.98 26.48

Thrust half
bearings

37.28 37.38

X2
X3

Crankshaft thrust

X3

0.068 0.41

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

1 - 11

ENGINE

(1 mm = 0.03937 in)
CYLINDER HEAD - TIMIMG

mm

1
Valve guide seats on
cylinder head

7.042 7.062

2
Valve guide

Valve guides and seats


on head

Valve guide

Valves:

6.970 6.999
60 0.25

6.970 6.999
45 0.25

Valve stem and


relevant guide

0.052 0.092

Seat on head for valve


seat:
1

Outer diameter of
valve seat;
Angle of valve seat
on cylinder head:

X Sinking

60

45

0.59 1.11

0.96 1.48

Between valve seat


and head

Valve seats

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W190

ENGINE

(1 mm = 0.03937 in)
CYLINDER HEAD - TIMIMG

mm

Height of valve spring:

H1

free spring

47.75

H 2 under a load of:


339.8 9 N
741 39 N

H1
H2

35.33
25.2

Protrusion of injectors
X

1 2 3 4

Sets for camshaft bushes


nos. 1-5

59.222 59.248

Seats for camshaft


nos. 2-3-4

54.089 54.139

Camshaft support
pins:
15

53.995 54.045

Outer diameter of
camshaft bushes:

Inner diameter of
bushes

54.083 54.147

Bushes and seats


in cylinder block

Bushes and support


pins

0.038 0.162

Cam lift:
H

H
H

6.045
7.582

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1 - 13

ENGINE

(1 mm = 0.03937 in)
CYLINDER HEAD - TIMIMG
1

2
3

Seat of tappet in
cylinder block

mm

16.000 16.030

2
3

15.924 15.954
15.960 15.975

Outer diameter of
tappet:

Between tappets and seats

Tappet rods

0.025 0.070

1
Rocker arm shaft

21.965 21.977

Rocker arms

22.001 22.027

2
Between rocker arms
and shaft

0.024 0.162

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1.3

ENGINE

W190

DESCRIPTION OF ENGINE OPERATION

The illustrations the configuration and the shape of


some components illustrated in these diagrams can

show some differences, being they indicative only.

ENGINE CROSS SECTION

Fig. 1-7

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W190

ENGINE

ENGINE LONGITUDINAL SECTION

Fig. 1-8

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1 - 15

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1.4

W190

ENGINE

DESCRIPTION OF MAIN GROUPS

CYLINDER HEAD
On the pig iron made heads, the seats of the following items are located:
Valve seats:
A directly machined for lower power engines;
B inserted, on higher power 4 or 6 cylinder engines.
Fuel discharge duct from the electric injectors, obtained directly during the casting inside the cylinder
head.

Electric injectors (2).


Thermostat (4).
Fuel neck (9) for electric injectors.
Also, on the cylinder heads are mounted:
Exhaust manifold (1):
Support (7) for the electric injectors wiring 3.
Intake manifold (5) with seat for cold starting air
heater (6).

5
1

7
2

9
4

For engines with valve seats directly machined in


the cylinder head

B
For engines with valve seats inserted in the
cylinder head

Fig. 1-9

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1 - 17

ENGINE

1.4.1 LUBRICATION
The forced circulation lubrication is provided by the
following components:
rotor type oil pump (5), located in the front of the
cylinder block, driven by a straight teeth gear;
water/oil heat exchanger (3) located in the cylinder
block, with oil filter support;

oil pressure relief valve (1) incorporated in the filter support;


by-pass valve (4) cutting-off the oil filter when
clogged, incorporated in the filter support;
cartridge oil filter (2).

2
3

Flow of oil under pressure


Return flow of oil by gravity

Oil filler

Fig. 1-10

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ENGINE

W190

1.4.2 COOLING
The engine cooling system, of a closed-circuit, forced
circulation type, includes the following components:
radiator, dissipating the heat removed from the
engine by the coolant;
fan;

a heat exchanger cooling lubricating oil (see


lubrication);
a centrifugal type water pump located in the front
side of the cylinder block;
a thermostat regulating the circulation of the coolant.

Water flowing from the


thermostat
Water re-circulating the
engine
Water entering the pump

Fig. 1-11

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1 - 19

ENGINE

1.4.3 FAN DRIVE SYSTEM


General description
The configuration of the cooling system of the engine
is as follows:
A hydraulic pump connected to engine (1) (fuel pump
side) powers two hydraulic motors driving, respectively, the coolant radiator fan and the aftercooler fan.
A controlling valve is located between the two circuits having a dual function: to modulate the oil flow
to the hydraulic motors according to the engine rpm
and to invert the rotation direction of the radiator fan
upon a command by the button located in the cab.

Once the oil is sucked by pump (1) it is forwarded to


controlling valve block (2) and through solenoid valve
(3) it reaches bi-directional hydraulic motor (4) driving
the main fan.
Also through solenoid valve (3) oil under pressure
reaches the second hydraulic motor (5) driving the
aftercooler fan, then it is discharged.

TO DISCHARGE LINE

BI-DIRECTIONAL MOTOR (14 cu cm/rev.)


(ENGINE RADIATOR)

SINGLE DIRECTION MOTOR (14 cu cm/rev.)


(AFTERCOOLER)

4
5
1/2 BGP

10
220 BAR

1/2 BGP

11
220 BAR

7
G1

1/4 BGP

200 BAR

A
6

P1 3/4"BSP

Fig. 1-12
1. Pump - 2. Fan hydraulic control block - 3. Solenoid valve - 4. Bi-directional hydraulic motor - 5. Single direction hydraulic
motor - 6. Proportional valve - 7. Safety valve - 8. Orifice (2 mm) - 9. Safety valve - 10. Safety valve - 11. Safety valve.

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W190

ENGINE

FAN HYDRAULIC CONTROL BLOCK

DIMENSIONS OF PORTS
P1 T
A B
G1 MT

THREADED 3/4" BSP


T1

THREADED 1/2" BSP

THREADED 1/4" BSP

T1

MT1

P1

A
C1

Fig. 1-13
1. Drilled block - 2. Safety valve - 3. Proportional valve - 4. Safety valve - 5. Solenoid valve - 6. Anti-cavitation valve 7. Safety valve - 8. Safety valve - 9. Dowel.

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1 - 21

ENGINE

1.4.4 HIGH PRESSURE ELECTRONIC FUEL


INJECTION SYSTEM (COMMON RAIL)
DESCRIPTION OF SYSTEM

Electrical system

The system is composed of the electrical system and


the hydraulic system.

The controller directs the operation of the engine


through the sensors installed on it.

6
2

7
3
8
9
4

10

Fig. 1-14

1. Fuel pressure sensor - 2. Engine coolant temperature sensor - 3. Engine oil temperature and pressure sensor 4. Engine crankshaft sensor - 5. Electric injector - 6. Air pressure temperature sensor - 7. Camshaft sensor - 8. Fuel heater
and fuel temperature sensor - 9. Pressure regulator - 10. EDC 7 controller.

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ENGINE

INJECTION SYSTEM ASSEMBLY


REF. DESCRIPTION
1

Position sensor on accelerator pedal

Key switch

Parking brake engaged switch

Gearshift in neutral switch

EDC main fuse (20 Amp)

Diagnostic connector

Blink-Code button

Engine oil pressure

Coolant temperature

10

Revolution counter

11

Pre-heater ON indicator

12

Starter motor

13

Crankshaft sensor

14

Pre-heater activation solenoid switch

15

Fuel temperature sensor

16

Fuel heater resistor

17

Timing sensor

18

Pressure regulator solenoid valve

19

Coolant temperature sensor

20

Pre-heater resistor

21

Electric injectors

22

Air temperature/pressure sensor

23

Fuel pressure sensor

24

Oil temperature/pressure sensor

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W190

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W190

1 - 23

ENGINE

INJECTION SYSTEM ASSEMBLY

21

22

20

19

23

18

16

17
15
24
14
12

13

7
6
8

10

5
MEGA
FUSE

w \

w \ E H@

w \ E H@

w \

w w

11

CAN LINE

1
OFF

ACC.
ON

ACCELERAT. PEDAL

START

PEDAL PROXIMITY SENSOR


POTENTIOMETER

Fig. 1-15
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ENGINE

W190

DESCRIPTION OF INJECTION SYSTEM


Control of engine pre-heater resistor

Limitation of maximum speed

The pre-heater is activated every time even just one


of the coolant, air or fuel sensors measures a temperature < 5 C (41 F).

At 2300 rpm, the controller limits the delivery of fuel


by reducing the opening time of the electric injectors.

Timing recognition
Through the signals of the sensor on the camshaft
and the one on the crankshaft, the starting cylinder
where the fuel must be injected is identified.

Cut-off
The cutting-off of fuel during the engine slow down or
when used to brake is managed by the controller by
performing these logics:
it cuts-off supply to the electric injectors;

Control of injection
The controller, in accordance with the information provided by the sensors, controls the pressure regulator,
changing the modes of the pre-injection and the main
injection.
On tector engines, the pre-injection is activated at all
engine speeds.
Closed circuit control of the injection pressure
Depending upon the engine load, determined by the
processing of the signals provided by the various sensors, the controller controls the regulator to provide
constantly an optimised pressure.
Control of pilot and main injection advance
The controller, depending upon the signals provided
by the various sensors, defines the optimised injection point in accordance with an internal mapping.

it reactivates the electric injectors just before reaching low idle speed;
it controls the fuel pressure regulator.
Control of smoke emission during accelerations
When high loads are required, the controller, depending upon the signals provided by the air intake measuring device and the crankshaft speed sensor, controls the pressure regulator and changes the actuation time of the electric injectors, to prevent the engine from smoking.
After Run
When cutting-off the engine, the microprocessor of
the controller memorises some data in the EPROM
including a trouble memory, so that the data are available when a new starting occurs.

Control of low idle speed


The controller processes the signals provided by the
various sensors and regulates the quantity of fuel injected. It controls the pressure regulator and changes
the injection timing of the electric injectors.
Within certain thresholds, it considers also the voltage of the batteries.
Overheating protection
In the event the coolant temperature reaches 110 C
(230 F) the controller decreases the performance of
the engine.
Once the temperature drops below 100 C (212 F)
the engine resumes normal operations.

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1 - 25

ENGINE

Hydraulic system
The common rail system is equipped with a special
pump keeping the fuel constantly at high pressure,
independently from the timing and the cylinder going
to receive the injection and accumulates it in a common rail duct for all the electric injectors.

When the solenoid valve of an electric injector is energised by the controller, fuel is injected into the relevant cylinder directly from the rail.
The hydraulic system is composed of a low-pressure
circuit and a high-pressure circuit.

Thus, at the inlet of the electric injectors fuel at the


injection pressure calculated by the controller is always available.

3
1
4
2
5

6
7

Low pressure
High pressure
Fig. 1-16
1. Electric injector - 2. Common rail - 3. Pressure limit device for fuel return - 4. Common rail pressure relief valve 5. Pre-filter installed on the frame - 6. High pressure pump - 7. Rotor type mechanical pump - 8. Fuel filter.

The high-pressure circuit is composed of the following pipes:


piping connecting the high pressure pump outlet to
the common rail;
pipes from the common rail supplying the electric
injectors.
The low-pressure circuit includes the following pipes:

pipes supplying the mechanical fuel pump through


the controller heat exchanger, the manual priming
pump and the pre-filter;
pipes supplying the high pressure pump through the
fuel filter.
The fuel system is completed by the fuel discharge
circuit from the common rail, the injectors and the
high-pressure pump cooling circuit.

fuel suction pipe from tank to pre-filter;

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1 - 26

W190

ENGINE

Hydraulic diagram

7
DISCHARGE
SUCTION (LOW PRESSURE)
HIGH PRESSURE PUMP SUPPLY
(LOW PRESSURE)
HIGH PRESSURE

3
18
8
13

17

ECU
EDC7

9
10

16

11

15

12

14
Fig. 1-17
1. High pressure pump - 2. High-pressure pump pressure relief valve, 5 bar - 3. Modulating valve installed on fuel return
from the injectors 1,3 - 2 bar - 4. Common rail pressure relief valve - 5. Common rail - 6. Pressure sensor - 7. Electric
injector - 8. Return pipe - 9. Controller heat exchanger - 10. Mechanical priming pump - 11. Pre-filter mounted on frame 12. Fuel tank - 13. Mechanical fuel pump - 14. Fuel filter - 15. Pressure regulator - 16. High-pressure pump cooling pipe 17. By-pass valve - 18. By-pass valve.

The pressure regulator, located after the high-pressure pump, regulates the flow of fuel required by the
low-pressure system. Subsequently, the high-pressure
system supplies correctly the common rail. This solution, pressurising the fuel required only, improves
the energetic performance and limits the heating of
the fuel in the system.
Pressure relief valve (2) installed on the high-pressure pump, keeps the pressure at the inlet of the pressure regulation constantly at 5 bar (71.51 psi).

Pressure relief valve (3) located on the cylinder head,


installed on the return of the electric injectors, regulates the fuel return flow from the electric injectors at
a pressure of 1.3 to 2 bar (18 to 29 psi).
Two by-pass valves are located in parallel to the fuel
pump.
By-pass valve (18) makes the fuel to re-flow from the
outlet of the mechanical pump to its inlet, when the
pressure at the inlet of the fuel filter exceeds the allowed value.
By-pass valve (17) allows the filling of the fuel system by manual priming pump (10).

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1 - 27

ENGINE
HIGH PRESSURE PUMP CP3

FUEL MECHANICAL PUMP


A

Sect. A-A

Fig. 1-18
A
Pressure regulator on inlet
Located on the inlet of the high-pressure pump,
(3, Fig. 1-19) on the low-pressure system, it modulates the quantity of fuel supplied to the high-pressure pump in accordance with the commands received
from the controller.

B
C
3

It is mainly composed of the following components:


trapezoidal section plunger;
valve control pin;
pre-load spring;
solenoids.

D
E

When no command signal is received, the pressure


regulator is normally open, thus the high-pressure
pump is in maximum flow condition.

Fig. 1-19

The controller modulates a PWM command to control


in a larger or smaller manner the fuel passage section
toward the high-pressure pump.

A. Connection for fuel discharge outlet to filter support. B. Connection for fuel inlet from controller heat exchanger C. Connection for fuel inlet from fuel filter - D. Connection
for fuel outlet from fuel pump to filter - E. Fuel outlet connection to rail - 1. High pressure pump - 2. Fuel pump 3. Pressure regulator (solenoid valve NA modulated by
controller with PWM signal).

The component cannot be replaced individually; thus


it must not be removed.

3-radial piston pump driven timing gear, without need


for timing setting, with fuel rotor pump mounted on
the rear side.

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W190

ENGINE

Internal structure of the high pressure pump


Sect. B-B
7
B

1
5

Sect. C-C

Fig. 1-20
1. Cylinder - 2. Three lobe element - 3. Plate type inlet valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft - 7. Lowpressure fuel inlet - 8. Fuel ducts for pumping element supply.

Each pumping group is composed of:


piston (5) actuated by a three-lobe element floating
on pump shaft (6). Element (2), floating on a out-ofline part of shaft (6) during the rotation of the shaft
does not rotate with it but it is only moved circularly
on a larger radius, with the result that it actuates,
alternatively, the three pumping elements;
a plate type suction valve (3);
a ball delivery valve (4).

Note The high pressure-fuel pump group cannot be


overhauled, thus the securing screws must not be
tempered with nor it must be removed. The only intervention allowed is replacing the drive gear and replacing pressure regulator (3).

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1 - 29

ENGINE
Rail

Operation
The cylinder is filled through the plate intake valve
only when the supply pressure is capable of opening
the delivery valves located on the pumping elements
(about 2 bar) (29 psi).

The quantity of fuel supplying the high-pressure valve


is dosed by the pressure regulator, located on the
low-pressure system; the pressure regulator is controlled by the EDC7 controller through a PWM signal.
When fuel is forwarded to the pumping element, the
relevant piston is moving downward (suction stroke).
Once the stroke of the piston is inverted, the intake
valve closes and the fuel in the pumping element
chamber, being prevented from getting-out, is compressed over the value of the supply pressure in the
rail.
The pressure generated in this manner causes the
opening of the discharge valve and compressed fuel
reaches the high-pressure circuit.
The pumping element compresses the fuel until it
reaches the TDC (delivery stroke). Then, the pressure decreases until the discharge valve closes.
The piston of the pumping element returns toward the
BDC and the residual fuel decompresses.
Once the pressure in the pumping element chamber
becomes lower than the supply pressure, the intake
valve opens again and the cycle is repeated.
Delivery valves must always be free in their movement, free from impurities and oxidation.

Fig. 1-21
1. Rail - 2. Flow limiters - 3. Fuel inlet from high pressure
pump - 4. Pressure sensor - 5. Pressure relief valve.

The volume of the rail has reduced dimensions to provide a fast pressurisation when starting, at low idle
and in case of large flows.
It has anyway, a volume sufficient to minimise the
fluctuations caused by the opening and the closing of
the injectors and the operation of the high-pressure
pump. This function is further eased by a calibrated
orifice located after the high-pressure pump.
A fuel pressure sensor (4) is screwed on the rail. The
signal forwarded by this sensor to the controller provides a feedback information, on which the pressure
value in the rail is measured and corrected, if required.

The delivery pressure to the rail is modulated between


250 and 1350 bar (3625 to 19580 psi) by the controller, through the solenoid valve of the pressure regulator.
The pump is lubricated and cooled by the fuel itself.
The cut-off/reactivation time of the radialjet pump on
the engine is greatly reduced compared with traditional
injection pumps, since it does not require timing setting.
In case of removal-reinstallation of the piping between
fuel filter and high-pressure pump, keep your hands
and components perfectly clean.

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W190

ENGINE

Pressure relief valve


The pressure relief valve (1750 bar) (25381 psi) on
the common rail protects the components of the
4

system in the event a flow limiter intervenes.

B
A

Fig. 1-21
1. Body - 2. Piston - 3. Stop - 4. Spring - 5. Discharged directed to tank - 6. Seat on rail.

A. Normally, the tapered end of the piston keeps the


discharge toward the tank closed.

B. In case the fuel pressure of 1750 bar (25381 psi)


in the rail is exceeded, the piston moves and the
pressure excess is discharged into the tank.

Flow limiters
They are located on the rail fuel outlet connections.
Their function is to protect the integrity of the engine
or the vehicle in the event of internal spills (example
injector stuck open) or external (example: damaged
high-pressure pipes).
If this occurs, the operation of the system is provided,
within certain limits, by the components of the other
cylinders in operational conditions.

WARNING
After the intervention to block the leakage of fuel
from the rail, the flow limiter is automatically reset under the action of the spring. However, f the
cause of its intervention is not eliminated, at the
next starting tentative the engine could operate
only at low idle or at low speed or to be cut-off
again, depending upon the entity of the leakage.

1
1

3
5 2

5 2

Fig. 1-22
1. Body - 2. Piston - 3. Fuel inlet - 4. Spring - 5. Securing thread on rail.

A. The passage of fuel from the rail to the electric


injectors occurs through holes drilled on the small
diameter of the piston.
Under normal conditions, the fuel pressure is on
both sides of the piston, kept by the spring in open
position.

B. In the event of a large pressure drop after the


limiter, the inlet pressure prevails and moves the
piston toward the opposite side, cutting-off the
outflow of fuel.

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1 - 31

ENGINE

Electric injector
The injector has a design similar to traditional ones.
The electric injector can be considered composed of
two parts:

The solenoid valve controls the lifting of the injector


needle.

actuator-nozzle composed of pressure rod (1), needle (2) nozzle (3);


control solenoid valve composed of coil (4) and pilot valve (5).

Injector in rest condition

12

7
11

1
10

13

2
8

3
Fig. 1-23
1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball plunger - 7. Control area - 8. Pressure chamber 9. Control volume - 10. Supply-control duct - 11. Outlet of control fuel - 12. Electric connector - 13. Spring.

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W190

ENGINE

Beginning of injection
When solenoid (4) is energised it moves ball plunger
(6) upward. The fuel of control volume (9) flows toward re-flow duct (12) causing a pressure drop in control volume (9).

At the same time the fuel pressure in pressure chamber (8) causes the lifting of needle (2) with the subsequent injection of the fuel into the cylinder.

12

6
9

7
11

1
10

13

2
8

Fig. 1-24
1. Pressure rod - 2. Needle - 3. Nozzle - 4. Solenoid - 5. Pilot valve - 6. Ball plunger - 7. Control area - 8. Pressure chamber 9. Control volume - 10. Supply-control duct - 11. Outlet of control fuel - 12. Electric connector - 13. Spring.

End of injection
Once solenoid (4) is de-energised, plunger (6) returns
into position closed, re-creating equilibrium of forces

returning needle (2) into closed position, terminating


the injection.

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W190

ENGINE

1.5 TROUBLESHOOTING GUIDE


FOREWORD
Experience is the factor facilitating the solution of troubles.
To partially overcome the lack of experience by the
repair engineer on this new electronic device, since
no previous systems to which refer existed, we list in
the pages to follow a TROUBLESHOOTING GUIDE.
The troubleshooting guided is composed of two sections, neatly defined:
the first one, organised by Blink Code, refers to
troubles that can be directly identified by the EDC7
controller. These troubles are of are mostly of an
electric- electronic nature;
the second, organised by symptom, describes possible troubles not directly identifiable by the controller. These troubles are mostly of a mechanical-hydraulic nature.
The troubleshooting guides do not replace the diagnosis with electronic diagnostic equipment, but should
be considered as integration to the same.

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1 - 33

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W190

ENGINE

1.5.1 TROUBLESHOOTING WITH PT-01


INSTRUMENT
The PT-01 380001218 diagnostic instrument shown

in the illustration is supplied with a set of connecting


cables as well as an Operation Manual.

1. outer power connection


2. diagnostic connecting cable

1.
2.
3.
4.
5.

P T- 0 1

HW failure
transm. K line comun.
transm. line K reception
transmission L line communication
line bus CAN
1. serial port
2. porta USB

CAN

6. power

7. navigation buttons
8. communication status
indicators

1
4
7

2
5
8
0

3
6
9
X
1010

9. numerical buttons

10. CANCEL button


11. USB port indicator

12. OK button
13. serial port indicator

Controller-instrument
connecting cable
Connection point

P T- 0 1

CAN

Fig. 1-25

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ENGINE

1.5.2 TROUBLESHOOTING WITH BLINK


CODE
Performance of the EDC indicator lights
The panel with the trouble indicator light is located in
the cab and can be reached after removing the plastic cover behind the operator's seat.

ON
ENGINE
DIAGNOSTIC

1-26

Fig. 1-26

ACTIVATION/READING THE BLINK CODE


By actuating the "ENGINE DIAGNOSTIC" switch it
is possible to monitor the operational condition of the
controller and to identify the presence of the error
codes activated.
Method:

Engine inoperative
Key on second click (ON)
"Diagnostic" switch ON

The code is composed of two digits divided by a dot


(Ex. "2.3") and it is shown by slow flashes followed
by fast flashes.
If no troubles are identified in the system, the EDC
indicator light does not provide any information and
comes ON once only. If, as an example, the first active code is "2.3" we have:
a. 2 slow flashes;
b. pause;
c. 3 fast flashes.
Important The connection and disconnection operations of the controller must be performed with the positive
terminal of the battery disconnected.

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W190

ENGINE

TROUBLE CODES
FLASH
CODE
1.4
1.8
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.7
3.8
3.9
5.1
5.5
5.3
5.6
5.2
5.4
5.7
5.8
6.1
6.2
6.3
6.4
6.5
7.2
7.6
7.8
8.1
8.2
8.3
8.4
8.5
9.4
9.6
9.7

DESCRIPTION OF TROUBLE
VEHICLE
Signal, accelerator pedal
Indicator EDC on dashboard
ENGINE 1
Signal, coolant temperature sensor
Signal, turbo-charging air temp. sensor
Signal, fuel temp. sensor
Signal, turbo-charging pressure sensor
Signal, ambient pressure sensor
Signal, oil pressure sensor
Signal, oil temperature sensor
Relay, heated filter control
Relay, control for pre-post heater resistor
ENGINE 2
Battery voltage
Indicator, pre-post heater
Resistor, pre-post heater
INJECTORS
Solenoid valve, injector cylinder 1
Solenoid valve, injector cylinder 5
Solenoid valve, injector cylinder 3
Solenoid valve, injector cylinder 6
Solenoid valve, injector cylinder 2
Solenoid valve, injector cylinder 4
Bank 1 (cylinders 1-2-3)
Bank 2 (cylinders 4-5-6)
ENGINE RPM
Signal, crankshaft sensor
Signal, camshaft sensor
Engine speed conformity
Engine over-speed
Starter motor relay
INTERFACES
Line CAN
DASHBOARD
Indicator light, oil pressure
Indicator light, coolant temperature
FUEL PRESSURE
Fuel pressure control
Signal, fuel pressure
Solenoid valve, pressure regulator
Monitoring of rail press. regulation valve
Pressure drop in rail
CONTROLLER
Main relay
Internal error in the controller
Sensors power

TYPE OF FLASHING:
POWER REDUCTION:

2 = Intermittent
1 = Continuous
0 = 0% reduction 1 = Power curve reduced
4 = Engine inoperative

CODE

SAE
CODE

TYPE OF
FLASH

POWER
REDUCTION

APP1
LP6

0120
1675

1
0

3
0

CTS
BTS
FTS
BPS
APS
OPS
OTS
HP7
HP1

0115
0110
0180
0235
0105
0520
0195
1686
1680

1
0
0
1
0
1
0
0
0

0
0
0
0
0
1
0
0
0

BAT
LP1
TGHV

0560
1670
1875

1
0
0

2
0
0

SV1
SV2
SV3
SV4
SV5
SV6
C1
C2

0201
0202
0203
0204
0205
0206
1606
1607

1
1
1
1
1
1
1
1

2
2
2
2
2
2
3
3

CRK
CAM
ESS
CMOL
HP8

0335
0340
0320
0219
1687

1
1
1
2
0

2
2
0
0
0

CANDEF

1611

LP4
LP5

1673
1674

0
0

0
0

MPROP
FPS
HPC1
MPRV
DRV

0233
0190
1690
0231
0233

2
2
2
2
2

3
3
3
3
4

MMR
STSP
PSS

1625
1285
0561

1
1
1

0
3
0

0 = OFF
2 = 50% torque

3 = Engine speed reduced

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1 - 37

ENGINE

1.5.3 DIAGNOSIS OF MAIN MALFUNCTIONS


The main malfunctions of the engine are:
1 The engine fails to start;
2 The engine overheats;
3 The engine is low powered;
4 The engine produces black or dark grey smoke;
5 The engine produces grey smoke (tending to
white);

6
7
8
9
10

The engine produces blue smoke;


The engine makes unusual knocks;
The engine stops;
Excessive or insufficient oil pressure;
Excessive fuel consumption.

THE ENGINE FAILS TO START

Connections of the battery terminals efficient.

NO

Clean, check, tighten or replace terminal nuts.

NO

Perform checks described in Repair Manual.

YES

Batteries efficient.

YES

Starter motor efficient.

NO

Perform checks described in Repair Manual ".

YES

No air leakages in low pressure supply system.

NO

Eliminate cause of leakage.


Bleed system.

YES

No traces of water in supply system.

NO

Eliminate causes for infiltration.Clean fuel


system, including tank.

NO

Replace.

YES

Fuel pre-filter - filter efficient.

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1 - 38

W190

ENGINE

Pre-post heater system efficient.

NO

Diagnose with PT-01.

YES

High-pressure pump efficient.

NO

Test engine with PT-01.

NO

Test engine with PT-01.


Check efficiency of O-Ring.

YES

Injector efficient.

YES

Compression ratio correct.

NO

Overhaul the engine or restrict intervention to


components involved, (valves, piston rings
etc.).

NO

Check for possible spills and top-up level.

NO

Check, adjust tension and replace parts as


required.

THE ENGINE OVERHEATS

Coolant level correct.

YES

Water pump and fan drive belts efficient.

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W190

1 - 39

ENGINE

Water pump efficient.

NO

Overhaul or replace group.

YES

Thermostat efficient.

NO

Replace.

NO

Perform an accurate washing; check if there


are spills. Replace item if required.

NO

Clean or replace defective parts.

NO

Check and replace as required.

NO

Replace.

NO

Replace.

YES

Radiator efficient.

YES

Air cleaner and circuit piping efficient.

YES

Engine brake disengages.

YES

Cylinder head gasket efficient.

YES

Fan efficient.

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1 - 40

W190

ENGINE

THE ENGINE LACKS POWER

Fuel filters efficient.

NO

Replace, proceeding as described in


"Operation and Maintenance" Manual.

YES

Low and high-pressure supply systems


efficient.

NO

Check tightness of system connections.

YES

Thermostat efficient.

NO

Replace.

YES

Tank filled with fuel.

NO

Check fuel level.

NO

Check transfer pump and clean suction form


possible impurities.

NO

Engine test with PT-01, replace as required.

NO

Engine test with PT-01, replace


required.Check tightness of O-Ring.

NO

Disconnect the fuel return pipe from the rail


and check if leaking.

YES

Fuel suction in tank efficient.

YES

High-pressure pump efficient.

YES

Injectors efficient and flow limiter correctly


operating.

as

YES

Rail pressure relief valve efficient.

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W190

1 - 41

ENGINE

Compression rate correct.

NO

Engine test with PT-01.

NO

Repair or replace the group.

NO

Check - recondition.

YES

Turbocharger efficient (integrity of blades,


bearings, actuators).
YES

Valve clearance correct.

THE ENGINE PRODUCES BLACK


OR DARK GREY SMOKE

Air cleaner efficient.

NO

Replace.

YES

Injectors efficient.

NO

Engine test with PT-01.Check tightness


of O-Ring.

NO

Engine test with PT-01.

YES

Compression rate correct.

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1 - 42

W190

ENGINE

THE ENGINE PRODUCES GREY


SMOKE (TENDING TO WHITE)

Injectors efficient.

NO

Engine test with PT-01.Check tightness of ORing.

YES

Level of coolant correct.

NO

Probable passage of coolant into the


combustion chambers. Replace cylinder head
gasket or overhaul engine.

THE ENGINE PRODUCES BLUE SMOKE

Presence of oil in the cylinders.

YES

Excessive oil consumption.Oil leaking from the


turbine. Leakage from valve guides.

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1 - 43

ENGINE

THE ENGINE MAKES


UNUSUAL KNOCKS

Knock in crankshaft.

YES

Check: plays and out-of round of main journals,


securing of main journal caps and flywheel; oil
pressure. Replace parts or overhaul engine.

NO

Knock in conrods.

YES

Check: plays and out-of round of conrod


journals, securing of conrod journal caps
conrod square; oil pressure. Replace parts or
overhaul engine.

NO

Knock in pistons.

YES

Check: play between pitons - cylinder sleeves;


integrity of piston rings; play pins-piston
seats.Replace parts or overhaul engine.

NO

Knock in cylinder heads.

YES

Check: clearance between rocker arms and


valves, timing. Adjust.

NO

YES

Knock in timing.

Check gears and replace as required.

NO

Knock in air compressor.

YES

Overhaul or replace air compressor.

YES

Check and calibrate them as prescribed by S.I.


1094 or replace them.

NO

Knock in injectors.

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1 - 44

W190

ENGINE

THE ENGINE STOPS

Tank filled with fuel.

NO

Refuel and bleed, if required.

YES

Fuel filters efficient.

NO

Replace.

YES

Fuel supply circuit efficient.

NO

Check the circuit and bleed.

INSUFFICIENT OR ESCESSIVE
OIL PRESSURE

Pressure relief valve works correctly.

NO

Check and replace, if required.

YES

Oil pump and delivery piping efficient.

NO

Check and replace, if required.

YES

Main and conrod journals efficient.

NO

Replace bearings and grind crankshaft, if


required.

NO

Change engine oil with other with appropriate


viscosity.

YES

SAE viscosity of engine oil correct.

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W190

10

1 - 45

ENGINE

EXCESSIVE FUEL CONSUMPTION

Fuel tank and pipes efficient.

NO

Eliminate possible leakages and replace faulty


parts.

YES

Air cleaner efficient.

NO

Replace.

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1 - 46

W190

ENGINE

1.6 ENGINE SUPPORTS


The engine is secured to the rear module of the frame
in four points by brackets.

1
6

Frontally by the torque converter-transmission group


and rearward by the engine itself. All the brackets, in
turn, rest on elastic pads.

5
1

3
8
9
7
10

1
6

11
12

5
Fig. 1-27 Engine supports

Notes - 1

224 Nm

110 Nm

110 Nm

380 Nm

1. Screw M16 x 110 - 2. Screw M12 x 40 - 3. Screw M20 x 45 - 4. Screw M10 x 100 - 5. Nut - 6. Rear bracket - 7. Rear
bracket - 8. Washer - 9. Upper plate - 10. Elastic pad - 11. Lower plate - 12. Washer

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1 - 47

ENGINE

1.7 ENGINE OVERHAUL


4
Remove fuel filter (5) from support (1);
Disconnect the low-pressure fuel pipes (2 - 3 - 4)
from support (1);
Remove support bracket (1) from the cylinder block.

10

Fig. 1-30
5
Disconnect fuel piping (2) from the rail and high-pressure pump (9) and remove from the cylinder block by
removing securing screws (4 and 6).

Note When loosening connection (7) of piping (2) it is


necessary to prevent the rotation of connection (10) of
high-pressure pump (9) with an appropriate wrench.

Fig. 1-28

1-31

Fig. 1-29

Fig. 1-31

Note To disconnect the low-pressure fuel pipes (2 - 3


- 4 Fig. 28) from the relevant connecting joints, it is
necessary to press stop (1) as shown in Figure B.

Remove screws (2) and disconnect oil piping (3) from


compressor pipe (1) and from the cylinder block.
Remove starter motor (4) from the flywheel cover.

After disconnecting the piping, return stop (1) into locking position of Fig. A to prevent that it could be deformed.

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ENGINE

Fig. 1-32
Install brackets (1) on the engine cylinder block and
secure them to an overhaul stand (2).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

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W190

1 - 49

ENGINE

1
6
2
7

10

5
11

Fig. 1-33
1. Connections for electric injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil
temperature and pressure sensor - 5. Crankshaft sensor - 6. Electric injector - 7. Air pressure-temperature sensor 8. Timing sensor - 9. Fuel heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC 7 controller.

Disconnect the engine cable disconnecting connectors (1) from electric injectors harness (6), (7) air pressure/temperature sensor, (3) fuel pressure sensor, (11)
controller, (10) high-pressure pump sensor, (8) timing
sensor, (2) engine coolant temperature sensor, (5)
engine rpm sensor.
Disconnect from rail (2): fuel piping (7) following the
procedures described in Fig. 29. Disconnect fuel pipes
(5) from rail (2) and from electric injectors manifolds
(6).

2
3

Note When disconnecting connections (4) securing


pipes (6) to rail (2) it is necessary to prevent the rotation of
flow limiters (3) with an appropriate wrench.
Remove screws (1) and remove rail (2).

6
Fig. 1-34

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1 - 50

W190

ENGINE

1
2

2
3

9
10
11

12

5
6
7
8

13
Fig. 1-37

Fig. 1-35
Disconnect fuel return pressure relief device (1), piping (2) as described in Fig. 29.

Loosen nuts (1) securing tappet adjustment and loosen


the adjusters.

Remove nut (10). Loosen band (6) and remove oil


fume pipe (9).

Remove screws (2), remove rocker arm group (3) composed of support (6), rocker arms (4) pins (5) and remove bridges (7) from the valves.

Remove connections (13-11) and remove piping (12).

Remove tapped rods (8).

Remove nuts (7) and remove tappet cover (8) complete with gaskets.

1
7

2
8

3
4

Fig. 1-36

Fig. 1-38

Remove nuts (7) and disconnect the electric wiring of


electric injectors (8).
Remove screws (1) and disconnect electric injector
wiring support (2) complete with gaskets.
Remove screws (5) disconnect air temperature/pressure sensor (6).
Remove nuts (3) and extract fuel manifolds (4).

Remove the screws securing the electric injectors with


tool 380001099 (1) and extract electric injectors (2)
from the cylinder head.

Note The fuel manifolds (4) removed, must not be reused, but replaced by new ones.

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W190

1 - 51

ENGINE

3
2

2
3

6
6

5
7

Fig. 1-40

Fig. 1-39
Remove screw (4) securing oil piping retainer (5).
Disconnect oil piping (5) from oil heat exchanger/filter
support (7).
Remove nuts (2) and remove turbocharger (3) from
exhaust manifold (1).

Remove screws (1) and remove the air conveyor assembly from the heater. Remove screws (3) remove
cover (2) and the thermostat underneath (5).
Note The outer screws marked are shorter.

Remove securing screws (6) and remove the exhaust


manifold in two pieces with the relevant gaskets.
1

2
Fig. 1-41
Sling brackets (1) with steel ropes and a hoist to remove cylinder head (2) from the cylinder block.

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1 - 52

W190

ENGINE

1
2
1
3

Fig. 1-42

Fig. 1-44

Remove cylinder head gasket (1).

Remove screws (2) and remove alternator support (3).

Using the appropriate wrench on the automatic belt


tensioner (3) loosen the tension of belt (2) and remove it.

Remove oil filter (1).

Remove screw (4) and remove automatic belt


tensioner (3).
6
1
2
3

Fig. 1-45

Fig. 1-43

Remove screws (4) and remove oil temperature sensor (3).

Remove screws (2) and remove alternator (1).

Remove screws (1) and remove oil heat exchanger


filter support (2), intermediate plate (6) and the relevant gaskets.
Remove oil level sensor (5).

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W190

1 - 53

ENGINE

1
1

4
2
2

Fig. 1-46

Fig. 1-48

Remove screws (1) and remove controller (2) complete with heat exchanger.

Install tool (2) on flywheel housing (1) to prevent the


rotation of flywheel (3).
Loosen screws (4).

1
4

3
5
6
3
Fig. 1-47

Fig. 1-49

Remove nut (1) and remove timing sensor (2).

Remove screws (2) and remove pulley (3) and damper


flywheel (1).

Remove nuts (3) and remove high-pressure pump (4)


complete with fuel pump (5).

Remove screws (6) and remove hub (5) and phonic


wheel (4).

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1 - 54

W190

ENGINE

1
2

5
1

2
6

4
Fig. 1-50

Fig. 1-52

Remove screws (1) and remove water pump (2).

Remove screws (1) and remove oil pump (2).

Remove screw (3) and remove roller (4).

Note Oil pump (2) cannot be overhauled.

Remove screw (5) and disconnect rpm sensor (6).

1
1

2
4

2
Fig. 1-51

Fig. 1-53

Remove screws (1) and remove front cover (2).

Remove tool (2).

Note Record the installation position of screws (1) since


they have different length.

Remove screws (1) securing flywheel (3) to crankshaft (4).

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W190

1 - 55

ENGINE

2
2

3
Fig. 1-54

Fig. 1-56

Install two pins (2) of appropriate length in the holes


of crankshaft (3).

Turn the engine upside down.

Pullout engine flywheel (1) so that it is possible to


sling it with a hoist and store it.

Remove screws (2) to remove plate (3) and remove


oil sump (1).

1
2
1

4
2

Fig. 1-55

Fig. 1-57

Remove screws (1) and remove rear cover (2).

Remove screws (1) and remove oil suction strainer


(3).

Note Record the installation position of screws (1) since


they have different dimensions.

Remove screws (2) and remove stiffening plate (4).

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W190

ENGINE

1
1

3
2
Fig. 1-58

Fig. 1-60

Remove screws (1) and remove gear (3) from camshaft (2).

Remove screws (1) securing conrod cap (2) and remove them.
Extract the pistons complete with conrods from the
top of the cylinder block.
Note Keep the half-bearings in the relevant seats, since,
in the event they are reused, they must be installed in the
same position found at the removal.

2
1
2

Fig. 1-59

Remove screws (2) and remove timing gear housing


(1).

Fig. 1-61

Note Record the installation position of screws (2) since


they have different dimensions.
Remove screws (1) and remove main journal caps
(2).

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W190

1 - 57

ENGINE

3
Fig. 1-62

Fig. 1-64

The last but one main journal cap (1) and the relevant
support have half- bearing (2) equipped with a thrust
ring.

Remove main journal half-bearings (1).


Remove screws (2) and remove oil jets (3).

Note Record the installation position of the upper and


lower half-bearings, since in case of reinstallation they must
be placed in the same location they had before being removed.

1
3

Fig. 1-63

Fig. 1-65

With tool (1) and a hoist remove crankshaft (2) from


the cylinder block.

Remove screws (1) and remove plate (2) retaining


camshaft (3).
Note Record the installation position of plate (2).

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ENGINE

W190

Fig. 1-66

Extract carefully camshaft (1) from the engine cylinder block.

1
1

Fig. 1-67
Extract tappets (1) from the cylinder block.

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W190

1 - 59

ENGINE

1.7.1 REPAIR INTERVENTIONS


CYLINDER GROUP
Inspections and measurements
Once the engine disassembly is over, proceed with a
thorough cleaning of the cylinder- cylinder block group.
Use the appropriate rings to handle the cylinders group.
Check accurately that the cylinder block is free from
cracks.
Check the condition of machining plugs. If they are
rusty or there is a slightest doubt about their sealing,
replace them.
Examine the surfaces of the cylinder sleeves; they
must be free from signs of seizing, scratches,
ovalisation, tapering and excessive wear.
Measure the inner diameter of the cylinder sleeves,
to identify the amount of ovalisation, tapering and wear
using bore gauge (1) equipped with dial meter previously zeroed on ring caliper (2) for the cylinder sleeve
diameter.

The measurements must be performed for each single cylinder at three different sleeve heights and on
two planes perpendicular between them: one parallel
to the longitudinal centre line of the engine (A) the
other perpendicular (B). On the latter plane and in
correspondence with the first measurement the maximum wear is normally found.
When an ovalisation, tapering or any wear is found,
proceed with a grinding and reconditioning of the
sleeves. The reconditioning of the cylinder sleeves
must be performed in relation to the diameter of the
spare pistons oversized 0,5 mm from the nominal
value and at the prescribed installation play.

Note In the event a ring caliper is not available, use a


micrometer for the zeroing.

1st
B
2nd

3rd
1
1
2
Fig. 1-69
2

Fig. 1-68

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W190

ENGINE

Check that the mounting face of the cylinder head,


on the cylinder group, is not deformed
102,02 + 0,01
0,4 S F S W D
SEE NOTE

0,06 F
0,015

1,25 + 0,25

Rz 12,0 ISO CUT OFF 2,5

(25 - 30)

1
(25 - 30)

Fig. 1-71
This check can be performed, after removing dowel
(4) with calibrated ruler (2) and feeler gauge (3).
After identifying deformed zones, grind flat the mounting face.
The flatness error must not exceed 0.075 mm.

Fig. 1-70
Note In case of reconditioning, all the cylinder sleeves
must have the same over-sizing (0.5) (mm).

Note The grinding of the cylinder block can be made


only after making sure that, after the operation, the protrusion of the cylinder sleeve from the cylinder block does
not exceed the prescribed value.
Check the conditions of machining plugs (1) of the
cylinder group. If rusty or in case of any doubt about
their tightness, replace them.
Once the grinding is done, cut-off the cylinder sleeves
as indicated in the figure.

Check the main journal bearing seats proceeding as


follows:
install the main journal caps without bearings;
tighten the securing screws to the prescribed torque;
using an appropriate bore gauge, check that the diameter of the seats has the prescribe value.
In the event a larger dimension is found, replace the
cylinder block.

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1 - 61

ENGINE

TIMING
Camshaft
54.005
54.035

Fig. 1-72

CAMSHAFT MAIN DATA


The data listed refer to the normal diameter of the journals.
The surfaces of the camshaft journals and the cams
must be extremely smoothed. In the event they show

Checking the lifting of the cams and the alignment


of the pins
Place the camshaft on centres and, using a dial gauge
in hundredths of mm placed on the central journal,
check that the alignment error does not exceed 0.04
mm, otherwise replace the camshaft. Also, check the
lifting of the cams: it must be 6.045 mm for the exhaust and 7.582 mm for the intake ones. If different
values are measured, replace the camshaft.
Check the diameter of camshaft (2) support journals
with micrometer (1) on two centre lines perpendicular
between them.

signs of seizing and scratches, replace the shaft and


the relevant bushes.

1
2

Fig. 1-73

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1 - 62

W190

ENGINE

BUSHES
Camshaft bushes (2) must force into the relevant
seats.
The inner surfaces must be free from traces of seizing or wear.
Measure the diameter of the camshaft front and rear
bushes (2) and intermediate seats (1) with bore gauge
(3).
The measurements must be made on two lines perpendicular between them.

2
1

Fig. 1-74

Sect. A-A
A

54.089
54.139
59.222
59.246
54.083
54.147

Fig. 1-75

MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT SEATS


* Dimension to be obtained after pressing the bushes.

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W190

1 - 63

ENGINE

Replacing the bushes


To replace the front and rear bushes use to remove
and reinstall them puncher 380000667 (2) and handle
380000668 (3).

Installation of tappets - camshaft

Note During the installation bushes (1) must be oriented that lubrication holes (2) coincide with the ones on
the seats of the cylinder block.

Fig. 1-78

1
3

Lubricate tappets (1) and install them in the relevant


seats of the cylinder block.

2
Fig. 1-76

Tappets

16.000
16.030

15.924
15.954
15.960
15.975

11
29
47

15.924
15.954
Fig. 1-77
MAIN DATA OF TAPPETS AND RELEVANT SEATS
ON THE CYLINDER BLOCK

Fig. 1-79

Lubricate the camshaft support bushes and install


camshaft (1) taking care during the operation, the
bushes or the support seats in the cylinder block are
not damaged.

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1 - 64

W190

ENGINE

1
1

3
2

Fig. 1-80

Fig. 1-82

Position plate (1) retaining camshaft (3) with the groove


directed toward the upper side of the cylinder block
and the stamping toward the operator, tighten screws
(2) to the prescribed torque.

Install jets (2) and tighten securing screws (1) to the


prescribed torque.

Fig. 1-81

Check the axial play of camshaft (1).


It must be 0.23 0.13 mm.

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ENGINE

CRANKSHAFT
Measuring main and conrod journals

CAUTION

All the main and conrod journals must always be


ground to the same reduced diameter class.
The diameter reduction of the main and conrod
journals must be recorded by an appropriate stamping on the side of crank no. 1.
For reduced conrod journals digit M.
For reduced main journals digit B.
For reduced conrod and main journals digits MB.

Fig. 1-83
In the event excessive traces of seizing, scratches
or ovalisation are identified, it is necessary to regenerate the journals, by grinding them. Prior to proceeding with the journal (2) grinding operation, measure
the crankshaft journals with micrometer (1), to define
the diameter to which the journals must be reduced.
Note It is recommended to record the value measured on a table. See Figure 85.
The reduction classes are:

82.99
83.01

MIN
MAX

68.99
69.01

Fig. 1-84
TABLE ON WHICH THE VALUES RELATIVE TO THE MEASUREMENT OF THE MAIN AND CONROD
JOURNALS OF THE CRANKSHAFT
* Nominal value

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ENGINE

0.06 B-C

0.03 B-C
0.03 B-C

0.150 B-C
0.007
0.007

0.03 B-C

0.5

0.03 B-C

1 - 66

0.05 B-C
0.017

0.03 B-C
0.022 B-C

L
0.03 B-C
0.007
0.007

Fig. 1-85
*
**

Measured on a radius exceeding 45.5 mm

0.500 between adjacent main journals


MAIN CRANKSHAFT TOLERANCES
FRAME ON TIMING SIDE

45

INTERMEDIATE
FRAMES

2 x 45

FIRST FRAME
FRONT SIDE

45

Fig. 1-86
TOLERANCES
OF SHAPE

OF ORIENTATION
OF POSITION
OF OSCILLATION

FEATURES SUBJECT OF THE TOLERANCE


Roundness
Cylindricality
Parallelism
Perpendicularity
Straightness
Concentricity
Circular oscillation
Total oscillation
Taper

CLASS OF IMPORTANCE GIVEN TO THE FEATURES


OF THE PRODUCT

GRAPHIC SYMBOL
/

/
//

GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

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ENGINE

Replacement of oil pump drive gear

Main journal installation protrusion

2
3
Fig. 1-87

Fig. 1-89

Check that the teeth of gear (1) are not damaged or


worn, otherwise pull it out with the appropriate puller
(3). When installing a new gear, it is necessary to
warm it up for 10 minutes in an oven at 180 C
(355 F) and key it on the crankshaft.

Install crankshaft (2).


Check the play between main journal and the relevant

Installation of crankshaft bearings


1
2
3

Fig. 1-90

Fig. 1-88
Note When it is found that the bearings do not need
to be replaced, it is necessary to re-install them in the
same order and position found when disassembling.
Main journal bearings (1) are supplied as spares reduced on the inner diameter 0.25 - 0.500 mm.
Note Do not attempt adapting the bearings.
Clean accurately main journal half-bearings (1) with
lube hole and install them in their seats.
The last but one main journal bearing (1) is equipped
with thrust washers.

bearings as follows:
clean accurately all the components and eliminate
all traces of oil;
place on the main journals (4) of the crankshaft a
piece of calibrated wire (3);
install caps (1) complete with half-bearings (2) on
the relevant caps.

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ENGINE

1
2
Fig. 1-91

Fig. 1-93

Install screws (1) pre-lubricated and tighten them in


three subsequent phases.
1st phase with torque wrench at 50 6 Nm.
2nd phase with torque wrench at 80 6 Nm.

remove the caps from the supports.


The play between the main bearings and the relevant
journals is measured by comparing the width of calibrated wire (2) in the max. squeezing point with the
graduated scale printed on wrapping (1) of the calibrated wire.
The numbers listed on the scale indicate the play in
mm of the matching.
In the event a play value is measured different from
the one prescribed, replace the bearings and repeat
the measurement. Once the correct play is obtained,
lubricate the main journal bearings and install permanently the supports, tightening the securing screws
as previously described.

Fig. 1-92

3rd phase with tool (1) positioned as indicated in the


figure and tighten further screws (2) with an angle of
90 5.

1
2
3
Fig. 1-94
Checking the end play of the crankshaft
The endplay check is done by placing a magnetic
base dial gauge (2) on crankshaft (3) as indicated in
the figure. Normal play is 0.068 0.41.
In the event a larger play is measured, replace the
journal half bearings of the last but one rear support
(1) with thrust washers and repeat the play check
between crankshaft main journals and half-bearings.

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ENGINE

CONROD - PISTON ASSEMBLY

3
1
2

1
2
7

8
6

Fig. 1-95

Fig. 1-97

COMPONENTS OF THE CONROD PISTON ASSEMBLY

The removal of circlips (2) retaining piston pin (2) is


done sing scribing point (3).

1. Circlips - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws 6. Half bearings - 7. Conrod - 8. Bush.

Note Spare pistons oversized 0.5 mm are provided


as spare parts.

1
2

Fig. 1-96
Removal of piston rings (1) from piston (2) using pliers (3).

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ENGINE

Pistons
Measuring the piston diameter

Fig. 1-99

Fig. 1-98
Measurement using micrometer (2) of the diameter of
piston (1) to determine the installation play.

The play between piston and cylinder sleeve can be


measured also as indicated in the figure with a feeler
gauge (1).

Note The diameter must be measured at 12 mm


from the base of the skirt of the piston.

1.5
2.705
2.735

2.560
2.605

2.350
2.380

3.975
4.000

2.420
2.440

4.020
4.040

220'

40.008
40.014

39.996
40.003

Fig. 1-100

MAIN DATA OF KS. PISTON PINS AND PISTON RINGS


* The dimension is measured on a diameter of 99 mm

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ENGINE

Piston pins

Piston rings

1
1
2

Fig. 1-101

Fig. 1-103

Measurements of the diameter of piston pin (1) using


micrometer (2).

Check the thickness of piston rings (2) using micrometer (1).

Conditions for a correct pin-piston matching

1
2

1
3

Fig. 1-104

Fig. 1-102

Lubricate pin (1) and the relevant seat on the piston


with engine oil. The pin must enter the piston with a
slight pressure of the fingers and must not come-out
from it under its own weight.

Check the play between piston rings (3) of the second and third grooves and the relevant seats on piston (2) with feeler gauge (1).

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ENGINE
Conrods
1
42.987
43.013
3
2

**
**

43.279
43.553

40.019
40.033

39.996
40.003

Fig. 1-105
DIAGRAM FOR THE MEASUREMENT OF PLAY X
BETWEEN THE FIRST PISTON GROOVE AND
TRAPEZOIDAL RING

Due to the peculiar shape of the first trapezoidal ring,


the play between groove and the ring itself must be
measured as follows: have piston (1) protruding from
the cylinder block so that ring (2) protrudes about half
from cylinder sleeve (3).
In this position, use a feeler gauge to check play (X)
between ring and seat: this play must be within the
prescribed value.

72.987
73.013

1.955
1.968

Fig. 1-107
MAIN DATA OF CONROD, PISTON PIN BUSH AND
HALF BEARINGS
*

Dimension of inner diameter to be obtained after


pressing into the conrod small end and boring.

** Dimension not measurable at free conditions.

1
2

Fig. 1-106

Measurement of the play between the tip of piston


rings (2) installed in cylinder sleeve (3) using feeler
gauge (1).

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ENGINE

Bushes
Check that the bush of the conrod small end is not
loose and that it is free from scratches or traces of
seizing.
The removal and installation is done using an appropriate puncher.
During the installation, make sure scrupulously that
the oil duct holes on the bush and conrod coincide.
Using a borer recondition the bush so that the prescribed diameter is obtained.

CONROD BODY
1234
W
CONROD WEIGHT
NO.
0001
V
W
9999
X

Checking the conrods

CAP
1234
A
CONROD NO. YEAR
0001
A 1998
B 1999
9999
C 2000
D 2001

123
DAY
001
366

Fig. 1-108
1
Each conrod is marked:
On the body and on the big-end cap indicating the
matching and the cylinder in which it is installed.
Thus, in case of replacement it is necessary to proceed with the numbering of the new conrod with the
same numbers of the old one.
A letter on the conrod body indicating the weight
class of the conrod mounted in production:
V, 1820 1860 (marked yellow);
W, 1861 1900 (marked green);
X, 1901 1940 (marked blue);
Spare conrods are provided in class We marked
green*.
No removal of material is allowed.

2
5
3
4

Fig. 1-109

Check the parallelism of the conrod centre lines (1)


using device (5) operating as follows:
install conrod (1) on the mandrel of tool (5) and lock
it with screw (4);
place mandrel (3) on "V" prisms resting conrod (1)
on stop bar (2).

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W190

ENGINE

Checking the torsion

Checking the flexion

1
2

2
B

3
5

4
4

Fig. 1-110

Fig. 1-111

Check the torsion of conrod (5) comparing two points


(A and B) of pin (3) on the horizontal plane of the
conrod.
Place support (1) of dial gauge (2) so that the latter is
pre-loaded ~ 0.5 mm on pin (3) in point A and zero
dial gauge (2). Move mandrel (4) with conrod (5) and
compare on the opposite side (B) of pin (3) any possible discrepancy; the difference between A and B must
not exceed 0.08 mm.

Check the flexion of conrod (5) by comparing two


points C and D of pin (3) on the vertical plane of the
conrod centre line.
Position vertical support (1) of dial gauge (2) so that
the latter rests on pin (3) in point C.
Swing the conrod for and back trying to find the highest position of the pin and zero dial gauge (2) under
this condition.
Move the mandrel (4) with conrod (5) and repeat on
the opposite side D of pin (3) the position of the highest point. The difference between point C and point D
must not exceed 0.08 mm.

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ENGINE

Installation of conrod-piston group


Conrods-pistons matching

1
2

2
3
4

Fig. 1-114
Position piston (1) on the conrod following the configuration of the figure, insert pin (3) and secure it with
circlips (2).

Fig. 1-112

On the crown of the piston the following references


are engraved:
1. Spare part number and design modification number;
2. Arrow indicating the installation sign of the piston
into the cylinder sleeve; it must be oriented toward the front side of the cylinder block;
3. Etching indicating the inspection of the 1st groove
insert;
4. Date of manufacture.

Installation of piston rings

1
2

1
2
3
4

Fig. 1-115
5
To reinstall piston rings (1) into piston (2) use pliers
(3).
The rings must be installed with the wording "TOP"
upward. Also, the ring gaps must be placed so that
they are shifted 120 among them.

Fig. 1-113

Install piston (2) on conrod (4) with pin (3) so that


reference arrow (1) for installation of piston (2) in the
cylinder sleeve and digits (5) etched on conrod (4) are
seen as indicated in the figure.

Note Piston rings are provided as spares in the following dimensions:


standard, marked by yellow paint;
oversized 0.5 mm and marked by yellow/green paint;

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ENGINE

Fig. 1-116

Fig. 1-118
CONROD - PISTON ASSEMBLY IN THE PASSAGE

Install half bearings (1) both on the conrod and the


cap.
Note If the replacement of the conrod bearings is
not required, it is necessary to reinstall them in the
same order and in the same position they were before
being removed.
Do not attempt adapting the half bearings.

Installation of conrod piston assembly into the


cylinder sleeves

the gap of the piston rings are shifted 120 among


them;
the conrod/piston assemblies have the same weight;
the arrow engraved on the crown of the pistons is
directed toward the front side of the cylinder block
or the recession on the skirt of the piston corresponds to the oil jets.

Measuring the mounting play of the conrod journals


To measure the play perform the following operations:

1
2

3
2

Fig. 1-117

Fig. 1-119

Lubricate well the pistons, including the piston rings


and the inside of the cylinder sleeves.
Using band 380000220 (2) install conrod-piston assemblies (1) into the cylinder sleeves, checking that:
the number of each conrod corresponds to the matching number on the cap;
DIAGRAM FOR THE INSTALLATION OF THE

clean accurately the parts and eliminate all traces


of oil;
place a piece of calibrated wire (2) on the journals;
install conrod caps (3) with the relevant half bearing
(4).

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ENGINE

2
1

Fig. 1-122

Fig. 1-120

tighten screws (1) previously lubricated with engine


oil, with torque wrench (2) to the prescribed torque.

remove the cap and determine the play comparing


the width of calibrated wire (1) with the data of the
scale printed on wrapping (2) containing the wire.

1
1

Fig. 1-123
Fig. 1-121

install tool (1) on the ratchet wrench and tighten


screws (2) 60 further.

In the event a play value is measured different from


the one prescribed, replace the bearings and repeat
the measurement. Once the correct play is obtained,
lubricate the main journal bearings and install permanently the supports, tightening the securing screws
as previously described.
Note Prior to the final installation of the securing
screws of the conrod cap, check that their diameter,
measured in the centre of the thread length, is not 0.1
mm smaller than the diameter measured at about 10
mm from the tip of the screw.
Check manually that conrods (1) slide axially on the
crankshaft journals and that the their axial play measure with feeler gauge (2) is 0.10 0.33 mm.

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W190

ENGINE

Check of piston protrusion

It must be uniform (no crumbs) free from air bubbles,


thin or discontinued zones.
Imperfections must be corrected in the shortest time.
Avoid using excess material to seal the joint.
Excessive sealant tends to escape on both sides of
the joint and clog the passage of lubricants.
After completing the application of sealant, the joints
require an immediate installation (10 - 20 minutes).

1
Fig. 1-124

6
4

Once the reassembly of the conrod-piston assemblies


is completed check with dial gauge (1) equipped with
base (2) the protrusion of pistons (3) at TDC with respect to the upper face of the cylinder block.
It must be 0.28 0.52 mm.

10

8
3

Timing gear housing


Fig. 1-126
1

TIGHTENING DIAGRAM OF GEAR REAR SECURING SCREWS

Reinstall housing (1) on the engine cylinder block.


Install the securing screws in the position found at
the disassembly and tighten them to the torque indicated here below, in the sequence illustrated in the
figure.
Screws M12 65 89 Nm
Screws M8 20 28 Nm
Screws M10 42 52 Nm
Fig. 1-125
DIAGRAM OF APPLICATION ZONE FOR LOCTITE
5999 SEALANT

Clean accurately the mounting faces of flywheel housing (1) and of the timing gear housing.
The cleaning of the surfaces to be sealed is required
and absolutely required to ensure an effective sealing.
Apply LOCTITE 5999 sealant on housing (1) so that a
seam a few mm thick in diameter is formed.

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ENGINE

Setting of timing
1

1
2

Fig. 1-129
Tighten screws (1) securing gear (2) to camshaft (3)
to the prescribed torque.

Fig. 1-127

Flywheel housing
Use a felt pen to mark the tooth of drive gear (1)
mounted on crankshaft (2) on the side face of which
) for the timing setting is engraved.
mark (

3
4

Fig. 1-130

2
DIAGRAM OF APPLICATION ZONE FOR LOCTITE
5999 SEALANT

Fig. 1-128

Turn crankshaft (4) and camshaft (2) so that when


installing on the latter driven gear (1) the signs engraved on gears (1 and 3) coincide.

Clean accurately the mounting faces of flywheel housing (1) and of the timing gear housing.
The cleaning of the surfaces to be sealed is required
and absolutely required to ensure an effective sealing.
Apply LOCTITE 5999 sealant on housing (1) so that a
seam a few mm thick in diameter is formed.
It must be uniform (no crumbs) free from air bubbles,
thin or discontinued zones.
Imperfections must be corrected in the shortest time.
Avoid using excess material to seal the joint.
Excessive sealant tends to escape on both sides of
the joint and clog the passage of lubricants.
After completing the application of sealant, the joints
require an immediate installation (10 - 20 minutes).

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W190

ENGINE

1
17

16

15

18

14

13

19
20

FLYWHEEL

12
1
3

11
4

10

Fig. 1-131
Fig. 1-133
DIAGRAM OF THE TIGHTENING SEQUENCE OF
THE SCREWS SECURING THE FLYWHEEL HOUSING
Reinstall housing (1) on the engine cylinder block.
Install the securing screws in the position found at
the disassembly and tighten them to the torque indicate here below, in the sequence illustrated in the
figure.
Screws M12
75 95 Nm
Screws M10
44 53 Nm

Check the mounting face of the clutch disc. If signs


of scratching are found turning is required.
The nominal thickness of the flywheel is 49.6 0.13
mm.

Replacing the engine flywheel ring gear


Check the conditions of the teeth of ring gear (2). If
failures or excessive wear of the teeth are found remove it from the flywheel (1 Fig. 134) with a punch
and install a new one, previously heated to 150 C
(302 F) for 15 20 minutes. The bevel on the inner
diameter must be directed toward the flywheel.

3
1

4
6
5

Fig. 1-132

Install item (5) of tool 380000666 on the tail (6) of the


crankshaft, secure it with screws (4) and key a new
seal (3) on it.
Place item (1) on item (5) tightening nut (2) until seal
(3) is fully installed in flywheel housing (7).

3
Fig. 1-134

Install two pins (2) of appropriate length in the holes


of crankshaft (3) and install flywheel (1) using a sling
and a hoist (1).

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ENGINE

Fig. 1-135

Fig. 1-137

Install screws (4) securing flywheel (3) to the crankshaft.


Install tool (2) on flywheel housing (1) to prevent flywheel (3) from turning.

Install oil pump (1).


Tighten securing screws (2) to the prescribed torque.

1
2

Fig. 1-136

Fig. 1-138

Tighten screws (1) securing flywheel (2) in two phases:


1st phase, tightening with torque wrench to a torque
of 30 4 Nm;
2nd phase, tightening to an angle of 60 5.

Install a new seal (2) on water pump (1).

Note The angular tightening is performed using the


appropriate measuring tool.

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W190

ENGINE

1
1

2
2
Fig. 1-139

Fig. 1-141

Install water pump (1).


Install screws (2) and tighten them to the prescribed
torque.

Clean accurately the mounting face of the cylinder


block front cover (2) and install it.
Install screws (1) and tighten it to the prescribed torque.

2
1
2

3
4
6
5

Fig. 1-140

Fig. 1-142

Remove seal (2) from front cover (1) clean accurately


the mounting face and apply LOCTITE 5999 sealant
on it.

Install item (5) of tool 380000666 on the tail (6) of the


crankshaft, secure it with screws (4) and key a new
seal (3) on it.
Place item (1) on item (5) tightening nut (2) until seal
(3) is fully installed in flywheel housing (7).

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ENGINE
2

1
2
3

Fig. 1-143

Fig. 1-145

Install plate (1) suction strainer (2) install securing


screws (3) and tighten them to the prescribed torque.

Install oil sump (1) and install plate (3) on it.


Install screws (2) and tighten them to the prescribed
torque.

5
6
1
1
2
2
3
4

Fig. 1-144

Fig. 1-146

Arrange gasket (1) on oil sump (2).

Key phonic wheel (1) and hub (2).


Install securing screws (3) and tighten them in two
phases.
1st phase with torque wrench to a torque of 50 5
Nm
2nd phase, tightening to an angle of 60 5.

Note The gaskets free from defects can be reused.

Note The angular tightening is performed using the


appropriate measuring tool (4).

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W190

ENGINE

1
4
2

1
3

2
3

Fig. 1-147

Fig. 1-149

Install anew sealing ring on rpm sensor (3).


Install rpm sensor (3) in front cover (1) and tighten
securing screw (2) to the prescribed torque.

Lubricate sealing ring (2) with engine oil and place it


on oil filter (3).
Tighten manually oil filter (3) on the connection of
support (1) until it contacts it; tighten oil filter (3) 3/4
turn further.
Install a new sealing ring on oil temperature/pressure
sensor (4) and install it on support (1).
Install screws (5) and tighten them to the prescribed
torque.
Install a new sealing ring (6) in the seat in the cylinder
block.

1
2
3
4

5
2

3
4

Fig. 1-148
Install on the cylinder block: a new seal (1) heat exchanger (2) a new seal (3) and oil filter support (4).
Install screws (5) and tighten them to the prescribed
torque.

Fig. 1-150
Position alternator support (1) so that pins (3 and 4)
are against the engine block.
Install screws (2) and tighten them to the prescribed
torque.

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ENGINE

4
1

2
2

3
6

Fig. 1-151

Fig. 1-153

Reinstall alternator (1).


Install screw (2) and tighten it to the prescribed torque.

Reinstall high-pressure pump (6) complete with fuel


supply pump (5) and tighten nuts (3) to the prescribed
torque. Install support (4) with a new sealing ring, timing sensor (2) with a new sealing ring and tighten the
relevant securing nut (1) to the prescribed torque.

1
2
1
2
3
3

Fig. 1-152

Fig. 1-154

Reinstall automatic belt tensioner (2).


Install screw (3) and tighten it to the prescribed torque
with an appropriate wrench, turn belt tensioner (2) so
that belt (1) is engaged on the pulleys and guide rollers.

Reinstall controller (3) complete with heat exchanger


to the cylinder block and tighten screws (2) to the
prescribed torque.
Note It is advisable to replace support elastic pads (1).

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W190

ENGINE

CYLINDER HEAD
Disassembly of valves
2
A

1
2

Fig. 1-157
S

Remove sealing rings (1 and 2) from the relevant valve


guides.

Fig. 1-155
Intake (1) and exhaust (2) valves have the head with
the same dimensions.
The central slot () of the head of exhaust valve (2)
discriminates it from the intake valve.

Note Sealing rings (1) for the intake valve are yellow;
sealing rings (2) for exhaust valves are green.

Hydraulic test of the cylinder head

Note Prior to disassembling the valves from the cylinder


head number them so that, in case they are not replaced, it
is possible to reinstall them in the original position.
A = suction side

S = exhaust side

2
1

1
4

Fig. 1-158

Check the hydraulic tightness using an appropriate


tooling.
Inject, using a pump, water heated to ~ 90 C (195 F)
at a pressure of 2 3 bar.
If spills occur at cup plugs (1) replace them, using an
appropriate punch to remove and reinstall them.

Fig. 1-156
The disassembly of the valves is performed with tool
(1) pressing plate (3) so that, compressing springs (4)
it is possible to remove cotters (2). Then remove:
plate (3) springs (4).
Repeat the operation for all the valves.
Turn the cylinder head upside down and extract valves
(5).

Note Prior to installing the plugs, apply a hydro-reactive


sealant to the sealing face.
In case of spills from the cylinder head it is necessary to replace it.

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ENGINE

The check of the mounting face of cylinder head

VALVES
MAIN DATA OF THE INTAKE AND EXHAUST
VALVES

EXHAUST
VALVE

INTAKE
VALVE
6.970
6.990

6.970
6.990

1
Fig. 1-159

59.75
60.25

44.75
45.25
The check of the mounting face of cylinder head (1)
on the cylinder block is done using ruler (2) and feeler
gauge (3).
The deformation measured along the entire of the
cylinder head must not exceed 0.2 mm.
For higher values, recondition the cylinder head in
accordance with the values and precautions indicated
in the figure.
0.025/25x25
04 C

32.87
33.13

32.87
33.13

Fig. 1-161

De-scaling inspection and grinding of the valves

D
A
B
C

0 3 TOTAL
0.01/50 x 50
Fig. 1-160

Nominal thickness A of the cylinder head is 105


0.25 mm. The maximum amount of metal B allowed
to be removed must not exceed 1 mm.
Note After the reconditioning, check the depression of
the valves and recondition the valve seats if required to reobtain the valve prescribed depression.

Fig. 1-162
Remove carbon scaling from the valves using an appropriate metal brush.
Check that the valves do not show signs of seizing,
cracking or burning.
Regrind, as required, the valve seats with grinder adequate removing as little material as possible.

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W190

ENGINE
GUIDE VALVES
7.051
7.053

Fig. 1-163
Measure valve stem (1) with micrometer (2). It must
be 6.970 6.999.

INTAKE

EXHAUST

Fig. 1-165

Check of play between valve stem, valve guide and


valve roundness

Use a bore gauge to measure the inner diameter of


the valve guides. It must be the value indicated in the
figure.

VALVE SEATS
Regrinding - replacement of valve seats

1
2

1
2
Fig. 1-164
The inspections must be done using dial gauge (1)
with a magnetic base place as illustrated. The play
must be 0.052 0.092 mm.
Turn valve (2) to check that the out-of-round does not
exceed 0.03 mm.

Fig. 1-166
Check valve seats (2). When slight scratches or
burnings are found, regrind using adequate (1) in accordance with the angle values indicated in the Figure.

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W190

1 - 89

ENGINE

VALVE SEATS IN CYLINDER HEAD

30.8
EXHAUST

69.5
70.5

69.5
70.5

45

60

29.5
30.5

29.5
30.5

30.7

3.4
3.6

INTAKE

3.02
3.28

Fig. 1-167
MAIN DATA OF VALVE SEATS
The valve seats are obtained when casting the cylinder head and subsequently machined.

1.1
1.5
EXHAUST

27.25
27.75

INTAKE

27.25
27.75

39.5
40.5

34.837
34.863

34.837
34.863

36.78

36.78

Fig. 1-168
The valve seats are obtained when casting the cylinder head and subsequently machined. In the event it
is not possible to recondition the valve seats by just
regrinding them, it is possible to use inserts supplied
as spare parts.
Under these conditions, the seats with the dimensions
indicated in the figure must be obtained, then install
the valve seats.

To install the valve seats into the cylinder heads, warm


the cylinder head to 80 100 C (176 212 F) and,
using an appropriate puncher, install new valve seats
(2) previously cooled.
Then, regrind the valve seats adequate in accordance with the values listed in Fig. 169.

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W190

ENGINE

EXHAUST

69.5
70.5

69.5
70.5

45

60

29.5
30.5

29.5
30.5

3.37
3.63

3.02
3.28

INTAKE

Fig. 1-169
MAIN DATA OF VALVE SEATS

1
2
3

Fig. 1-170

After the reconditioning operations, use dial gauge (1)


with base (2) to check valve depression (3) is at the
prescribed value.

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1 - 91

ENGINE

Note Sealing rings (2) for intake valves are yellow; sealing rings (3) for exhaust valves are green.

VALVE SPRINGS
P1
P2

2
1

H1

H2
4
5

Fig. 1-171
MAIN DATA FOR THE INSPECTION OF INTAKE
AND EXHAUST VALVE SPRINGS

Prior to the installation, check the flexion of the valve


springs using the spring load device. Check the load
and elastic deformation data with those of new valves
indicated in the table here below.

H
H1
H2

Height
mm
47.75
35.33
25.2

Under a load of
kg
Free
P 339.8 9 Nm
P1 741 39 Nm

Install on the cylinder head: spring (4) upper cup (3).


Use tool (1) to press spring (4) and secure the valve
parts with cotters (2).

Reinstallation of the cylinder heads

ASSEMBLY OF THE CYLINDER HEAD

Fig. 1-173

Fig. 1-174

Fig. 1-172
Lubricate the stem of valves (1) and insert them into
the relevant valve guide in accordance with the position recorded during the disassembly.
Install sealing rings (2 and 3) on the valve guides.

Check that the mounting faces of the cylinder head


and cylinder block are clean.
Do not soil the cylinder head gaskets.
Place cylinder head gasket (1) with the wording "ALTOTOP" oriented toward the cylinder head.
The arrow indicates the point where the thickness of
the gasket is measured.

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W190

ENGINE
12

20
16

24
23

15
19

4
1

7
11

5
9

2
3

17

10
6

21

13

25

18
14

26
22

Diagram of the cylinder head securing screws tightening sequence:


1st phase, pre-tightening with torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75x150 ( ) 55 5 Nm
2nd tightening phase with angle 90 5
3rd tightening phase with angle 90 5
Front side

Fig. 1-175

Before re-using screws (2) securing the cylinder heads,


measure the diameter of the thread of the screws with
micrometer (1) checking that it is no less than ..
mm in all points, otherwise replace them.

Tightening of cylinder head securing screws

3
1
2

1
2
Fig. 1-177
Install a new O-Ring (2) lubricated with vaseline and a
new sealing washer (3) on electric injector (1).

1
Fig. 1-176
2
Install cylinder head (1) install screws (2) and tighten
them in three subsequent sequences, following the
sequence and the procedures indicated in the figure
to follow.
3
Note The angle tightening is done using tool (3).
Fig. 1-178
Install electric injectors (1) in the seats on the cylinder heads, oriented so that fuel inlet hole (2) is directed toward seat side (3) of the fuel manifolds.

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1 - 93

ENGINE

Fig. 1-179

Fig. 1-181

Use tool 380001099 (1) to set electric injector (2) in


its seat.
Install the electric injector securing screws without
tightening them.

Using a torque wrench, tighten gradually and alternatively screws (1) securing the electric injectors to a
torque of 8.5 0.8 Nm.
Tighten nuts (2) securing fuel manifolds (3) to a torque
of 50 Nm.

1
4
RODS

3
Fig. 1-180
Install a new O-Ring (3) lubricated with vaseline on
fuel manifold (2) and introduce it into the cylinder head
seat so that positioning ball (5) coincides with the relevant seat (4).
Note The fuel manifolds (2) removed must not be reinstalled. Replace them with new parts.

Fig. 1-182

Install securing nuts (2, Fig. 181) without tightening


them.

The rocker arm rods must be free from deformations;


the spherical contact seats with the setting screw and
the tappet (arrows) must be free from traces of seizing or wear, otherwise replace them. The rods controlling the intake and exhaust valves are identical
and interchangeable.

Note During the operation, handle electric injector (1)


so that manifold ( 2 ) enters fuel intake hole
(2, Fig. 179) of the same correctly.

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W190

ENGINE

Rocker arm group

1
4

Fig. 1-183

Fig. 1-185

COMPONENTS OF THE ROCKER ARM GROUP:


1. Screws - 2. Support - 3. Pins - 4. Rocker arms.

Install rods (2).


Install the valves on bridges (1) with mark () directed toward the exhaust manifold.

1
22.001
22.027
2
21.965
21.977

3
4
5

Fig. 1-184

Fig. 1-186

MAIN DATA OF PIN - ROCKER ARM


Check the pin / rocker arm mating surfaces that must
be free from excessive wear or damages.

Check that rod setting screws (1) are fully loosen to


prevent stiffening of the same on rods (2, Fig. 186)
when installing the rocker arm group. Then install the
rocker arm groups composed of support (5) rocker
arms (3) pins (4) and secure them on the cylinder
head tightening securing screws (6) to a torque of 36
Nm.

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ENGINE

Setting of the valve clearance

3
1
2

Fig. 1-187

Set the clearance between rocker arms and valves


using Allen wrench (1) wrench (3) and feeler gauge
(2).
The operating clearance is:
0.05
intake valves 0.25 0.05 mm
exhaust valves 0.51 0.05 mm.
Note To speed-up the setting of the rocker arm-valve
clearance, proceed as follows:
Turn the crankshaft, balance the valves of cylinder no. 1
and adjust the valves marked by an asterisk as indicated in
the table:

cylinder no.
intake
exhaust

1
-

2
*

3
*
-

4
*

5
*
-

6
*
*

Turn the crankshaft, balance the valves of cylinder


no. 6 and adjust the valves marked by an asterisk as
indicated in the table:
cylinder no.
intake
exhaust

1
*
*

2
*
-

3
*

4
*
-

5
*

6
-

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1 - 95

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1 - 96

W190

ENGINE

Intake manifold

3
2

1-190

5
Fig. 1-188
Cold starting air heater (5) is located inside intake
manifold (4). In case of malfunction, it is necessary
to replace it, removing nuts (1) insulating washer (2)
and spacers (3). Install the new heater (5) reversing
the removal operations.

Install a new O-Ring (8) to air temperature/pressure


sensor (7) and install the latter on intake manifold (4)
tighten screws (6) to the prescribed torque.

Note Insulating washer (2) must be replaced with a new


one. Nuts (1) must be tightened to the prescribed torque.

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1 - 97

ENGINE
1

3
2

Fig. 1-189

Fig. 1-191

Apply LOCTITE 5999 to the mounting face of intake


manifold (1) and install it on the cylinder head.
Tighten screws (2) to the prescribed torque.

Connect new fuel pipes (1) to rail (3) and electric injector manifolds (2).
Note Pipes (1) must always be replaced when removed.

5
1
2

3
4

6
7

Fig. 1-190

Fig. 1-192

Install rail (2) and tighten securing screws (1) to the


prescribed torque, connect ground cable (3) to intake
manifold (4) and tighten securing nut (5) to the prescribed torque.

Note The connections of pipes (7) must be tightened to


a torque of 20 Nm, using the appropriate wrench (5) and
torque wrench (4).
Connections (6) must be tightened holding the key section of flow limiters (1) with the appropriate wrench (1).
Connect fuel pipe (3) to rail (2) following the procedures described in the figure to follow.

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W190

ENGINE

1
2
Fig. 1-193

Fig. 1-195

Press holder (1) in the direction of the arrow (Fig. B)


and connect the pipe to rail (2, Fig. 190) return the
holder into the initial locking position "A".

Install harness support (2) install screws (1) and tighten


them to the prescribed torque.

Note make sure that the fuel pipe is connected correctly.

4
2
1
Harness support
3
1

Fig. 1-196

4
3

Connect electric wires (1) to electric injectors (3) and


tighten securing nuts (2) with the torque wrench
380000158 (4) to the prescribed torque.

Fig. 1-194

Check the conditions of electric wires (5); if damaged,


replace them cutting the bands tightening them to
support (2) removing screws (4) securing it to connectors (3).
Install a new gasket (1) on support (2).

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1 - 99

ENGINE

1
7

3
2

1
2

5
6

Fig. 1-197

Fig. 1-199

Install a new gasket (2) on rocker arm cover (1).

Re-install exhaust manifold (1) with new gaskets.


Install securing screws (7) and tighten them to the
prescribed torque.
Re-install exhaust manifold (1) turbocharger (3) with
anew gasket and tighten securing nuts (2) to the prescribed torque.
Connect oil pipe(5) to heat exchanger support (6) and
secure it to exhaust manifold (1) with screw (4).

1
2

Fig. 1-198

Install rocker arm cover (1) install nuts (2) and tighten
them to the prescribed torque.

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1 - 100
1
2

W190

ENGINE

10
11

12
13
14
6
7

15

8
Fig. 1-200

Fig. 1-201

Connect piping (14) with connections (13-15) and new


copper washers to rocker arm cover (10) and timing
housing (6).
Connect piping (7) to the connection located on timing housing (6) and tighten it with elastic band (8).
Install a new O-Ring on the connection of piping (11)
and install it on rocker arm cover (10). Secure piping
(11) to rocker arm (10) with band and nut (12).
Connect piping (2) to pressure limiter (1) as described
in the figure to follow.

Press holder (1) in the direction of the arrow (Fig. B)


and connect the piping.
Return the holder into the original locking position A.
Note Make sure that fuel piping is correctly installed.

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ENGINE

1 - 101

2
7

4
9

10

5
11
Fig. 1-202
1. Connections for electric injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil
temperature and pressure sensor - 5. Crankshaft sensor - 6. Electric injector - 7. Air pressure temperature sensor 8. Timing sensor - 9. Fuel heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC7 controller.

Reconnect the engine cable using connectors (1) electric injector harness (6); air pressure/temperature sensor (7); rail pressure sensor (3); high pressure pump
sensor (11); timing sensor (8); coolant temperature
sensor on thermostat; rpm sensor (5).

Install the lifting device to the engine lifting eyes, sling


it to the hoist and remove the engine from the rotary
stand. Remove the securing brackets to the stand.

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W190

ENGINE
2

1
2
3
3

1-31

Fig. 1-203

Fig. 1-205

Complete the assembly of the engine:


Reinstall starter motor (4) onto the flywheel housing
and tighten the securing nuts to the prescribed torque.
Insert oil pipe (3) with a new O-Ring and secure it to
turbocharger (1) with screws (2) tightening them to
the prescribed torque.

Reinstall bracket (2) complete with fuel filter support


(1) to the cylinder block, install screws (3) and tighten
them to the prescribed torque.

4
1
2

9
6
7

10

2
3
4
5

Fig. 1-204

Fig. 1-206

From the left side.


Connect fuel pipe (2) to the rail and to high-pressure
pump (9) and secure it to the cylinder block with
screws (4 and 6) tightening them to the prescribed
torque.

Tighten manually the fuel filter on support (1) until it


touches, then tighten further 3/4 turn, connect pipes
(2-3-4) and the relevant connectors of support (1) as
described in the figure to follow.

Note the connections of pipe (2) must be tightened to a


torque of 20 Nm using an appropriate wrench and torque
wrench.
Connection (7) must be tightened holding at the same
time the wrench pattern (10) of the high-pressure pump.
Piping (2) must always be replaced with a new one during
the reassembly.

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W190

ENGINE

Fig. 1-207

Press holder (1) as indicated in figure B.


After disconnecting the piping, return holder (1) into
the locking position of figure A to prevent possible
deformation of the same.
Once the assembly is completed, fill the engine with
lube oil in the prescribed quantity and quality.

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1 - 103

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W190

ENGINE

1.7.2 TIGHTENING TORQUES


ITEM

TORQUE

Screw M8 securing the cylinder sleeve lube jets


Screw M12 securing the crankshaft main journal caps

1st phase
2nd phase
3rd phase

Studs M6 for camshaft sensors


Studs M8 for supply pump
Screw M12 securing gear rear housing
Screw M10 securing gear rear housing
Screw M8 securing gear rear housing
Nut M6 securing camshaft sensor
Screw M8 securing front cover

1st phase
2nd phase

Screw M8 securing camshaft longitudinal retaining plate


Screw M8 securing camshaft longitudinal retaining plate
Screw M8 securing camshaft gear
Screw M11 securing conrod caps

1st phase
2nd phase

Screw M10 securing under cylinder block plate


Nut M18 securing high-pressure gear
Nuts M8 securing fuel pump
Plug 1/2 in on cylinder head
Plug 1/4 in on cylinder head
Plug 3/4 in on cylinder head

90 5
82
12 2
77 12
47 5
24 4
10 2
81
24 4
24 4
24 4
36 4
60 5

0.8 0.2
1.2 0.2
7.7 1.2
4.7 0.5
2.4 0.4
1 0.2
0.8 0.1
2.4 0.4
2.4 0.4
2.4 0.4
3.6 0.4
6 0.5
60 5
4.3 0.4
10.5 0.5
2.4 0.4
2.4 0.4
3.6 0.5
1.2 0.2
0.35 0.035
75 5

1st phase

50 5
82
24 4
77 12
24 4
20 2
35 5
55 5

2nd phase
3rd phase
Screw securing rocker arm support
Nuts valve clearance setting
Nuts M14 securing supply piping from high-pressure
pump to Common rail
Screw M8 securing high pressure pipe connection
Screw M6 securing wall hole head for harness
Screw M8 securing electric injector
harness support
Nuts securing electric injector single harness
Screw M12 securing fuel filter bracket holder
Screw M8 securing fuel filter holder
Fuel filter

kgm
1.5 0.3
5 0.6
8 0.6

43 5
105 5
24 4
24 4
36 5
12 2
3.5 0.35

Screws M6 securing electric injectors


Nut securing connection for injector supply
Nut M6 pre-heater grill on intake manifold
Screw M8 securing intake manifold
Screw M12 securing rear brackets for engine lifting
Screws M8 securing Common rail
Connections M14 high pressure fuel pipes
Screw M12 (12 x 1.75 x 130) securing cylinder head
Screw M12 (12 x 1.75 x 150) securing cylinder head

Nm
15 3
50 6
80 6

5 0.5
0.8 0.2
2.4 0.4
7.7 1.2
2.4 0.4
2 0.2
3.5 0.5
5.5 0.5
90 5
90 5

36 5
24 4

3.6 0.5
2.4 0.4

20 2

2 0.2

24 4
10 2

2.4 0.4
1 0.2

24 4

2.4 0.4

1.5 0.25
0.15 0.025
77 8
7.7 0.8
24 4
2.4 0.4
contact + 3/4 turn

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W190

1 - 105

ENGINE

ITEM

TORQUE

Nm
kgm
Screw M22 securing oil pressure relief
80 8
8 0.8
valve on oil filter support
Screw M8 radiator gasket and oil filter support
24 4
2.4 0.4
Oil filter
contact + 3/4 turn
Mounting 1/8 in on turbine lubrication filter support
24 4
2.4 0.4
Nut M12 securing turbine lubrication piping
10 2
1 0.2
Screw M10 securing engine coolant inlet mounting
43 6
4.3 0.6
Securing 90 joint (if required) on engine coolant inlet
24 4
2.4 0.4
Piping on cylinder head for compressor cooling
22 2
2.2 0.2
Screw M6 securing connection for engine coolant draining
10 2
1 0.2
Mounting of pins on cylinder block for exhaust manifold
10 2
1 0.2
Screw M10 securing exhaust manifold on cylinder head
53 5
5.3 0.5
50 5
Screw M12 securing damper adapter
1st phase
5 0.5
and damper on crankshaft
2nd phase
90
Screw M10 securing pulley on crankshaft
68 7
6.8 0.7
Screw M8 securing water pump
24 4
2.4 0.4
Screw M10 securing auxiliary components drive belt tensioner
43 6
4.3 0.6
Screw M10 securing fixed pulleys for auxiliary components drive belt
43 6
4.3 0.6
Screw M10 securing flywheel housing
85 10
8.5 1
Screw M12 securing flywheel housing
49 5
4.9 0.5
Screw M6 securing heat exchanger for controller
10 2
1 0.2
Screw M8 securing heat exchanger for controller
24 4
2.4 0.4
Connection M12 inlet-outlet for fuel on heat exchanger
12 2
1.2 0.2
Nut M8 securing valve cover
24 4
2.4 0.4
Screw M6 securing camshaft sensor
82
0.8 0.2
Screw M6 securing crankshaft sensor
82
0.8 0.2
Screw M14 securing engine coolant temperature sensor
20 3
2 0.3
Screw M5 securing oil pressure-temperature sensor
61
0.6 0.1
Screw securing fuel pressure sensor
35 5
3.5 0.5
Screw M14 securing fuel temperature sensor
20 3
2 0.3
Screw securing air temperature-pressure sensor on intake manifold
61
0.6 0.1
Screw M12 securing engine oil level sensor
12 2
1.2 0.2
pins M10
71
0.7 0.1
Securing of turbine to exhaust manifold: 6 cylinders
nuts M10
43 6
4.3 0.6
Adapter M12 on turbine for lube oil pipes (inlet)
35 5
3.5 0.5
Fixture piping on M10 adapter for turbine lubrication
35 5
3.5 0.5
Fixture oil piping on M10 adapter
43 6
4.3 0.6
for turbine lubrication to cylinder block
Fixture M8 oil discharge piping on turbine
24 4
2.4 0.4
Fixture connection M6 for oil return from cylinder head to flywheel housing 10 2
1 0.2
1st phase
30 4
3 0.4
Screw M12 securing engine flywheel
2nd phase
60 5
Screw M8 securing front bracket for lifting of engine
24 4
2,4 0,4
Screw securing engine oil sump
24 4
2.4 0.4

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W190

ENGINE

AUXILIARY COMPONENTS
ITEM

TORQUE

Air compressor:
Nut 5/8 in securing drive gear
on compressor shaft
Nut M12 securing to flywheel housing
Alternator:
Screw M10 securing bracket on water inlet connection
Nut M10 securing alternator
Climate conditioner:
Screw M10 securing bracket
Screw M10 securing compressor
Starter motor:
Screw securing starter motor

Nm

kgm

125 19
77 12

12.5 1.9
7.7 1.2

43 6
43 6

4.3 0.6
4.3 0.6

43 6
24 4

4.3 0.6
2.4 0.4

43 6

4.3 0.6

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W190

1.8

ENGINE

TOOLING

TOOL NUMBER

DESIGNATION

P T- 0 1

380001218

PT-01 Diagnostic software


!

1
4
7

2
5
8
0

CAN

3
6
9
X
1010

380000665

Puller for crankshaft front seal

380000663

Puller for crankshaft rear seal

380001099

Injector puller

380000666

Tool for the installation of crankshaft front seal

380000664

Tool for the installation of crankshaft rear seal

380000732

Tool for crankshaft cranking

380000667

Punch for the removal and installation of camshaft bushes


(use with 380000668)

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1 - 107

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1 - 108

ENGINE

W190

TOOLING
TOOL NUMBER

DESIGNATION

380000220

Band for the insertion of pistons into the cylinder sleeve (60 - 120 mm)

380000668

Handle for interchangeable punches

380000158

Dynamometric screwdriver for the setting of injector


solenoid valve securing nut

380000216

Engine lifting hook

380000301

Engine overhaul rotary stand

380000661

Engine support brackets to be used with 380000301

380000362

Crankshaft lifting tool

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W190

ENGINE

TOOLING
TOOL NUMBER

DESIGNATION

380000304

Angle tightening measuring tool

380000221

Piston ring removal and installation pliers (65 - 110 mm)

380000302

Engine valve spring compression tool

380001223

Hydraulic steering pump securing screw wrench

380000228

Dial gauge (0 - 5 mm)

380000669

Seal puller tool

380000670

Oil filter wrench

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1 - 109

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1 - 110

ENGINE

TOOLING
TOOL NUMBER

DESIGNATION

380000144

Engine flywheel retaining tool

380000364

Dial gauge holder base

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

SECTION 2

TRANSMISSION
INDEX

PARAGRAPH

SUBJECT

2.1

GENERAL CHARACTERISTICS ............................................................................. 2-1

2.2

GENERAL DESCRIPTION ...................................................................................... 2-1

2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5

TRANSMISSION ASSEMBLY ................................................................................


Internal configuration of the transmission ................................................................
Transmission power diagram ...................................................................................
Pressure pick-up points and connections ................................................................
Transmission hydraulic diagram (1st speed forward) ................................................
Transmission control valve .....................................................................................

2-3
2-4
2-5
2-6
2-7
2-8

2.4
2.4.1
2.4.2
2.4.3

AUTOMATIC TRANSMISSION CONTROL SYSTEM .............................................


"Est-37" electronic controller ...................................................................................
Start-up procedure of transmission electronic controller ..........................................
Transmission pilot valve .........................................................................................

2-11
2-12
2-13
2-16

2.5

AUTOMATIC TRANSMISSION ELECTRIC DIAGRAM ........................................... 2-18

2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.4.1
2.6.4.2

TROUBLESHOOTING GUIDE ................................................................................


Display during the operation of the machine ............................................................
Display, during the start-up procedure with ab instrument ........................................
Table of trouble codes .............................................................................................
Troubleshooting using the "TESTMAN" device .......................................................
Connections and settings of the DPA-03 ............................................................
Configuration of testman software menu ............................................................

2.7
2.7.1
2.7.2

TRANSMISSION OVERHAUL ................................................................................ 2-46


Disassembly of control valve .................................................................................. 2-46
Re-assembly ........................................................................................................... 2-49

2.8
2.8.1
2.8.2
2.8.3

DISASSEMBLY OF THE TRANSMISSION ............................................................


Removal of the transmission control valve and the oil ducts plate from the transmission
housing ...................................................................................................................
Disassembly ...........................................................................................................
Assembly ................................................................................................................

2.9

PROPELLER SHAFTS ........................................................................................... 2-108

2.10
2.10.1
2.10.2
2.10.3
2.10.4
2.10.5
2.10.6
2.10.7
2.10.8

AXLES ....................................................................................................................
General description .................................................................................................
Differential description .............................................................................................
"LSD" differential .....................................................................................................
Final drives description ...........................................................................................
Disassembly of the axle ..........................................................................................
Axle reassembly .....................................................................................................
Installation and inspection of the pinion bearings pre-load .......................................
Correct mounting position of the pinion ...................................................................

2-110
2-110
2-115
2-117
2-118
2-120
2-132
2-155
2-156

2.11
2.12
2.13
2.13.1

WHEEL/TYRES ......................................................................................................
TROUBLESHOOTING ............................................................................................
VALUES OF REFERENCE FOR THE MAINTENANCE ..........................................
Tithtening torque values for main bolts ....................................................................

2-157
2-158
2-160
2-161

2.14

LIST OF OVERHAUL SPECIAL TOOLS ................................................................. 2-162

PAGE

2-19
2-20
2-21
2-22
2-43
2-44
2-45

2-55
2-55
2-55
2-72

Copyright New Holland

Copyright New Holland

W190

TRANSMISSION

2-1

2.1 GENERAL CHARACTERISTICS


TORQUE CONVERTER
- Name
- Type
- Radiator
- Minimum operating pressure

ZF - F&S 340
3 elements, single stage, single phase
Water cooling, with multiple radiating fins
4,3 bar

TRANSMISSION PUMP
- Name
TRANSMISSION
- Name
- Control
- Type
- Speeds

ZF WG 210
Manual or automatic
Controlled by solenoid valves, Integral Power-Shift, with constant
mesh gears with controlled modulation
4 forward and 3 reverse

CLUTCHES (TRANSMISSION)
- Type
- Actuation
- Pressure setting
- Oil capacity
- Weight (torque converter-transmission)

Oil-bath, multiple disc


Hydraulic
16 + 2 bar
26 l
470 kg

2.2 GENERAL DESCRIPTION


The W190 transmission is composed of a torque
converter group and 7 speed transmission, 4 forward
and 3 reverse (with automatic and manual control)
transfers the power to the two axles through three
propeller shafts, respectively two for the front one and
one for the rear.

The axles include a bevel gear set with proportional


torque differential (limited slip on request).

Front
Engine

Torque

Front

Transmission
Rear

Rear

Torque converter cover


Transmission ZF 4WG210
Hydraulic pumps
Front axle

Support

Front shaft
Fig. 2-1

Intermediate shaft

Rear shaft

Rear axle

Composition of the transmission

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Copyright New Holland

2-2

TRANSMISSION

W190

POWERSHIFT TRANSMISSION
The multi-speed reversible countershaft transmission
is hydraulically controlled by multiple disc clutches.
Al the gears are constant mesh and are supported by
anti-friction bearings.
The gears, bearings and clutches are cooled and lubricated by oil.
The 4-speed reversible transmission is equipped with
6 multiple disc clutches.
When shifting gear, the clutch pack involved is compressed by the mobile piston in an axial direction,
under the effect of pressurised oil.
A reaction spring controls the return of the piston,
releasing the clutch pack.

Transmission control
The transmission pump required to supply oil to the
torque converter and to control the transmission is
mounted on the input shaft of the transmission itself.
The pump delivery is Q = 105 lt/min at 2000 engine
rpm.
The pump sucks oil through a mesh filter from the oil
sump and forwards it through a delivery filter to the
pressure relief valve.
In case of clogging of the delivery filter, the flow is
diverted by the by-pass valve p = 5.5 bar to ensure
lubrication.
If this occurs, the indicator on the display is activated.

Delivery filter
Filtering ratio in accordance with ISO 4572:
15 = 25
10 = 5.0
30 75
Filtering surface, at least: 6700 sq. cm
Collecting capacity in accordance with ISO 4572 at
least: 17 g
The six transmission clutches are selected through proportional valves from P1 through P6 (Fig. 2 - 6).
The proportional valve (pressure regulating unit) is composed of pressure regulator (Y6) mobile element and
vibration damper.

The 9 bar pressure controlling the mobile element is


regulated by the pressure regulation valve. The oil
pressure (16 + 2 bar) is directed through the mobile
element to the relevant clutch.
Due to the direct proportional selection with separate
pressure modulation for each clutch the clutch pressures of the transmission clutches involved are controlled. In this manner, the engagement and release
of the clutches by a hydraulic intersection becomes
possible.
This causes a smooth gearshifting, without cuttingoff power.
During the gearshifting, the following criteria must be
considered:
- Speed of engine, turbine, central and output gear
train.
- Transmission temperature.
- Gearshifting mode (upshifting, downshifting reversing and shifting from Neutral).
- Load conditions (full or partial load, traction, overspeeding, considering the loading cycles during the
gearshifting).
The pressure relief valve limits the maximum control
pressure at 16 + 2 bar and directs the main flow to the
converter and lubrication circuit.
At the inlet of the torque converter a safety valve is
installed, protecting the converter from internal
overpressures (it opens at 11 bar).
The oil in the torque converter transfers the power
following the well-known hydrodynamic principle.
To prevent cavitation, the torque converter is constantly filled by oil.
This is obtained by a pressure retaining valve, installed
on the rear of the torque converter, set at least 4.5
bar.
The oil discharged by the torque converter is directed
to the heat exchanger.
From the heat exchanger, the oil is directed to the
transmission and the lubrication circuit, so that all lube
points are supplied by cooled oil.
Six pressure regulators are installed in the ElectroHydraulic control valve - see Fig. 2-7.
The correspondence of the pressure regulators to the
single speeds can be seen in Fig.s 2-5, 2-6.

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Copyright New Holland


W190

TRANSMISSION

2-3

2.3 TRANSMISSION ASSEMBLY

2
14

16

13
13

12
3
11

10

5
9
15

17

18

19

Fig. 2-2

1. Lifting eyes - 2. P.T.O - 3. Electro-hydraulic control valve - 4. Connection of return line from parking brake M26x1.5 - 5. Hydraulically actuated parking brake - 6. Transmission mounting holes M20 - 7. Connection for oil filler neck and dipstick - 8. Brake disc - 9. Output
flange - 10. Delivery filter (fine) - 11. Filter head - 12. Pressure system connection M16 x 1.5 - 13. P.T.O. 1 - 14. Torque converter - 15. Steering emergency pump -16. Breather - 17. Transmission output front shaft - 18. Oil draining plug - 19. I.D. plate

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Copyright New Holland

2-4

TRANSMISSION

W190

2.3.1 INTERNAL CONFIGURATION OF THE TRANSMISSION


12
1
11

10
3
9
4
GEAR DIAGRAM
5
KR
AN

KV

K4

K2

K1

K3

AB

6
7

13
14
15

Fig. 2-3
1. "KR" clutch shaft - 2. P.T.O. coaxial with engine - 3. "KV" clutch shaft - 4. "K2" clutch shaft - 5. "K3" clutch shaft - 6. Rear
output flange - 7. Converter side output flange - 8. Output shaft - 9. Transmission pump - 10. Input flange - Input through
universal joint - 11. Torque converter - 12. Engine speed induction sender - 13. "K4" clutch shaft - 14. Torque converter
pressure relief valve - 15. "K1" clutch shaft

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Copyright New Holland


W190

TRANSMISSION

2-5

2.3.2 TRANSMISSION POWER DIAGRAM

1st speed forward

2nd speed forward


KR

KR
KV

Turning direction
106
Z=51
113
Z=23

104
Z=32

Engine speed
induction sensor

KR
KV

K4

K2

AN

K4

K2

K1
K1

K1

K3

K1

K3

K1

K3

204
Z=63

AB

AB

KR

115
Z=52
101
Z=54

102
Z=55

Gear set speed


induction sensor

AN

K4

108
Z=58

AN

K4

K2

4th speed forward

KR
KV

AN

K4

K2

K3

112
Z=36

KV

AN

3rd speed forward

103
Z=56

201
Z=55

110
Z=52

KV
111
Z=23

Turbine speed
induction sensor

Legenda:
KV = Forward clutch
KR = Reverse clutch
K1 = 1st speed clutch
K2 = 2nd speed clutch
K3 = 3rd speed clutch
K4 = 4th speed clutch
AN = Input
AB = Output

AB

AB

1st speed reverse

2nd speed reverse

K2

105
Z=44

K3
Transmission output
speed sensor
AB

Idle gears

AN

Clutch diagram
Travel direction
Forward

107
Z=49

AB
Reverse

Legenda: Power flow

KV

AN

KV

AN

KR

KR

KR
KV
114
Z=55

3rd speed reverse

Speed
1
2
3
4
1
2
3

Clutch
KV/K1
KV/K2
KV/K3
K4/K3
KR/K1
KR/K2
KR/K3

Ratio
3,745
2,089
1,072
0,636
3,551
1,981
1,017

K4

K2

K1

K3

AB

K4

K2

K1

K3

AB

K4

K2

K1

K3

AB

Fig. 2-4

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Copyright New Holland


2-6

TRANSMISSION

2.3.3 PRESSURE PICK-UP POINTS


AND CONNECTIONS

48

47

W190

21

VIEW X

The locations indicated (53) correspond to the positions of Fig. 2-6.


The measurements are performed with hot transmission (about 80 95 C) (176 203 F).

65

51

69

H
G

57
54

68

49

60
53

34

55

58

56

16

Y
No. DESIGNATION OF POSITION

51 =
52 =
53 =
55 =
56 =
57 =
58 =
60 =
63 =
65 =
15 =
16 =
21 =
34 =
47 =
48 =
54 =
49 =
68 =
69 =
70 =
71 =

CONNECTION

HYDRAULIC OIL AND TEMPERATURE MEASURING POINTS:


Front side of converter - opening pressure
11 bar
M10x1
Rear side of converter - opening pressure
4.3 bar
M14x1.5
Forward clutch
16 + 2 bar
KV
M10x1
Reverse clutch
16 + 2 bar
KR
M10x1
Clutch
16 + 2 bar
K1
M10x1
Clutch
16 + 2 bar
K2
M10x1
Clutch
16 + 2 bar
K3
M10x1
Clutch
16 + 2 bar
K4
M10x1
Rear side of converter
M14x1.5
temperature 100 C (212 F) for short time 120 C - 248 F)
System pressure
16 + 2 bar
M10x1
Flow measuring points:
Connection to heat exchanger
1 5/16"-12 UN-2B
Connection from heat exchanger
1 5/16"-12 UN-2B
INDUCTION SENDERS, SPEED SENSOR AND SWITCHES:
Induction sender
n Turbine
M18x1.5
Speed sensor
n Output and tachometer
Induction sender
n Central gear train
M18x1.5
Induction sender
n Engine
M14x1.5
Filter contanimation switch
M14x1.5
CONNECTIONS:
Connection plugs on electric-hydraulic control
Pressure system
(Optional)
M16x1.5
Control
(Optional)
M16x1.5
Steering emergency pump - Pressure line
M22x1.5
Steering emergency pump - Pressure line
M22x1.5

INDICATION ON
VALVE BLOCK

VIEW Y

15
52/63

16

70

B
E
D
A
C
F

D
S

15

71

52/63

K
CODES
Travel direction
FORWARD

REVERSE

J
G

NEUTRAL
Clutches engaged
Location on block
Number of measuring point

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Speed

1
2
3
4
1
2
3

Pressure regulator active


Y1
Y2
Y3
Y4

K4
F
60

KR
E
55

K1
D
56

Clutch engaged

Y5

K3
C
58

Y6

KV
B
53

K1
KV
K3
K4
KR
KR
KR

KV
K2
KV
K3
K1
K2
K3

K2
A
57

Fig. 2-5

Copyright New Holland


W190

TRANSMISSION

2-7

2.3.4 TRANSMISSION HYDRAULIC DIAGRAM (1st speed forward)


The locations indicated (53) correspond to locations of Fig. 2-5.
Legenda:
WT
= Heat exchanger
WGV = Torque converter rear pressure valve 4.3 bar
WSV = Torque converter safety valve 11 bar
HDV
= Main pressure relief valve 16 + 2 bar
RV-9 = Pressure reduction valve 9 bar
NFS
= Mobile element
D
= Vibration damper
B
= Orifice
P1
= Proportional valve K4
P2
= Proportional valve KR
P3
= Proportional valve K1
P4
= Proportional valve K3
P5
= Proportional valve KV
P6
= Proportional valve K2
Y1..Y6 = Pressure regulators
TEMP = Temperature sensor
FDV
= Filter differential pressure valve (by-pass valve)
p = 5.5 bar

K4

P1
B

60

KR

Y1

P2
B

NFS

Y2

55

K1

P3
B

NFS

Y3

56

K3

P4
B

NFS

Y4

58

KV

P5

Y5

NFS

53

K2

P6

Y6

NFS

57

NFS

RV-9
TEMP
HDV

Hydraulic control valve


diagram

65

Torque converter
51

Legenda:

63

= Main pressure
= Main regulated pressure
= Piloting pressure
= Converter inlet pressure
= Converter outlet pressure
= Lubrication
= Oil return to sump

Travel direction
FORWARD

REVERSE

NEUTRAL
Clutches engaged
Location on block
Number of measuring point

Speed
1
2
3
4
1
2
3

K4
F
60

KR
E
55

K1
D
56

52

By-pass
valve p=1.5
bar

15

16

Transmission pump
p = 16 + 2 bar
Qp 0 105 lt/min
n = Engine at 2000 rpm

Oil sump
Lubrication
Y5

KV
B
53

Main hydraulic
diagram

Clutch engaged

Y6

K3
C
58

Fine filter
Filtering ratio in accordance with ISO 4572:
30 75 15 25 10 5
Collecting capacity in accordance with
ISO 4572 at least: 17 g
Filtering surface, at least:
6700 sq. cm

FDV

WGV

CODES
Pressure regulator active
Y1
Y2
Y3
Y4

WSV

K1
KV
K3
K4
KR
KR
KR

KV
K2
KV
K3
K1
K2
K3

K2
A
57

Fig. 2-6

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2-8

TRANSMISSION

W190

2.3.5 TRANSMISSION CONTROL VALVE


Main pressure relief valve 16 + 2 bar
Pressure reduction valve 9 bar
Housing

Connector/harness

Cover

Cover

Cover

Control valve body

SECTION A - A
Main pressure relief valve
16 + 2 bar

Control valve body

Pressure reduction valve 9 bar

Connector/
harness

Intermediate plate

Oil ducts plate

Power socket
SECTION B - B
PROPORTIONAL VALVE P5

Pressure
regulator

Vibration
damper

Follow-up
plunger
Discharge
line

Fig. 2-7

Pressure
reduction
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Operating
pressure

Copyright New Holland

W190

TRANSMISSION

2-9

TRANSMISSION CLUTCH ENGAGEMENT PRESSURE VARIATION GRAPHS

Clutch 1 beginning of
disengagement

G ra d ie n t
(nEng)

= f

Pressure

Clutch 2 End
of engagement

Clutch 2 Beginning
of engagement

Clutch disc slipping phase

Fast filling

Time

Modulation

2-8

Fig. 2-8

Gearshifting

The fast filling time depends upon:


- dimension of clutch
- play of clutch
Pressure

Clutch filling
Clutch
filling

Fast filling time

Modulating time

The modulating pressure depends


upon:
- pressure regulator
- flow amplification valve
- clutch spring
- clutch ring

Pressure
Compensazione

Pressione
Veloce

The piston moves


against the discs

Fig. 2-9

Time

Clutch filling

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Copyright New Holland

2 - 10

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland


W190

TRANSMISSION

2 - 11

2.4 AUTOMATIC TRANSMISSION CONTROL SYSTEM

Kick-down + down shift


button

Direction reverser
auxiliary switch

Transmission
gearshift lever

Automatic transmission
selector switch

"EDC" engine
controller

"Brown Box"
controller

"est-37" transmission
controller

Auxiliary direction
inversion actuation
switch

"LTS" switch
Multi function
display

Transmission sensors

COOLANT TEMP

"LTS" solenoid valve

T\M OIL TEMP

20
F

30

10
40
50

FUEL

1\10 h

HOURMETER
HOUR

km\h

Dashboard

Fig. 2-10

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2 - 12

TRANSMISSION

W190

2.4.1 "EST-37" ELECTRONIC


CONTROLLER
The transmission control unit consists of a control electronic unit EST-37 and a hydraulic control unit.
The EST-37 electronic control unit, connected to a
32-bit microprocessor, controls the gearshifting sequence of the transmission. The optimised modulating pressure is calculated for each gearshifting as a
function of the load and the speed for the clutch involved.

A continuous regulation of the parameters constantly


ensures a high quality of the gearshifting.
Also, the software includes extended functions to ensure the line of command and to support the diagnostic system. The control electronic unit has a CAN interface for the exchange of data with the vehicle and
engine electronic system.

Technical specifications:
Nominal voltage: 24 Volt
Max. current absorbed: 10 Amp
Operating temperature: -40 C (- 40 F)
through + 70 C (158 F)
Protection class: IP54
Weight: 0.9 kg

Identification
plate

Connection

Protections:
The controller is protected against
- short-circuits
- voltage jumps
- wrong connections
Fig. 2-11

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Copyright New Holland

W190

TRANSMISSION

2 - 13

2.4.2 START-UP PROCEDURE OF


TRANSMISSION ELECTRONIC
CONTROLLER
In order to optimise the operational parameters of the
transmission it is necessary to start-up the controller
every time one of the following conditions occur:
- disassembly/assembly of the transmission;
- replacement of an electronic component or a transmission component.
The same procedure should be performed when the
modulation of the gearshifting is insufficient.
In fact, the clutch packs, after a certain use, have different plays from the original values.

The determination of the filling parameters, in fact, provides the optimisation of the tolerances, the disc play,
the pressure level inside the clutches and the filling speed
of the clutches during the gearshifting.
The start-up of the controller is possible using the following tooling:
AEB Starter (tool No. 380000818)
DISPLAY (tool No. 380001297)

DISPLAY
380001297

AEB-STARTER
380000818

W190-2R001

Fig. 2-12 Connection of the transmission start-up tooling.


The display and the AEB must be connected to the sockets indicated, located behind the plastic panel
of the cab, behind the operator's seat.

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Copyright New Holland

2 - 14
1.

TRANSMISSION

W190

Introduction

The AEB starter is a tool for the start-up of Ergopower


transmissions.
It is especially useful when used together with the ZFDisplay, since it provides all the messages on the
conditions of the AEB.
The AEB "per se" does not provide any information.

2.

List of abbreviations

AEB: setting of automatic filling parameter


TCU: transmission control unit

3.

Procedure for the start-up of the AEB

Note The AEB does not start when any trouble


code is present on the display, except trouble "F6".

Step to do

Display message

Remarks

Transmission heating

normal operating messages

Disengage starting

none

Connect the AEB-Starter

move gearshift lever into N


engage parking brake

Start the engine

"PL"

Bring the engine speed


to 800 rpm

"PL" if starting conditions


OK

Press the AEB-Starter


button

"ST" if starting conditions


OK

The button must not be released


before the TCU has started the AEB
or an error code is shown

Keep the button until


AEB starts

"K1"
(Information about
the AEB conditions)

TUC started the AEB and moves to


regulate K1, K2, KR.
(the button can be released)

Wait until the AEB finishes

"OK"
(AEB successful)

10

Disengage the starting and


disconnect the AEB-Starter

none

TCU must identify PL for at least 2


sec.s before it is possible to press the
button

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Copyright New Holland

W190
4.

TRANSMISSION

2 - 15

Display

Symbol

Meaning

PL

AEB-Starter is connected to diagnostic


pick-up

ST

The AEB-Starter is pressed

K1,..K4,KV,KR

Calibration of clutches K1, K4,KV,KR

e Kx

Remarks

Wait for starting, start-up of


clutch Kx

= e Kx

Fast filling time determination


clutch Kx

= e Kx

Determination of compensation
pressure of clutch Kx

OK

Calibration of all clutches terminated

The transmission stays in neutral, the TCU must be


restarted (starting on/off) after removing the AEB

STOP

AEB cancelled (activation stopped)

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

STOP e Kx

AEP stopped, clutch Kx cannot be


calibrated

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

Wrench e Kx

Kx cannot be calibrated,
AEB terminated

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

Engine speed too low


increase engine speed

Engine speed too high


reduce engine speed

Transmission oil temperature too low


warm-up transmission

Transmission oil temperature too high


cool-down transmission

FT

Transmission temperature not in the


range defined during the calibration

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

FB

ABNORMAL operating mode or


transmission temperature sensor
defective or recording of values
calibrated by EEPROM failed

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

FO

Output speed is not zero

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

FN

Gearshift lever not in position Neutral

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

FP

Parking brake not engaged

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

STOP

AEB-Starter used in incorrect manner


or defective

The transmission stays in neutral, the TCU must


be restarted (starting on/off)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

2 - 16

TRANSMISSION

W190

2.4.3 TRANSMISSION PILOT VALVE

N-LOCK

3
4

ND

IN N (NEUTRAL) POSITION F.
R. CANNOT BE SELECTED

A BC D

RED
Y E L LOW
PINK
GREEN
BLACK
GREEN
BLUE
VIOLET

A BC D

A B C D

A B C D

X2

X1
F
N
R
D
1
2
3
4

1
2
3

ZF

=
=
=
=
=
=
=
=

FORWARD
NEUTRAL
REVERSE
NEUTRAL MECHANICAL LOCKING
1st SPEED
2nd SPEED
3rd SPEED
4th SPEED

ZF
TECHNICAL SPECIFICATIONS
CONNECTION DIAGRAM OF RANGE SELECTOR
NOMINAL VOLTAGE

UN =12 Volt
UN =24 Volt

OPERATING VOLTAGE

UDIR =9 - 15 Volt
UDIR =19 - 23 Volt

TESTING VOLTAGE

UPR =14 o.5 Volt


28 0.5 Volt

OUTPUT CURRENT
(INDUCTIVE LOAD)

AD1 AD7
ILmin = 10 mAmp
ILPR = 0.6 Amox

OUTPUT LEVEL (ACTIVE)


OPERATING TEMPERATURE

UA = US - 0.3 Volt
- 30 C .. + 70 C

PROTECTION CLASS DIN 40050 BL.9


ELECTRIC COMPONET PARTS
IN THE ELECTRIC
CONNECTION BOX

IP 65
IP 20

(+)
X2,A

A2

X1,D
X1,C
X1,B
X1,A
X2,B
X2,C
X2,D

A1
K1

K2

(-)
K1
K2
A1
A2

=
=
=
=

STARING BLOCK RELAY


BACK-UP LIGHT RELAY
CONTROLLER EST-2/EST-17
GERASHIFT SELECTOR

Fig. 2-13

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

TRANSMISSION

2 - 17

VALVE ENERGISING TABLE


OUTPUT SIGNAL
OUTPUT
SIGNAL
SPEED
GEAR

FORWARD
FORW.

KD

REVERSE
REV.

NEUTRAL
NEUTRAL.
1 2 3 4

AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7

PILOT VALVE ELECTRIC DIAGRAM


CONNECTION
DIAGRAM

SW
S6

1
S4
2

1
2

1
S5
2

GN
BL
VI
XI
RT

S1
3
S2
3
S3
3

1
2

1
2
1
2

AD3 (B3)

AD2 (B2)

AD1 (B1)

AD7 (KD)

A ED1 (+/VP)

GR

D AD6 (N)

GE

B AD4 (AVANTI)

RS
X2

C AD5 (RETROMARCIA)

X1
CONTACT
PATTERN

X2
CONTACT
PATTERN

A B C D

A B C D

CABLE COLOUR CODE


WS
BR
GN
GE
GR
RS
BL
RT
SW
VI

WHITE
BROWN
GREEN
YELLOW
GREY
PINK
BLUE
RED
BLACK
VIOLET

Fig. 2-14

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

2 - 18

TRANSMISSION

W190

2.5 AUTOMATIC TRANSMISSION ELECTRIC DIAGRAM


F1

K1.38
K1.15
F2

# S35
no with
# S35 not
FNRI
with push
button FNR !
button
pressed

1
P

VP (+)

A2

F
N
R
B1
B2
Function B3
function button
button

S2

S35#
45
3

B4

VP (+) F

A2.2

R
N

SignalC-Signal
C
function
function button
button

B
C
D
E
F

62

4
44
31
20
30

X3:B
X3:D
X3:C
X2:C
X2:B
X2:A
X2:D

43
67
64
63
65
22

XX
86

K1

XX
85

B1
B2
B3

1
2

19
3

1
2

41

1
2

42

23

68

S31

S3

66

VP1 VPE1VPE2
EF4

21

ED3

ED18

H1

K2

29

52

ED11

ADM1

XX

S38

XX 2

XX

X3:A

K5

7
ADM2

VMG2

XX
5
ADM4
SD4

SDDK

ED9
3ED13
ED3
ED12

EUPR

36

A9

15

18

A5
3

SD1

ED4
ED6
ED5
ED1
ED2

AIP1
AIP2
AIP3
AIP4
AIP5
AIP6
VPS1
VPS1
ER1
VMGR2

A1

ED7

EF1
VMG1

EF2

ER2

EF3
VCS
28

CANF_H

CANF_L CANF_T

25

26

27

1
2
3
4
5
6
7

56
10
32
33
9
51
12
13
39
46

8
9

49 1

4
1

A6
3

Y1
Y2
Y3
Y4
Y5
Y6
VPS1(+)

A3

TEMP
TEMP

B15

VM1 VM2
1

14

1 2

A7

Recommended screening
K1.31

Twisted pair (38 rev/min)


for L > 2 m

Fig. 2-15

POS.

LEGENDA

A1
A2.1
A2.2
A3
A5
A6
A7
A9

EST-37 CONTROLLER
DM-3 CONTROL LEVER
SWITCH - FNR
TRANSM. HYDRAULIC LOCK
DIAGN. INTERFACE (CONNECTOR)
DISPLAY
INTERFACE-CAN (CONNECTOR)
TACHOMETER WITH FREQUECY DIVIDER
(CLIENT SCOPE)
ENGINE SPEED PICK-UP
TRBINE PICK-UP
INNER SPEED PICK-UP
OUTPUT SPEED SENSOR
SENSOR - CONVERTER TEMPERATURE
FUSE 7.5 Amp
FUSE 7.5 Amp
INDICATOR LIGHT
STARTING SAFETY REALY
INVERTER CONTROL RELAY
SPEED SIGNAL RELAY

B1
B2
B3
B4
B15
F1
F2
H1
K1
K2
K5

POS.

LEGENDA

S2
S3
S31
S35
S38

CLUTCH CUT-OFF SWITCH


AUTO7MANUAL MODE SELECTION SWITCH
PARKING BRAKE RETURN SWITCH
GEARSHIFT LEVER SWITCH
SPEED SIGNAL SWITCH

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

TRANSMISSION

2 - 19

2.6 TROUBLESHOOTING GUIDE


The diagnosis of possible operating malfunctions on
the transmission group can be performed using the
display indicated here below tool 380001297. Under
engine operating conditions and gearshift selector in
neutral position, the troubles are displayed by symbol
"g" and the showing of an alpha-numerical code identifying the type of failure.

The error codes are composed of two decimal digits.


The first one indicates the type of signal, the second
the signal and the type of error

Definition of error codes


First digit

f ed

a bc

left
digit

right
digit

Fig. 2-16

The display must be connected through harness


380001297 provided to the socket indicated located
behind the plastic panel in the cab, behind the operator's seat.

1 hex
2 hex
3 hex
4 hex
5 hex
6 hex
7 hex
8 hex
9 hex
A hex
B hex
C hex
D hex
E hex
F hex

Meaning of digit

Input digital signal


Input analogical signal
Speed signal
CAN error signal
CAN error signal
CAN error signal
Output current analogical signal
Output current analogical signal
Output analogical signal
Output analogical signal
Transmission error. Clutch error
Logic error
Power supply
High speed signal
General error

Please find here below some symbols relative to different operating conditions of the machine and the
list of trouble codes with their meaning and the possible repair intervention.

Fig. 2-17

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

2 - 20

TRANSMISSION

W190

2.6.1 DISPLAY DURING THE OPERATION OF THE MACHINE


Symbol

Meaning

1F, 1R
2F, 2R
3F, 3R
4F
5F
6F
LF, LR
F or R no speed
F or R
flashing
NN

Effective speed and direction


the left digit indicates the speed
the right digit indicates the direction

**
*N
1 bar (special
symbol)
2 bars
3 bars
4 bars
4 bars and 2
arrows
Flashing
lbars
Wrench
Defect code
WS
WR
WT
WE
PN

F or R
flashing

EE
flashing

recovery speed
clutch disengagement
F or R direction selected while the
turbine speed is too high
No neutral, wait for neutral after
supply or serious trouble
Oil temperature too low, no speed
available
Oil temperature too low, one speed
only available
Manual mode 1st speed

Remarks

WARNING The speed engages if the turbine


speed decreases
To engage speed, move gearshift lever into neutral
at first then into position F or R
Warm-up engine/transmission
Warm-up engine/transmission

Manual mode 2nd speed


Manual mode 3rd speed
Manual mode 4th speed
Automatic mode
4 WG: downshifting mode activated Engine and turbine speed differential exceeds a
certain limit and the clutch lock is not activated
At least one defect activated
Select neutral to read trouble code
See trouble code list
Alarm, sump temperature
Shifting between speeds/direction while moving, in neutral
only indicated if no defects monitored (wrench)
Alarm delay temperature
Shifting between speeds/direction while moving, in neutral
only indicated if no defects monitored (wrench)
Alarm, torque converter
Shifting between speeds/direction while moving, in
temperature
neutral only indicated if no defects monitored (wrench)
Alarm, high engine speed
Shifting between speeds/direction while moving, in
neutral only indicated if no defects monitored (wrench)
Direction F or R selected with
Transmission in neutral until the parking brake
parking brake engaged
is released
WARNING The machine starts moving after
releasing the parking brake
Selection of forward or reverse
Speed selected if engine speed is decreased
direction while the turbine speed is
too high
WARNING The rotor is
engaged when the turbine
speed decreases
No communication with
Check connections between TCU and display
display

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

TRANSMISSION

2.6.2 DISPLAY, DURING THE START-UP PROCEDURE WITH AB INSTRUMENT


Symbol

Meaning

PL

FO

AEB-Starter is connected to
diagnostic pick-up
AEB-Starter button pressed
Calibration clutch K1 K4, KV,KR
Wait for starting, start-up
clutch Kx
Fast filling time determination
clutch Kx
Determination compensation
pressure of clutch Kx
Calibration of all clutches
determined
AEB cancelled
(activation terminated)
AEB stopped, clutch Kx cannot be
calibrated
Kx cannot be calibrated, AEB
terminated
Engine speed too low
increase engine speed
Engine speed too high
decrease engine speed
Transmission oil temperature
too low
warm-up transmission
transmission oil temperature
too high
cool down transmission
Transmission temperature not within
the range defined during the calibration
Operating mode ABNORMAL or
transmission temperature sensor
defective or recording of values
calibrated by EPROM failed
Output speed not at zero

FN

Control lever not in neutral

FP

Parking brake not engaged

STOP

AEB-Starter used in incorrect or


defective manner. Device wrong or
wrong cable.

ST
K1,..K4,KV,KR
- e Kx
= e Kx
= e Kx
OK
STOP
STOP and Kx
Chiave and Kx
E
E
T

FT
FB

Remarks

The transmission stays in neutral, TCU must be


restarted (starting off/on) after removing AEB
The transmission stays in neutral, TCU must be
restarted (starting off/on)
The transmission stays in neutral, TCU must be
restarted (starting off/on)
The transmission stays in neutral, TCU must be
restarted (starting off/on)

The transmission stays in neutral, TCU must be


restarted (starting off/on)
The transmission stays in neutral, TCU must be
restarted (starting off/on)

The transmission stays in neutral, TCU must be


restarted (starting off/on)
The transmission stays in neutral, TCU must be
restarted (starting off/on)
The transmission stays in neutral, TCU must be
restarted (starting off/on)
The transmission stays in neutral, TCU must be
restarted (starting off/on)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 21

TCU shifts transmission to neutral


OP mode:
transmission shutdown

LOGICAL ERROR AT GEAR RANGE SIGNAL


TCU detected a wrong signal combination for the
gear range
cable from shift lever to TCU is broken
cable is defective and is contacted to battery voltage or vehicle ground
shift lever is defected

LOGIC ERROR AT DIRECTION SELECTION


SIGNAL
wire from gearshift lever to TCU
cut-off
wire defective and connected to battery voltage or
ground of vehicle
gearshift lever defective

LOGIC ERROR IN THE PARKING BRAKE STATUS


Parking brake status signal monitored by TCU
and signal forwarded to CAN do not coincide
one of the wires from status switch to electronic
box defective
one of the status switches is defective

11

12

14

TCU moves the transmission into DCO status


OP-Mode: normal

check the cables from electronic boxes to status


switches
check signals of the status
switches

check cables between TCU to


gearshift lever
check combination of signals
of gearshift lever in positions
F-N-R

Failure cannot be detected in systems with DW2/DW3 shift lever

check the cables from TCU to


shift lever
check signal combinations of
shift lever positions for gear
range

The defect is identified if TCU


monitors a valid signal for the direction at the gearshift lever

Fault is taken back if TCU detects


a valid signal for the position

Remarks

Possible step or intervention

transmission control unit


Electronic control unit
power take-off

2 - 22

TCU moves transmission into neutral


OP mode:
transmission cut-off

Reaction TCU

TCU
EEC
PTP

MEANING OF TROUBLE CODE


Possible cause identification of trouble

open circuit
short circuit
mode of operation

Abbreviations:

Trouble
Code
(hex)

o.c.
s.c.
OP-Mode

2.6.3 TABLE OF TROUBLE CODES

Copyright New Holland

TRANSMISSION
W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

MEANING OF TROUBLE CODE


Possible cause identification of trouble

LOGIC ERROR AT SIGNAL 2 GEARSHIFT LEVER DIRECTION SELECTION


TCU detected a wrong signal combination for the
direction
wire from gearshift lever 2 to TCU cut-off
wire defective and connected to battery voltage or
ground of vehicle
gearshift lever defective

S. C. TO BATTERY VOLTAGE AT CLUTCH


CUT OFF INPUT
the measured voltage is too high:
cable is defective and is contacted to battery voltage
clutch cut off sensor has an internal defect
connector pin is contacted to battery voltage

S. C. TO GROUND OR O.C. IN CLUTCH CUTOFF INPUT


voltage measure is too low:
wire defective contacting ground of vehicle
wire not connected to TCU
clutch cut-off sensor defective
connection terminal connected to battery
voltage

S. C. VOLTAGE BATTERY AT LOAD SENSOR


INPUT
the voltage measured is too high:
wire defective and connected to battery voltage
load sensor defective
the terminal is connected to battery voltage

Trouble
Code
(hex)

15

21

22

23

The delay function is


in trouble TCU uses
lack of load
OP-Mode: normal

check wire between TCU and


sensor
check connectors
check load sensor
check mounting tolerance of
load sensor

check wire between TCU and


sensor
check connectors
check clutch cut-off sensor

Availability of retarder depends on


default load

The defect is identified if TCU


monitors a valid signal for the direction at the gearshift lever

check the cables from TCU to


shift lever 2
check signal combinations of
shift lever positions F-N-R

check the cable from TCU to


the sensor
check the connectors
check the clutch cut off sensor

Remarks

Possible step or intervention

W190

The clutch cut-off


function is inoperative
OP-Mode: normal

Clutch cut off function


is disabled
OP-Mode: normal

TCU shifts transmission into neutral when


selector is activated
OP-Mode:
transmission inactive
when selector activated

Reaction TCU

Copyright New Holland

TRANSMISSION
2 - 23

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Reaction TCU

No reaction TCU use


lack of temperature
OP-Mode: normal

No reaction TCU use


lack of temperature
OP-Mode:
V
normal

No reaction TCU use


lack of temperature
OP-Mode: normal

No reaction TCU use


lack of temperature
OP-Mode: normal

MEANING OF TROUBLE CODE


Possible cause identification of trouble

S. C. TO GROUND OR O.C AT CONVERTER


OUTPUT TEMPERATURE SENSOR
the voltage measured is too high:
wire defective and connected to battery voltage
wire not connected to TCU
temperature sensor defective
the terminal is connected to battery voltage or is
broken

S. C. TO GROUND OR O.C. AT CONVERTER


OUTPUT TEMPERATURE SENSOR
the voltage measured is too low:
wire defective contacting ground of vehicle
temperature sensor defective
connection terminal connected to ground

S. C. TO GROUND TO TRANSMISSION DISCHARGE LINE TEMPERATURE INPUT


the voltage measured is too low:
wire defective contacting ground of vehicle
temperature sensor defective
connection terminal connected to ground

S. C. TO BATTERY VOLTAGE OR O. C. TO
MODULATOR TEMPERATURE SENSOR INPUT
the voltage measured is too high:
wire defective contacting ground of vehicle
wire not connected to TCU
temperature sensor defective
connection terminal connected to battery or broken

Trouble
Code
(hex)

24

25

26

27

check wire between TCU and


sensor
check connectors
check temperature sensor

Remarks

2 - 24

check wire between TCU and


sensor
check connectors
check temperature sensor

check wire between TCU and


sensor
check connectors
check temperature sensor

check wire between TCU and


sensor
check connectors
check temperature sensor

Possible step or intervention

Copyright New Holland

TRANSMISSION
W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

MEANING OF TROUBLE CODE


Possible cause identification of trouble

S.C. ON BATTERY VOLTAGE OR O. C. AT


CONVERTER OUTPUT TEMPERATURE SENSOR INPUT
the voltage measured is too high:
wire defective and connected to battery voltage
wire not connected to TCU
temperature sensor defective
connection terminal connected to battery or broken

S. C. TO GROUND AT CONVERTER OUTPUT


TEMPERATURE SENSOR INPUT
the voltage measured is too low:
wire defective contacting ground of vehicle
temperature sensor defective
connection terminal connected to ground

S.C. BATTERY VOLTAGE OR O. C. ENGINE


SPPED INPUT
TUC monitors a voltage exceeding 7.00 Volt at
speed input terminal
wire defective and connected to battery voltage
wire not connected to TCU
wire not connected to TCU
speed sensor defective

Trouble
Code
(hex)

27

28

31

check wire between TCU and


sensor
check connectors
check temperature sensor

check wire between TCU and


sensor
check connectors
check temperature sensor

check wire between TCU and


sensor
check connectors
check temperature sensor

Possible step or intervention

Remarks

W190

No reaction TCU use


lack of temperature
OP-Mode: normal

No reaction TCU use


lack of temperature
OP-Mode: normal

No reaction TCU use


lack of temperature
OP-Mode: normal

Reaction TCU

Copyright New Holland

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 25

OP-Mode: replaces
clutch controlIf trouble
occurs at output
speed, TCU moves to
Neutral
OP-Mode: recovery

OP-Mode: replaces
clutch controlIf trouble
occurs at output
speed, TCU moves to
Neutral
OP-Mode: recovery

LOGIC ERROR AT ENGINE SPEED INPUT


TCU monitors an engine speed higher than
threshold and immediately after it monitors zero
speed
wire/connection defective and grounding on vehicle
speed sensor defective
sensor gap wrong

S. C. TO BATTERY VOLTAGE OR O. C. AT
TURBINE SPEED INPUT
TCU monitors a voltage exceeding 7.00 Volt at
speed input terminal
wire defective and connected to battery voltage
wire not connected to TCU
speed sensor defective
terminal connected to battery voltage or broken

S. C. TO GROUND AT TURBINE SPEED INPUT


TCU measures a voltage lower than 0.45 Volt at
speed input terminal
wire/connection defective and grounding on vehicle
speed sensor defective

33

34

35

No reaction TCU use


lack of temperature
OP-Mode: normal

S. C. TO GROUND AT ENGINE SPEED INPUT


TCU measures a voltage lower than 0.45 volt at
speed input terminal
wire/connection defective and grounding on vehicle
speed sensor defective

32

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

check wire between TCU and


sensor
check connectors
check temperature sensor

This trouble is reset after powering


TCU

Remarks

2 - 26

check wire between TCU and


sensor
check connectors
check speed sensor

check wire between TCU and


sensor
check connectors
check temperature sensor

check wire between TCU and


sensor
check connectors
check temperature sensor

Possible step or intervention

Copyright New Holland

TRANSMISSION
W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Reaction TCU

OP-Mode: replaces
clutch controlIf trouble
occurs at output
speed, TCU moves to
Neutral
OP-Mode: recovery

OP-Mode: replaces
clutch control

OP-Mode: replaces
clutch control

OP-Mode: replaces
clutch control

MEANING OF TROUBLE CODE


Possible cause identification of trouble

LOGIC ERROR AT TURBINE SPEED INPUT


TCU monitors an engine speed higher than
threshold and immediately after it monitors zero
speed
wire/connection defective and grounding on vehicle
speed sensor defective
sensor gap wrong

S. C. TO BATTERY VOLTAGE OR O. C. AT
INNER SPEED INPUT
TCU monitors a voltage exceeding 7.00 Volt at
speed input terminal
wire defective and connected to battery voltage
wire not connected to TCU
speed sensor defective
terminal connected to battery voltage or broken

S. C. TO GROUND AT INNER SPEED INPUT


TCU measures a voltage lower than 0.45 Volt at
speed input terminal
wire/connection defective and grounding on vehicle
speed sensor defective

LOGIC ERROR AT INNER SPEED INPUT


TCU monitors an engine speed higher than
threshold and immediately after it monitors zero
speed
wire/connection defective and grounding on vehicle
speed sensor defective
sensor gap wrong

Trouble
Code
(hex)

36

37

38

39

check wire between TCU and


sensor
check connectors
check engine speed sensor
check sensor gap

W190

check wire between TCU and


sensor
check connectors
check engine speed sensor

This trouble is reset after powering


TCU

This trouble is reset after powering


TCU

check wire between TCU and


sensor
check connectors
check temperature sensor
check sensor gap

check wire between TCU and


sensor
check connectors
check engine speed sensor

Remarks

Possible step or intervention

Copyright New Holland

TRANSMISSION
2 - 27

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Special mode for


speed selection
OP-Mode: replaces
clutch controlI trouble
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery
Special mode for
speed selection
OP-Mode: replaces
clutch controlI trouble
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery

S. C. TO GROUND AT OUTPUT SPEED


TCU measures a voltage lower than 1 Volt at
speed input terminal
wire/connection defective and grounding on vehicle
speed sensor defective

LOGIC ERROR AT OUTPUT SPEED INPUT


TCU monitors an engine speed higher than
threshold and immediately after it monitors zero
speed
wire/connection defective and grounding on vehicle
speed sensor defective
sensor gap wrong

check wire between TCU and


sensor
check connectors
check speed sensor
check sensor gap

check wire between TCU and


sensor
check connectors
check speed sensor

check wire between TCU and


sensor
check connectors
check speed sensor

Possible step or intervention

This trouble is reset after powering


TCU

Remarks

2 - 28

3C

3B

Special mode for


speed selection
OP-Mode: replaces
clutch controlI trouble
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery

S. C. TO BATTERY VOLTAGE OR O. C. AT
OUTPUT SPEED INPUT
TCU monitors a voltage exceeding 12.5 Volt at
speed input terminal
wire defective and connected to battery voltage
wire not connected to TCU
speed sensor defective
terminal connected to battery voltage or fails to
make contact

3A

Reaction TUC

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Copyright New Holland

TRANSMISSION
W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

No reaction

No reaction

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutch TCU
moves to neutral
OP-Mode: stop TCU

MODE SIGNAL TEST


CAN signal for test status mode is wrong
cluster controller defective
interference on Can-Bus

Signal request AEB


Signal CAN for AEB mode is wrong
I/O controller defective
interference on Can-Bus

S. C. ON BATTERY VOLTAGE AT K1 CLUTCH


The value of the resistance monitored by the valve
is off-limits, the voltage at valve K1 is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective

59

61

71

Special mode for


speed selection
OP-Mode: replaces
clutch controlI trouble
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery

ZERO OTPUT SPEED DOES NOT MATCH ANY


OTHER SPEED SIGNAL
TUC monitors zero output speed and turbine
speed or inner speed different from zero
speed sensor defective
sensor gap wrong

3E

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

This trouble is reset after powering


TCU

check signal of output speed


sensor
check output speed sensor gap
check wire between TCU and
sensor

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

W190

check I/O, Omron master


controller
check CAN-bus wire
check wire between I/O, Omron
master controller

check cluster controller


check CAN-bus wire
check wire to cluster controller

Remarks

Possible step or intervention

Copyright New Holland

TRANSMISSION
2 - 29

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

MEANING OF TROUBLE CODE


Possible cause identification of trouble

S. C. TO GROUND AT CLUTCH K1
The value of the resistance monitored by the valve
is off-limits, the voltage at valve K1 is too low.
wire/connection defective and connected to battery voltage
regulator defective

O. C. ON CLUTCH K1
The resistance value is off-limits.
wire/connection defective and connected to battery voltage
regulator defective

S. C. ON BATTERY VOLTAGE AT CLUTCH K2


The value of the resistance monitored by the valve is
off-limits; the voltage at valve K2 is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective

S. C. TO GROUND AT K2 CLUTCH
The value of the resistance monitored by the valve
is off-limits; the voltage at valve K2 is too low.
wire/connection defective and connected to battery voltage
regulator defective

Trouble
Code
(hex)

72

73

74

75

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutch TCU
moves to neutral
OP-Mode: stop TCU

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

Possible step or intervention


Remarks

2 - 30

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutch TCU
moves to neutral
OP-Mode: stop TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutch TCU
moves to neutral
OP-Mode: stop TCU

Reaction TCU

Copyright New Holland

TRANSMISSION
W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

S. C. TO BATTERY VOLTAGE AT K3 CLUTCH


The value of the resistance monitored by the valve
is off-limits; the voltage at valve K3 is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective

S. C. TO GROUND AT K3 CLUTCH
The value of the resistance monitored by the valve
is off-limits; the voltage at valve K3 is too low.
wire/connection defective and connected to battery voltage
regulator defective

77

78

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

O. C. ON CLUTCH K2
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective

76

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Remarks

W190

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

Possible step or intervention

Copyright New Holland

TRANSMISSION
2 - 31

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

MEANING OF TROUBLE CODE


Possible cause identification of trouble

O. C. ON CLUTCH K3
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective

S. C. TO BATTERY VOLTAGE AT K3 CLUTCH


The value of the resistance monitored by the valve
is off-limits; the voltage at valve K3 is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective

Trouble
Code
(hex)

79

81

Possible step or intervention

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission
check wire from TCU to controller
check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

Reaction TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

Remarks

Copyright New Holland

2 - 32
TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

O. C. ON CLUTCH K4
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective

S. C. TO BATTERY VOLTAGE AT KV CLUTCH


The value of the resistance monitored by the valve
is off-limits; the voltage at valve KV is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective

83

84

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

S. C. TO GROUND AT K4 CLUTCH
The value of the resistance monitored by the valve
is off-limits; the voltage at valve K4 is too low.
wire/connection defective and connected to battery voltage
regulator defective

82

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Remarks

W190

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

Possible step or intervention

Copyright New Holland

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 33

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

O. C. ON CLUTCH KV
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective

S. C. TO BATTERY VOLTAGE AT KR CLUTCH


The value of the resistance monitored by the valve
is off-limits; the voltage at valve KR is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective

86

87

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

S. C. TO GROUND AT KV CLUTCH
The value of the resistance monitored by the valve
is off-limits, the voltage at valve KV is too low.
wire/connection defective and connected to battery voltage
regulator defective

85

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Remarks

2 - 34

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

Possible step or intervention

Copyright New Holland

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutch TUC
moves to neutral
OP-Mode: stop TCU

TCU shifts to neutral


OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown

O. C. ON CLUTCH KR
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective

SLIPPAGE AT CLUTCH K1
TCU calculates a differential speed at closed
clutch K1. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at clutch K1
low main pressure
wrong signal at internal speed sensor
wrong signal at turbine speed sensor
wrong size of the sensor gap
clutch is defective

89

B1

TCU moves to neutral


OP-Mode: recovery if
trouble is monitored
on other clutchTCU
moves to neutral
OP-Mode: stop TCU

S. C. TO GROUND AT KR CLUTCH
The value of the resistance monitored by the valve
is off-limits, the voltage at valve KR is too low.
wire/connection defective and connected to battery voltage
regulator defective

88

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)
Remarks

W190

check pressure at clutch K1


check main pressure in the
system
check sensor gap at internal
speed sensor
check sensor gap at turbine
speed sensor
check signal at internal speed
sensor
check signal at turbine speed
sensor
replace clutch

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

check wire from TCU to controller


check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission

Possible step or intervention

Copyright New Holland

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 35

MEANING OF TROUBLE CODE


Possible cause identification of trouble

SLIPPAGE AT CLUTCH K2
TCU calculates a differential speed at closed
clutch K1. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at clutch K2
low main pressure
wrong signal at internal speed sensor
wrong signal at turbine speed sensor
wrong size of the sensor gap
clutch is defective

SLIPPAGE AT CLUTCH K3
TCU calculates a differential speed at closed
clutch K1. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at clutch K3
low main pressure
wrong signal at internal speed sensor
wrong signal at turbine speed sensor
wrong size of the sensor gap
clutch is defective

Trouble
Code
(hex)

B2

B3

Possible step or intervention

check pressure at clutch K2


check main pressure in the
system
check sensor gap at internal
speed sensor
check sensor gap at turbine
speed sensor
check signal at internal speed
sensor
check signal at turbine speed
sensor
replace clutch
check pressure at clutch K3
check main pressure in the
system
check sensor gap at internal
speed sensor
check sensor gap at turbine
speed sensor
check signal at internal speed
sensor
check signal at turbine speed
sensor
replace clutch

Reaction TCU

TCU shifts to neutral


OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown

TCU shifts to neutral


OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown

Remarks

Copyright New Holland

2 - 36
TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

MEANING OF TROUBLE CODE


Possible cause identification of trouble

SLIPPAGE AT CLUTCH K4
TCU calculates a differential speed at closed
clutch K1. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at clutch K4
low main pressure
wrong signal at internal speed sensor
wrong signal at turbine speed sensor
wrong size of the sensor gap
clutch is defective

SLIPPAGE AT CLUTCH KV
TCU calculates a differential speed at closed
clutch KV. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at clutch KV
low main pressure
wrong signal at internal speed sensor
wrong signal at turbine speed sensor
wrong size of the sensor gap
clutch is defective

Trouble
Code
(hex)

B4

B5

Possible step or intervention

check pressure at clutch K4


check main pressure in the
system
check sensor gap at internal
speed sensor
check sensor gap at turbine
speed sensor
check signal at internal speed
sensor
check signal at turbine speed
sensor
replace clutch
check pressure at clutch KV
check main pressure in the
system
check sensor gap at internal
speed sensor
check sensor gap at turbine
speed sensor
check signal at internal speed
sensor
check signal at turbine speed
sensor
replace clutch

Reaction TCU

TCU shifts to neutral


OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown

TCU shifts to neutral


OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown

Remarks

Copyright New Holland

W190
TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 37

No reaction
OP-Mode: normal

OVERTEMP SUMP
TCU measured a temperature in the oil sump that
is over the allowed threshold.

CONVERTER LOCKING CLUTCH SLIPPING


TCU monitors a different speed on the converter
locking clutch. If the value monitored is off-limits, TCU interprets it as a clutch slipping.
low pressure at converter locking clutch
low main pressure
wrong signal at engine speed sensor
wrong signal at turbine speed sensor
wrong sensor gap
clutch defective

CONVERTER OUTPUT OVERHEATING


TCU measures a temperature at the converter
output higher than allowable value.

B7

BB

C3

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

cool down machine


check oil level
check temperature sensor

check pressure at converter


lockup clutch
check main pressure in the
system
check sensor gap at engine
speed sensor
check sensor gap at turbine
speed sensor
check signal at engine speed
sensor
check signal at turbine speed
sensor
replace clutch

cool down machine


check oil level
check temperature sensor

check pressure at clutch KR


check main pressure in the
system
check sensor gap at internal
speed sensor
check sensor gap at turbine
speed sensor
check signal at internal speed
sensor
check signal at turbine speed
sensor
replace clutch

Possible step or intervention

Normal resistance to ambient


temperature: 1000-1500 .

Remarks

2 - 38

No reaction
OP: normal

TCU shifts to neutral


OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown

SLIPPAGE AT CLUTCH KR
TCU calculates a differential speed at closed
clutch KR. If this calculated value is out of range,
TCU interprets this as slipping clutch.
low pressure at clutch KR
low main pressure
wrong signal at internal speed sensor
wrong signal at turbine speed sensor
wrong size of the sensor gap
clutch is defective

B6

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Copyright New Holland

TRANSMISSION
W190

check wires and connectors to


sensors powered by AU1
check power to terminal AU1
(it must be about 5 Volt)

It moves to neutral
OP-Mode: Stops TCU

It moves to neutral
OP-Mode: Stops TCU

It moves to neutral
OP-Mode: Stops TCU

S.C. TO GROUND AT SENSOR POWERING


TCU monitors less than 4 Volt at terminal AU1
(5 Volt sensor power)

LOW BATTERY VOLTAGE


the voltage monitored at powering is lower than
10 Volt (12 Volt device)lower than 18 Volt
(24 Volt device)

HIGH BATTERY VOLTAGE


the voltage monitored at powering is higher than
18 Volt (12 Volt device)higher than 32.5 Volt (24
Volt device)

ERROR IN POWER VPS1


TCU switched on VPS1 monitoring VPS1 OFF or
TCU switched on VPS1 monitoring VPS1 still ON
wire/connection defective and connected to battery voltage
wire/connection defective and connected to vehicle ground
lack of permanent power at KL30
TCU defective

D2

D3

D4

D5

check fuses
check wires between batteries
and TCU
check connections between
batteries and TCU
replace TCU

check powering battery


check wires between batteries
and TCU
check connections between
batteries and TCU

Remarks

W190

check powering battery


check wires between batteries
and TCU
check connections between
batteries and TCU

check wires and connectors to


sensors powered by AU1
check power to terminal AU1
(it must be about 5 Volt)

S. C. VOLTAGE BATTERY TO SENSOR


POWERING
TCU monitors more than 6 Volts at terminal AU1
(5 Volt sensor power)

Possible step or intervention

D1

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Copyright New Holland

TRANSMISSION
2 - 39

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

No reaction
OP-Mode: normal

No reaction
OP-Mode: normal

It moves to neutral
OP-Mode: Stops TCU

S. C. BATTERY VOLTAGE AT DISPALY OUTPUT


TCU forwards data to the display and monitors
always a high voltage on connectors
wire/connection defective and connected to vehicle ground
display defective

S. C. TO GROUND AT DISPALY OUTPUT


TCU forwards data to the display and monitors
always a high voltage on connectors
wire/connection defective and connected to vehicle ground
display defective

COMUNICATIONS TROUBLE ON NET DEVICE

E3

E4

E5

check Omron Master


check cable of Device Net-Bus
check cable of Omron Master

Remarks

2 - 40

check wire between TCU and


display
check connections at display
replace display

check wire between TCU and


display
check connections at display
replace display

check fuse
check wires from transmission
to TCU
check connectors from gearbox to TCU
replace TCU

It moves to neutral
OP-Mode: Stops TCU

ERROR IN POWER VPS2


TCU switched on VPS2 monitoring VPS2 OFF or
TCU switched on VPS2 monitoring VPS2 still ON
wire/connection defective and connected to battery voltage
wire/connection defective and connected to vehicle ground
lack of permanent power at KL30
TUC defective

D6

Possible step or intervention

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Copyright New Holland

TRANSMISSION
W190

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Transmission stays in
neutral

OP-Mode: TCU stop


No reaction
OP-Mode: normal

CL1 OUT OF TIME


CAN CL1 message from cluster controller out of
time
interference on CAN-Bus
CAN cable/connector broken
CAN cable/connector defective or connected to
vehicle ground or battery voltage

ILLEGAL ID REQUEST TRHOUGH CAN

GENERAL DEFECT EEPROM


TCU unable to read a volatile memory
TCU defective

LOSS OF CONFIGURATION
TCU lost the correct configuration and is unable
to control the transmission
interference during saving of data or on a volatile memory
new TCU or from another machine

E5

E6

F1

F2

Often indicated by trouble code F2

Check display controller


Check CAN-Bus cable
Check cable of display controller

Reprogram the correct configuration for vehicle (ex. With cluster controller etc.)

Replace TCU

Check display controller


Check CAN-Bus cable
Check cable of display controller

Remarks

Possible step or intervention

W190

Transmission stays in
neutral
OP-Mode: TCU stop

TCU keeps the old information for:


test status modeplock
statusgearshifting
quality selection
OP-Mode: normal

TCU selects parameter defined by ID0


OP-Mode: recovery

DISPID1-OUT-OF-TIME
Out of time of message DISPID1 from display
controller
interference on CAN-Bus
CAN cable/connector broken
CAN cable/connector defective or connected to
vehicle ground or battery voltage

E5

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Copyright New Holland

TRANSMISSION
2 - 41

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

It moves to neutral

The transmission
stays in neutral
OP-Mode: stop TCU

No reaction
default values = 0 for
AEB
offset used
OP-Mode: normal

REQUEST FOR RECOVERY


No fault! Indicates that another computer requested the recovery via CAN

CLUTCH FAILURE
AEB was unable to regulate the correct clutch
load parameters
one of the AEB values off limits

LOSS OF CLUTCH REGULATION DATA


TCU was unable to monitor the correct clutch
regulation parameters
interference during saving of data or on a volatile memory
new TCU or from another machine

F4

F5

F6

TCU indicates the clutch involved


on the display

Remarks

2 - 42

perform AEB

check clutch

the outer controller cancelled


the request

re-configure with TCU configuration command (IDPC)

Speed range regulated


from 1st through 4th

LOSS OF CONFIGURATION fwd


TUC lost the FWD configuration
interference during saving of data or on a volatile memory
new TCU or from another machine

F2

Possible step or intervention

Reaction TCU

MEANING OF TROUBLE CODE


Possible cause identification of trouble

Trouble
Code
(hex)

Copyright New Holland

TRANSMISSION

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

W190

TRANSMISSION

2 - 43

2.6.4 TROUBLESHOOTING USING THE "TESTMAN" DEVICE


A complete instrument for the troubleshooting and repair of ZF transmissions is represented by the
2TESTMAN"standard set:

Windows 95/98
Pentium
MB/NT 32 MB
RAM
Free Hard disk capacity
Floppy disk drive

SYTEM

90 Mhz
Windows 95/98 16
20 MB
3 1/2"
COM 1 or COM2

Basic - Software

Diagnostic set
380001217

ZF Diagnostic adapter DPA - 04

Ad
602

+
EST - 37
Diagnosis
Software

W190-2R002

Fig. 2-17
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

2 - 44

TRANSMISSION

W190

2.6.4.1 CONNECTIONS AND SETTINGS OF THE DPA - 03

n
e to
ctio cabl
e
n
ic
Con nost
g
a
i
D

pi

up
ck-

"A"

C
le P
tab OM2
r
o
p
C
On
1 or
M
CO

The DPA-03 adapter must be connected by the cable


provided to the pick-up indicated located behind the
plastic panel in the cab, behind the operator's seat.

Fig. 2-19
For
Fortroubleshooting
Diagnostic always
position
= OFF
always in
positio
= OFF

Diagnose- und Programmier-Adapter


DPA 03

Lighted during
the operation

Data
U Batt

AUS

UPRG

KL30

KL15
ECU

EIN

V-24

Fig. 2-20

ISO 9141

DATA
DATA
Flashing
during .
flashes
at operation
the operation

SAE J 1708

No
connections
L-Ltg.
unbenutz

L-Ltg.

KL15
Fzg.
0501 211 102

Diagnosis
- ERGOPOWER
Troubleshooting
always
on
posiitionalways
KL 30in
ERGOPOWER
position "KL 30"

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

TRANSMISSION

2.6.4.2 CONFIGURATION OF TESTMAN SOFTWARE MENU

MAIN MENU

Repair assistance
Maintenance
To sub-programs
Tightening limit
To sub-programs
Setting values
To sub-programs
Special tools/Testers
To sub-programs
Repair
To sub-programs
Harnesses and connections diagrams
To sub-programs
Pressure
To sub-programs
Electric measurements values
To sub-programs
Troubleshooting
Reading of accumulation of defects
Cancellation of accumulation of defects
Reading of identification block
Inputs and Outputs - test
Test of system inoperative
Test of system in operation
Test device
Analogical display, speed, current etc.
Vehicle configuration
Starting AEB - Recording of values
Display AEB - Values K1, K2, K3
Display AEB - Values K4, KV, KR
ZF service telephone list

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 45

Copyright New Holland

2 - 46

TRANSMISSION

W190

2.7 TRANSMISSION OVERHAUL


2.7.1 DISASSEMBLY OF CONTROL VALVE
The figure on the left illustrates the transmission control valve assembly.

Fig. 2-21
Mark the disassembly location of the various covers,
housings and cable connector with respect to the control valve body.

Fig. 2-22
Remove the recessed head screws using tool
380001295.
Remove the oil ducts plate from the control valve body,
the first gasket, the intermediate plate and the second gasket.

Fig. 2-23

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

TRANSMISSION

2 - 47

Remove the retaining ring.

Fig. 2-24
Remove the recessed head screws using tool
380001295.
Remove the cover from the housing and from the cable/connector.

Fig. 2-25
Remove the cover on the opposite side.
Remove the pressure regulators and remove the cable and connector.

Fig. 2-26
Remove the recessed head screws using tool
380001295; remove the securing plates and pressure
regulators (x3).

Fig. 2-27

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

2 - 48

TRANSMISSION

Remove the two recessed head screws and secure


temporarily the housing with setting screws 380001276.
(The housing is subject to the action of the springs)
Remove the remaining screws.

W190

S
S

(S) setting screws.

Fig. 2-28
Separate the housing from the control valve body, loosening uniformly the setting screws.
S
(S) setting screws.
S

Fig. 2-29
Remove the components (fig. 2-30).
Remove in the same manner from the opposite side,
the pressure regulators, the housing and the relevant
components (Fig. 2-31).

Fig. 2-30

Fig. 2-31

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2.7.2 RE-ASSEMBLY
Note Inspect all the components and replace them
as required. Prior to their re-installation, check that all
the moving parts are free to slide in the housing. The
spools are individually interchangeable. Prior to the
installation, lubricate all the components.
Insert fully the diaphragms with the concave side facing upward.
Note Mounting positions indicated by arrows!

Fig. 2-32
The figure on the left illustrates the following components:
1 = Vibration damper
2 = Follow-up slider
3 = Pressure relief valve

(3x Spool and spring)


(3x Spool and spring)
(1x Spool and spring)

3
2

Fig. 2-33
Install the components as indicated in Fig. 2-33.
Note Press the spring of the follow-up sliders and
install temporarily the spools using the 5.0 mm diameter cylindrical pins as illustrated by the arrows in
Fig. 2-34.

Fig. 2-34

Install the two setting screws 380001276.


Install the gasket (arrow 1) and the housing cover
(Fig. 2-35). Install the cover tightening uniformly the
setting screws until it contacts the housing, then remove the cylindrical pins (mounting help) - See Fig.
2-36.
Note Pay attention with the different housing covers.
Install the cover with the 15 mm diameter cavity (arrow 2) oriented toward the pressure relief valve spring.

Fig. 2-35

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Fig. 2-36
Secure the hosing cover tightening the recessed hex
screws with tool 380001295.
Tightening torque ......................................... 5.5 Nm

Fig. 2-37
Install the pressure regulators and secure them using
the securing plates and the recessed hex head screws.
Note Install the securing plates with the fork facing
downward.
Pay attention to the radial mounting position of the
pressure regulators, see Figure.
Tightening torque ......................................... 5.5 Nm

Fig. 2-38

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Preliminary installation on the opposite side


The figure on the right illustrates the following components:
1 = Main pressure relief valve
2 = Follow-up slider
3 = Vibration damper
1

(1x Spool and spring)


(3x Spool and spring)
(3x Spool and spring)

Fig. 2-39
Install the components as illustrated in Figure 2-39.
Press the springs of the follow-up sliders and install
temporarily the spools using the 0.5 mm cylindrical
pins (mounting help) as illustrated by the arrows.
Install the two setting screws.
2

Install the gasket (Arrow 1) and the housing cover and


move them uniformly to contact the housing using the
setting screws.
Note Pay attention with the different housing covers.
Install the cover with the 19 mm diameter cavity (Arrow 2) oriented toward the pressure main relief valve!
Secure the housing cover tightening the recessed hex
head screws.

Fig. 2-40

Tightening torque ......................................... 5.5 Nm


Remove the cylindrical pins (mounting help).

Install the pressure regulators and secure them using


the securing plates and tighten the recessed hex head
screws using tool 380001295.
Note Install the securing plates with the fork facing
downward.
Pay attention to the radial mounting position of the
pressure regulators. see Figure.
Tightening torque ......................................... 5.5 Nm

Fig. 2-41

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Install the connector and the harness and connect


the pressure regulators (x 6).
Note pay attention to the mounting position of the
connector and harness, considering the marks as well
(Fig. 2-22).

Fig. 2-42
Insert the female connector into the housing with the
slide in correspondence with the guide in the cover.
Install the gasket (Arrow) and secure the cover with
the recessed hex head with tool 380001295.
Tightening torque ......................................... 5.5 Nm

Fig. 2-43
Secure the female connector using the retaining ring,
see Figure 2-44.
Install the opposite cover.

Fig. 2-44

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Install the oil ducts plate and secure it uniformly using the recessed hex head screws.
Tightening torque ......................................... 9.5 Nm

Fig. 2-45
Install the threaded plugs (8x) with new O-rings.
Tightening torque ............................................. 6 Nm
Note The installation of the transmission control
valve is described at page 2-102.

Fig. 2-46
Tighten the two setting screws and install gasket (1).
Note Pay attention to the different gaskets, see
figures 2-47 and 2-50.

1
Fig. 2-47
Intermediate plate - Version with mesh filter:
Insert the mesh filters (x6) into the relevant holes in
the intermediate plate, see arrows.
Note Pay attention to the mounting position - The
meshes must be oriented upward (directed toward the
oil ducts plate).

Fig. 2-48

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Install the intermediate plate with the mesh filters oriented upward.

Fig. 2-49
Install gasket (2).

2
Fig. 2-50

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2.8 DISASSEMBLY OF
THE TRANSMISSION
2.8.1 REMOVAL OF THE TRANSMISSION CONTROL VALVE AND THE OIL DUCTS PLATE
FROM THE TRANSMISSION HOUSING
Remove the two recessed head hex screws and install to setting screws 380001277 instead.
Remove the remaining screws and separate the control valve from the oil ducts plate.
Fig. 2-51
Remove both gaskets and the intermediate plate.
Remove the recessed head hex screws with tools
380001296 and hex nuts (fig. 2-52) and remove the
oil ducts plate from the transmission housing.
Remove the gasket.

Fig. 2-52
Extract the converter safety valve from the hole in
the housing.

Fig. 2-53

2.8.2 DISASSEMBLY
Remove the cover indicated from the side of the engine and remove the two M10 Allen screws securing
the converter to the engine through the flex disc.
Use an appropriate tooling to turn the crankshaft so
that the said screws are visible through the hole indicated.

Fig. 2-54

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Hold the transmission-torque converter housing slinging


it in four points (two frontally and two in the rear).
Remove the screws indicated and separate the transmission from the engine.
Note Be careful to prevent the converter from falling
out its seat.

Fig. 2-55

Remove the four screws indicated and remove the


flex disc.
Install four hooks in lieu of the screws and extract the
converter using a lifting device.

Extract the torque converter wheel drive shaft from


the cover (ball bearing).
Fig. 2-56

Remove the induction sender (Engine).

Fig. 2-57

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Remove the recessed head hex screws and separate


the converter bell.

Fig. 2-58
Hydraulic pump
Remove the recessed head hex screws.

Fig. 2-59
Place a puller separator on the stator shaft and use a
two-leg puller to pull carefully the pump assembly from
the housing holes.

Fig. 2-60
Remove the hydraulic pump from the stator shaft.
Remove the timing plate from the pump.
Note In the event signs of wear are found on the pump
housing or the timing plate, the entire pump must be overhauled!
Reinstall the timing plate and secure it with the pins in the
slide (2x).

Fig. 2-61

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Remove the recessed head hex screws with tool


380001296 and the two hex screws and remove the
oil supply housing.
Remove the seal.

Fig. 2-62
Torque converter pressure relief valve
Press the spring and remove the safety plant.
Then, remove the relevant components.

Fig. 2-63
Remove the recessed head hex screws.
Remove the cover and gasket.

Fig. 2-64
Disassembly of output and input shafts and clutches
Remove the safety plate, remove the recessed head
hex screws and extract the shaft, pushing with a pry
bar, the converter output flange.
Then, pushing again, extract the sealing ring from the
transmission housing hole.
Turn the transmission 180 and remove the rear output flange in the same manner.
Fig. 2-65

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Remove the speed sensor and the induction sensors


(Arrows).

Fig. 2-66
Remove the hex nuts and remove both covers (Arrows).
Remove the screws securing the cover to the transmission housing.

Fig. 2-67
Extract the two cylindrical pins (arrow).

Fig. 2-68

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Note The figures to follow illustrate the normal removal procedure for all the clutches!
The removal of the single clutches without using the
special tool (Clutch locking tool 380001279) makes
the disassembly extremely difficult!

Hold all the clutches in their position with locking tools


(380001279) installed on the transmission housing
cover.
Install the lifting hooks and sling them to a lifting device.

Fig. 2-69
Use a lifting device to remove the transmission housing cover with the clutches from the housing.

Fig. 2-70
Install the transmission housing cover on a rotary stand.

Fig. 2-71

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Remove the recessed head hex screws and extract


the output shaft with the two oil buffer plates.

Fig. 2-72
Extract the taper roller bearing.
Remove the opposite taper roller bearing in the same
manner.
Bush 380001293

Fig. 2-73
KR

Turn the transmission housing cover 180.

AN
KV

K4

K2

K1

K3

Fig. 2-74

The figure on the right illustrates the arrangement of


the single clutches and the output shaft in the transmission housing cover.
AN = Input
KV = Forward clutch
KR = Reverse clutch
K1 = 1st speed clutch
K2 = 2nd speed clutch
K3 = 3rd speed clutch
K4 = 4th speed clutch
Remove clutch locking tools (380001279).

Fig. 2-75

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Slightly lift clutch K4 with a pry bar and remove


clutch K1.

Fig. 2-76
Remove clutch K2.

Fig. 2-77
Remove clutch K3.

Fig. 2-78
Lift clutches KV and KR with two pry bars and remove clutch K4.

Fig. 2-79

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Lift and remove clutches KV and KR from the transmission housing cover as well as the input shaft.
Extract the bearing outer races from their holes on
the transmission housing.
Note in the event the taper roller bearings of the clutches
and the input and output shafts are not replaced, at least
maintain the original mating positions (outer races with inner races) for each bearing!
Mark the outer and inner races respectively for each
bearing.
Fig. 2-80

Turn the transmission housing cover 90.


Extract the retaining ring and remove the pump shaft
from the transmission housing cover.

Fig. 2-81

Remove the rectangular ring (arrow) and extract the


ball bearing from the shaft.

Fig. 2-82

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Disassembly of KV and KR clutches


Note The figures to follow illustrate the disassembly of
clutch KV. The disassembly of clutch KR is similar.
Remove the ring (arrow).

Fig. 2-83
Remove the taper roller bearing from the shaft.
Then remove the opposite taper roller bearing.
Bush 380001289

Remove the retaining ring.

Fig. 2-84

Extract the disc drum from the shaft.

Fig. 2-85

Fig. 2-86

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Remove the retaining ring and the clutch discs.

Fig. 2-87
Press the spring with tool 380001280; remove the
circlip and the components.

Fig. 2-88
Use compressed air to pullout the piston from the
cylinder.

Fig. 2-89
Remove both O-Rings (arrows).

Fig. 2-90

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Lift slightly the idle gear using two pry bars (fig. 2-91).

Fig. 2-91
Use a puller to separate the idle gear from the clutch
shaft (Fig. 2-92).

Fig. 2-92

Remove the circlip and extract the ball bearing.


Note Clutch KR is disassembled in the same manner.

Fig. 2-93

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Disassembly of clutches K1, K2 and K3


Note The figures here below illustrate the disassembly of clutch K3.
The disassembly of clutches K1 and K2 is similar.

Remove the rectangular ring.


Remove the taper roller bearing from the shaft.
Then remove the opposite taper roller bearing.

Bush 380001293

Fig. 2-94
Remove the sliding disc, the axial needle cage and
the axial thrust washer.

Fig. 2-95
Remove the idle gear.

Fig. 2-96

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Remove both needle bearings and the axial bearing.

Fig. 2-97
Remove the retaining ring and extract the clutch pack.

Fig. 2-98
Press the cup spring using tool 380001280 and remove the circlip.
Remove the components that are free.

Fig. 2-99
Insert retaining ring 380001269 in the slot of the clutch
drum.
Place the puller with the legs holding the retaining
ring and pullout the clutch drum from the relevant
shaft.

Fig. 2-100

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Disassembly of clutch K4
Remove the ring (arrow).

Fig. 2-101
Remove the taper roller bearing from the shaft.
Then remove the opposite taper roller bearing in the
same manner.
Bush 380001289

Fig. 2-102
Remove the retaining ring and separate the disc drum
from the shaft.

Fig. 2-103
Remove the retaining ring and extract the clutch pack.

Fig. 2-104

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Press the cup spring and remove the circlip.


Remove the components that are free.
Remove the piston.

Fig. 2-105
Use compressed air to push the piston out the cylinder.

Fig. 2-106
Remove the idle gear and remove the components
that are free.
Note It is not possible to separate the shaft from
the gear (hot pressed).

Fig. 2-107

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Disassembly of the drive shaft


Remove the rectangular ring.
Extract the taper roller bearing.
In the same manner, remove the opposite taper roller
bearing.
Bush 380001294

Fig. 2-108
If required, use a press to pullout the turbine shaft
from the drive shaft.
Note The turbine shaft is secured axially by a retaining ring that is broken during the extraction operation.

Fig. 2-109

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2.8.3 ASSEMBLY
Reinstallation of oil pipes

WARNING
To ensure a correct reinstallation of the oil pipes
the use of the special tools indicated in this
manual is mandatory.

Install suction pipe (1), pressure pipes (2) and lube


pressure pipe (3) in the hole of the transmission housing.

Secure the suction and pressure pipes using recessed


head hex screws.
Maximum torque (M8/8.8) ............................. 23 Nm
Fig. 2-110
Turn the housing 180.
Head the suction and pressure pipes (Arrows) in the
relevant holes of the housing, using special tools
380001287 - 380001286 - 380001289.

WARNING
The tips of the pipes must be perfectly flushed
with the face of the housing.
If required, correct the protrusion of the pipe to
make it flush.
Fig. 2-111
Install the O-Rings (2 x/pipe) in the slots of the two oil
pipes, lubricating them with clean oil.

Fig. 2-112

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Install the two pipes (Arrows) until they bottom into


the housing.
Install e new O-Ring on the treaded plug and install it.
Tightening torque ........................................ 140 Nm

Fig. 2-113
Install the two oil pipes (Arrows) into the transmission
housing cover; turn the cover 180 and head the oil
pipes into the relevant holes.

WARNING
The tips of the pipes must be perfectly flushed
with the face of the housing.
If required, correct the protrusion of the pipe to
make it flush.

Fig. 2-114
Install the studs (M8 x 25).
Tightening torque (studs) .............................. 9.0 Nm
Note Apply Loctite (type No. 262) on the thread.
Install new O-Rings on the plugs (Arrows) and install
them into the relevant holes.
Tightening torque .......................................... 40 Nm
Tightening torque .......................................... 50 Nm
Tightening torque .......................................... 80 Nm
Fig. 2-115
Press the sealing covers with the concave face upward.
Note Apply Loctite (type No. 262) on the thread.

Fig. 2-116

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Assembly of clutches KV and KR


Note The figures here below illustrate the reassembly
of clutch KV.
The disassembly of clutch K3 is similar.

Fig. 2-117
Preliminary reassembly of the clutch drum
Check the operation of the oil discharge centrifugal
valve.
Note The ball must be free. Clean it with compressed
air, as required.
Install the two O-Rings (arrows) without twisting them,
into the relevant slots of the piston, lubricating them
with clean oil.
Insert the piston until it bottoms in the clutch drum.
Fig. 2-118
Note Pay attention to the mounting position, see
the Figure.
Install the inner ring, the spring and the guide ring.

Fig. 2-119
Press the spring with tool 380001280 and secure it
with a retaining ring.

Fig. 2-120

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Clutch pack KV - KR
Note The arrangement of the clutch discs KV and
KR is the same.

The drawing shown here below illustrates the arrangement of the components.
Drawing ref:
1 = Clutch drum
2 = Piston
3 = Outer disc - lined with friction material on one face
only (q.ty 1)
4 = Inner discs (q.ty 10)
5 = Outer discs - with lining on both faces (q.ty 10)
6 = Retaining ring (upon request s = 2.1 . 4.2 mm)
7 = End spacer
Effective number of friction surfaces = 20.

2.7+0.2 mm
6

2
7

Fig. 2-121
WARNING
Install outer disc 3 with the unlined face directed
toward the piston.

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Setting the play between the discs = 2.7+ 0.2 mm


Note To set the play among the discs, retaining
rings with different thickness are available.
To ensure an error free measuring, install the discs
without oil at this stage.
Insert the clutch pack as indicated in the drawing at
page 72.

Fig. 2-122
Install the end spacer and insert the retaining ring
(ex. s = 2.55 mm).

Fig. 2-123
Press the end spacer with a force of 100 N (10 kg)
and place a dial gauge and zero it.
Then, push the end spacer with a screwdriver toward
the retaining ring until it contacts in (upward) and read
the play among the discs on the dial gauge
(Fig. 2-124).
Note In the event the reading gives a value different from the required one, correct it with a different
retaining ring (s = 2.1 . 4.2 mm).
Fig. 2-124
After completing the setting of the play among the
discs, remove the clutch pack, lubricate the discs
with clean oil and reinstall them.

WARNING
Use oil complying with the specifications of the
list of lubricants (section 0 of the Manual).

Fig. 2-125

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Insert the idle gear until all the inner discs are mounted
on the splined hub.
Note This operation facilitates the later installation
of the idle gear.
Then remove the idle gear again.

Fig. 2-126
Install the stud (arrow).
Note Apply Loctite (Type No. 241) on the threads.
Tightening torque (M10) ................................ 17 Nm

Fig. 2-127
Insert the ball bearing until it bottoms and secure it
with the retaining ring.

Fig. 2-128

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Install the needle bearing.

Fig. 2-129
Move the idle gear until it bottoms against the stop.
Note Support it on the inner race of the bearing.

Fig. 2-130
Warm-up the inner part of the clutch drum (to about
120 C - 248 F).

Fig. 2-131
Install the clutch drum previously assembled until it
bottoms.

Fig. 2-132

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Secure the clutch drum axially using the circlip.

Fig. 2-133
Check with compressed air the operation of the clutch.
Note If the components are installed correctly, the
opening and closing of the clutch can be heard distinctly.

Fig. 2-134
Press the taper roller bearing against the stop.
Install the opposite taper roller bearing in the same
manner.

Fig. 2-135
Install the rings (arrows).

Fig. 2-136

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Reassembly of clutches K1, K2 and K3


Note The figures here below illustrate the assembly
of clutch K3.
The assembly of clutches K1 and K2 is similar.
Install the stud (arrow).
Note Apply Loctite (Type No. 241) on the threads.
Tightening torque (M10) ................................ 17 Nm
Fig. 2-137
Warm-up the inner part of the clutch drum (fig. 2-135)
and install the drum until it bottoms (Fig. 2-136).

Fig. 2-138

Fig. 2-139
Check the operation of the oil discharge centrifugal
valve.
Note The ball must be free; clean with compressed
air as required.
Install the two O-Rings (arrows) without twisting them,
into the relevant slots of the piston, lubricating them
with clean oil.

Fig. 2-140

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Insert the piston until it bottoms in the clutch drum.


Note Pay attention to the mounting position, see
the Figure.

Fig. 2-141
Install the cup spring pack and the guide ring.
Note Pay attention to the arrangement of the cup
spring elements; see the drawing at page 2-79.

Fig. 2-142
Press the cup spring and secure it with the retaining
ring.

Fig. 2-143

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WARNING
The arrangement of the discs of clutch K1 and K2
is different from the one of clutches K2 and K3.
Please refer to the drawings to follow.

Clutch pack K1
2,4+0,2 mm

Drawing reference:
1 = Clutch drum
2 = Piston
3 = Outer disc - lined with friction material on one
face only (q.ty 1)
4 = Inner discs (q.ty 9)
5 = Outer discs - with lining on both faces (q.ty 9)
6 = Retaining ring (upon request s = 2.1 . 4.2 mm)
7 = End spacer

3
7

4
Effective number of friction surfaces = 18.
Note Install outer disc 3 with the unlined face directed toward the piston.

Fig. 2-144

Clutch pack K2
Drawing reference:

1,8+0,2 mm
1 = Clutch drum
2 = Piston
3 = Outer disc - lined with friction material on one
face only (q.ty 1)
4 = Inner discs (q.ty 7)
5 = Outer discs - with lining on both faces (q.ty 7)
6 = Retaining ring (upon request s = 2.1 . 4.2 mm)
7 = End spacer

1
Effective number of friction surfaces = 14.

Note Install outer disc 3 with the unlined face directed toward the piston.
Fig. 2-145

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Setting of the disc play


Disc play of clutch K1
Disc play of clutches K2 and K3

= 2.4+0.2 mm
= 1.8+0.2 mm

Note To set the play among the discs, retaining


rings with different thickness are available.
To ensure an error free measuring, install the discs
without oil at this stage.
Insert the clutch pack as indicated in the drawing at
page 2-79.
Fig. 2-146
Install the end spacer and insert the retaining ring
(ex. s = 3.1 mm).

Fig. 2-147
Press the end spacer with a force of 100 N (10 kg) and
place a dial gauge and zero it (Fig. 2-148).
Then, push the end spacer with a screwdriver toward
the retaining ring until it contacts in (upward) and read
the play among the discs on the dial gauge (Fig. 2-149).
Note In the event the reading gives a value different from the required one, correct it with a different
retaining ring (s = 2.1 . 4.2 mm).

Fig. 2-148
After completing the setting of the play among the
discs, remove the clutch pack, lubricate the discs
with clean oil and reinstall them.

WARNING
Use oil complying with the specifications of the
list of lubricants (section 0 of the Manual).

Fig. 2-149

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TRANSMISSION

Install sliding disc (1) (55 x 78 x 5) needle axial cage


(2) and axial thrust ring (3) (55 x 78 x 1).
Note Install sliding disc 1 with the bevel directed
toward the needle axial cage.

W190

3
2
1

Fig. 2-150
Install both needle bearings.

Fig. 2-151
Insert the idle gear until all the inner discs are inserted into the splined hub.

Fig. 2-152

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1
2
3

2 - 85

Install axial thrust ring (3) (55 x 78 x 1), needle axial


cage (2) and sliding disc (1) (55 x 78 x 5).
Note Install sliding disc 1 with the bevel directed
toward the needle axial cage.

WARNING
To ensure that all the inner discs are inserted in
the splined hub, the sliding disc must coincide
with the shaft collar.
Fig. 2-153
Press the taper roller bearing against the shoulder.
Press the opposite taper roller bearing against the
shoulder.

Fig. 2-154
Check the operation of the clutch using compressed
air.
Note If the components are installed correctly, the
opening and closing of the clutch can be heard distinctly.

Fig. 2-155
Install the ring (arrow) making sure that it is well
seated.
Install the opposite ring in the same manner.

Fig. 2-156

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Reassembly of clutch K4
Cool-down the shaft (about - 80 C) (- 110 F), warmup the gear (about + 120 C) (250 F) and install the
shaft until they contact.

Fig. 2-157
Secure the gear axially using the circlip.

Fig. 2-158
Install the stud (arrow).
Note Apply Loctite (Type No. 241) on the threads.
Tightening torque (M10) ................................ 17 Nm

Fig. 2-159
Check the operation of the oil discharge centrifugal
valve.
Note The ball must be free; clean with compressed
air as required.
Install the two O-Rings (arrows) without twisting them,
into the relevant slots of the piston, lubricating them
with clean oil.

Fig. 2-160

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Insert the piston until it bottoms in the clutch drum.


Note Pay attention to the mounting position, see
the Figure.

Fig. 2-161
Install the cup spring pack and the guide ring.
Note Pay attention to the arrangement of the cup
spring elements; see drawing.

Fig. 2-162
Press the cup spring with tool 380001280 and secure
it with the retaining ring.

Fig. 2-163

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Clutch pack K4
The drawing here below illustrates the arrangement of
the components.
Drawing reference:
1 = Clutch drum
2 = Piston
3 = Outer disc - lined with friction material on one
face only (q.ty 1)
4 = Inner discs (q.ty 5)
5 = Outer discs - with lining on both faces (q.ty 5)
6 = Retaining ring (upon request s = 2.1 . 4.2 mm)
7 = End spacer

1,2+0,2 mm
5
6

Effective number of friction surfaces = 10.


4

WARNING
Install outer disc 3 with the unlined face directed
toward the piston.
Fig. 2-164

Setting of the disc play = 1.2+0.2 mm


Note To set the play among the discs, retaining
rings with different thickness are available.
To ensure an error free measuring, install the discs
without oil at this stage.
Insert the clutch pack as indicated in the drawing.

Fig. 2-165
Install the end spacer and insert the retaining ring
(ex. s = 3.4 mm).

Fig. 2-166

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Press the end spacer with a force of 100 N (10 kg)


and place a dial gauge and zero it (Fig. 2-167).
Then, push the end spacer with a screwdriver toward
the retaining ring until it contacts in (upward) and read
the play among the discs on the dial gauge
(Fig. 2-168).
Note In the event the reading gives a value different
from the required one, correct it with a different retaining
ring (s = 2.1 . 4.2 mm).
Fig. 2-167
After completing the setting of the play among the
discs, remove the clutch pack, lubricate the discs
with clean oil and reinstall them.

WARNING
Use oil complying with the specifications of the
list of lubricants (section 0 of the Manual).

Fig. 2-168
Insert the idle gear until all the inner discs are inserted on the splined hub.
Note This operation facilitates the later installation
of the idle gear.
Then remove the idle gear again.

Fig. 2-169
Install the two axial shoulder rings and the needle
cage.
Note The upper and lower axial shoulder rings have
the same thickness (55 x 78 x 1).

Fig. 2-170

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Install the new needle bearings.

Fig. 2-171
Install the idle gear.

Fig. 2-172
Install axial thrust ring (3) (55 x 78 x 1), needle axial
cage (2) and sliding disc (1) (55 x 78 x 5).

1
2

Note Install sliding disc 1 with the bevel directed


toward the needle axial cage.

Fig. 2-173
Warm-up the inner part of the clutch drum (about
120 C 250 F).
Install the clutch drum previously assembled until all
the inner discs are inserted on the splined hub.

WARNING
Wear protective gloves.

Fig. 2-174

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Secure axially the clutch drum using the circlip.

Fig. 2-175
Check the operation of the clutch using compressed
air.
Note When the components are installed correctly,
the opening and closing of the clutch is perceived perfectly.

Fig. 2-176
Press the taper roller bearing against the shoulder.
Install the opposite taper roller bearing.

Fig. 2-177
Install the ring (arrow) making sure that it is properly
seated.
Install the opposite rectangular ring.

Fig. 2-178

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Pre-assembly of the drive shaft


Cool-down the shaft (about - 80 C - 110 F), warmup the gear (about + 120 C 250 F) and install the
shaft until they contact.

Fig. 2-179
Secure the gear axially using the circlip.

Fig. 2-180
Press the circlip in the appropriate slot of the turbine
shaft.

Fig. 2-181
Insert the turbine shaft and insert the circlip in the
slot of the drive shaft - thus the turbine shaft is axially
secured.

Fig. 2-182

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Press the taper roller bearing against the shoulder.


Then install the rectangular ring in the slot of the drive
shaft.
Press the opposite taper roller bearing.

Fig. 2-183
Pre-assembly and reinstallation of output shaft
Position the oil buffer plate.

Fig. 2-184
Warm-up the taper roller bearing and install it against
the shoulder.
Install the opposite taper roller bearing in the same
manner.

Insert the bearing outer races of all the bearings in


their seats on the transmission housing.
Install the O-Rings (arrows).
Fig. 2-185
KV

K2
K3

AN

Note When bearings that have many work hours are


reused, pay attention that the initial location of the outer
races are respected.

KR

K4
K1
AB

AN
KV
KR
K1
K2
K3
K4
AB

= Input
= Forward clutch
= Reverse clutch
= 1st speed clutch
= 2nd speed clutch
= 3rd speed clutch
= 4th speed clutch
= Output

Fig. 2-186

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Position the oil buffer plate.

Fig. 2-187
Insert the output shaft previously assembled.
Secure the oil buffer plate with the recessed head
hex screws.
Tightening torque (M8/8.8) ............................ 23 Nm

Fig. 2-188

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Reassembly of drive shaft and clutches


KR

Insert the bearing outer races of all the bearings in


their seats on the transmission housing.

AN
KV

Note When bearings that have many work hours are


reused, pay attention that the initial location of the outer
races are respected.
K4

K2
K1

K3

AB

AN
KV
KR
K1
K2
K3
K4
AB

= Input
= Forward clutch
= Reverse clutch
= 1st speed clutch
= 2nd speed clutch
= 3rd speed clutch
= 4th speed clutch
= Output

Fig. 2-189
WARNING
Prior to reinstalling the clutches and drive shaft,
smear grease on the rectangular rings and centre them on the relevant shafts.
Insert clutch KR, drive shaft and clutch KV together
in the transmission housing cover.

Fig. 2-190
Lift the drive gear and position clutch K4.

Fig. 2-191

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Reinstall clutch K3.

Fig. 2-192
Position clutch K2.

Fig. 2-193
Lift clutch K4 and position clutch K1.

Fig. 2-194
The figure on the left illustrates the reinstallation position of the single clutches in the transmission housing cover.
Smear grease on the rectangular rings (arrows) and
centre them on the relevant shafts.

KR
KV
K2
K4

K3

K1

Fig. 2-195

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Secure all the clutches using the appropriate tools


380001279.

Fig. 2-196
Turn the stand 180.
Install lifting hooks (arrows).

Fig. 2-197
Smear grease on the O-Rings of the two oil pipes.
Smear the mating faces with sealing compound
Loctite (type No. 574).
Position carefully, using an appropriate lifting rig, the
cover previously pre-assembled on the transmission
housing until they contact.
Note Make sure that the oil pipes coincide with the
relevant holes of the transmission housing cover.
Fig. 2-198
Remove the clutch locking tools 380001279.

Fig. 2-199

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Insert the two dowels centrally on the front side of the


housing.

Fig. 2-200
Secure the transmission housing cover with the recessed head hex screws.
Tightening torque (M10/8.8) ......................... 46 Nm
Note Pay attention to the position of the lifting hook;
see the figure).

Fig. 2-201
Assembly of the pump shaft (P.T.O.)
Install the ball bearing.
Install the rectangular ring (arrow) in the relevant slot.

Fig. 2-202
Smear grease on the rectangular ring, centre it with
the shaft and insert the pump shaft until it shoulders.

Fig. 2-203

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Secure the pump shaft using the circlip.

Fig. 2-204
Insert the O-Ring (arrow) in the ring slot of the oil
supply covers.

Fig. 2-205
Install the two covers (arrows) using hex nuts (use
flat washers).
Tightening torque .......................................... 23 Nm

Fig. 2-206

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Reassembly of the output flanges


Install the seal with the lip directed toward the cavity
containing the oil.
Note Use the appropriate punch 380001271 to obtain the correct mounting position.
Wet the rubber lined outer diameter with alcohol.
Smear grease on the sealing lip.

Fig. 2-207
Install the output shaft.
Install the O-Ring (arrow) in the gap between flange
and shaft.

Fig. 2-208
Secure the output flange using the retaining plate and
the recessed head hex screws.
Tightening torque (M10/8.8) ......................... 46 Nm

Fig. 2-209
Secure the recessed head hex screws using the safety
plates.
Punch 380001272.
Punch handle 380001278.
Install the converter side output flange in the same
manner.

Fig. 2-210

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Torque converter pressure valve


The figure on the left illustrates the components of
the torque converter pressure valve.

4
1
2
3
Fig. 2-211

1 = Plunger
2 = Spring
3 = Resting plate
4 = Retaining plate
Note Install the resting plate with the point (6 mm
diam) directed toward the retaining plate.
Insert the components in the sequence illustrated in
Fig. 2-211, press the spring and secure the valve with
the retaining plate.
Tighten the plug (arrow) equipped with a new O-Ring.
Tightening torque (M14x1.5)......................25 Nm

Fig. 2-212
Oil supply housing - Transmission pump
Install setting screws 380001275 (arrows) and install
the seal.

Fig. 2-213
Position the oil supply housing and secure it temporarily using the recessed head hex screws.
Note Install only the screws required to obtain a
good contact do not tighten.

Fig. 2-214

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Install the two setting screws 380001274 and insert


the stator shaft until it shoulders.
Note Pay attention that the holes coincide.

Fig. 2-215
Insert the O-Ring (arrow) in the slot and lubricate it
with oil.

Fig. 2-216
Install the transmission pump assembly and rest it
against the shoulder in a uniform manner, using the
recessed head hex screws (at this time without
O-rings).
Then remove the recessed head hex screws again.

Fig. 2-217
Install new O-Rings (figure) on the recessed head hex
screws.
Note Smear grease on the O-Rings.

Fig. 2-218

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Secure the pump the transmission using the recessed


head hex screws.
Tightening torque .......................................... 46 Nm

Fig. 2-219
Secure the oil supply housing using recessed head
hex screws and hex head screws (q.ty 2).
Tightening torque (Recessed head screw) ........23 Nm
Tightening torque (Hex head screw) ... .......... 46 Nm
Note Pay attention to the position of the lifting hook;
see arrow.
Hex wrench 380001296.

Fig. 2-220
Installation on engine - Torque converter
Tighten the torque converter bell with hex head screws.
Tightening torque (M10/10.9) ......................... 68 Nm

Fig. 2-221
Install the gasket and secure the cover with hex head
screws.
Tightening torque (M8/8.8) ........................... 23 Nm

Fig. 2-222

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Insert the torque converter bringing it to contact.


Note The impulse generating disc on the torque
converter must be located in a central position with
respect to the hole of the induction sender; see arrow/
figure 2-221.
This is the only way to make sure that the torque
converter is perfectly inserted into the bell.

Fig. 2-223
Secure the flex disc on the torque converter tightening the hex head screws to the prescribed torque.
Tightening torque (M12/10.9) ....................... 115 Nm
Note Install the screws with Loctite (Type no. 262)

Fig. 2-224
Torque converter safety valve
Insert the safety valve (assembled) into the hole on
the transmission housing.

Fig. 2-225

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Installation of the oil ducts plate and transmission control valve


Install the components as illustrated in the sketch
here below.
Tightening torque (M8) ................................. 23 Nm
(Hex nuts and recessed head hex screws)
Note Pay attention to the mounting position of
the various gaskets.

Drawing ref.
1=
2=
3=
4=
5=

Gasket
Oil ducts plate
Gasket
Intermediate plate
Gasket

Adapted Setting screws


Hex wrench 380001296
Fig. 2-226
Tighten the plug (arrow) with a new O-Ring.
Tightening torque (M16x1.5) ......................... 30 Nm

Fig. 2-227
Secure the transmission control valve with two
adapted setting screws then install the recessed head
hex screws with tool 380001295.
Tightening torque (M6) ................................ 9.5 Nm

Fig. 2-228

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Installation of plugs and oil level pipe


Install the two plugs (arrows) with new O-Rings.
Tightening torque (M18 x 1.5) ....................... 50 Nm
Tightening torque (M26 x 1.5) ....................... 80 Nm

Fig. 2-229
Install the oil dipstick pipe (arrow)
Note Install a new gasket.
Tightening torque (M8/10.9) ......................... 34 Nm

Fig. 2-230
Install the cover (arrow 1)
Note Install a new gasket.
Tightening torque (M8/8.8) ........................... 23 Nm
Install the plug (arrow 2) with a new O-Ring.
1

Tightening torque (M38x1.5) ....................... 140 Nm

2
Fig. 2-231
Speed sensor and induction senders
Figures 2-232 and 2-233 illustrate the mounting location of each induction sender and the speed sensor.
34 = Speed sensor
21 = Induction sender
47 = Induction sender
48 = Induction sender

n Tachometer output
n Turbine
n Central sender
n Engine
34
Fig. 2-232

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Apply grease on the O-Rings and install on the speed


sensor and induction senders.

48

2 - 107
47

21

Tightening torque .......................................... 23 Nm


(Recessed head hex screw/Speed sensor)
Tightening torque .......................................... 30 Nm
(Induction sensor)

Fig. 2-233
Install the breather (arrow).
Tightening torque .......................................... 12 Nm

Fig. 2-234
Secure the transmission torque converter group to
the engine block with four screws M10 of the flex disc
with Loctite 262 and tightening the screws to 68 Nm.
Then tighten the 12 securing screws to the engine to
a torque of 46 Nm after applying Loctite 262.

Fig. 2-235

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2.9 PROPELLER SHAFTS


GENERAL CHARACTERISTICS
DISTANCE BETWEEN
PINS (mm)

MAX TRANSMISSION
TORQUE (STALL) (Nm)

Front shaft

Universal joint

565.8

5855

Intermediate shaft

Universal joint

1037.3

5855

Rear shaft

Universal joint

105.6

5855

Front axle

Propeller
shaft

Intermediate
shaft
Rear axle
2

1
2

Fig. 2-233
Note -

Support

Rear shaft

Propeller shaft group


149 - 163 Nm

Threaded part: LOCTITE 262

88 - 102 Nm

Threaded part: LOCTITE 262

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6
1

2
10

1
2

4
2

5
9

Fig. 2-237

10

Front and intermediate prop-shafts

1. Spider - 2. Spider grease fitting - 3. Washer - 4. Front shaft - 5. Intermediate support - 6. Bearing 7. Seal - 8. Intermediate shaft - 9. Screw - 10. snap ring

2
1

Fig. 2-238

Rear prop-shaft

1. Screw 1/2"-20 - 2. Spring washer - 3. Spider - 4. Rear shaft - 5. Spider grease fitting

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2.10 AXLES
Traction

4-wheel drive
Ratio at bevel
gear 1 : 4.625
Ratio at wheels 1:5.2
Ratio at axle 1:24.05

Front axle

Rear axle

Secured to frame
Rigid type
Pivot pin
Semi-swinging type

Reduction and differential


Type

Common, 2 stage reduction

Differential housing

Integral type

Differential limiter

Torque proportional
differential

Final drive
Type

Epicyclic

Weight
Rear
Front

926 Kg (2041 lbs)


900 Kg (1984 lbs)

2.10.1 GENERAL DESCRIPTION


The axle is composed of a differential, final reduction
units, oil-bath disc brakes and axle shafts connected
to the wheels.
The power output from the transmission is driven by
the prop shafts to the front and rear axles. Thus, the
power is driven to the differential that splits it to the
axle right and left shafts driving the final drives, reaching the wheels.
The oil bath disc brake is mounted in front of the final
drive and operates as service brake. As for the ope
"3 - BRAKES SYSTEM".

The front axle is mounted directly on the front axle by


screws.
The rear axle is mounted with a pivot pin, using supports on both sides of the axle, secured by screws to
the rear frame. Consequently, the rear axle can pivot
around the axle of the differential with an amplitude
depending upon the ground conditions travelled by the
loader. The drive axle mounted with a pivoting pin improves the driving conditions of the loader when travelling on rough terrain.

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Fig. 2-239

Note -

Installation of axles on frame

788 Nm
Threaded parts: LOCTITE 262

1150 Nm

1. Front pivoting support - 2. Rear pivoting support - 3. Tyre - 4. Rim - 5. Front axle - 6. Rear axle

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Fig. 2-240

Note -

10

Assembly of rear axle and pivoting supports

227 Nm
Install with the groove toward plate (6)

Install with lip outwards

W190

Threaded parts: LOCTITE 262

Grease the inner surface of the bushes. Install the bevel towards the axle
Align the greasing holes with the grooves. Grease until it flows out the opposite side

1. Dust seal - 2. Front pivoting support - 3. Rear axle - 4. Dust seal - 5. Rear pivoting support - 6. Thrust plate - 7. Cover 8. Bushing - 9. Bushing - 10. Spacer discs

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4

2 - 113

7
1

10

11

12

13

Brake piping connection


ports, 2 points

Fig. 2-241

Note -

14

Front axle

230 Nm

230 Nm

Threaded part: LOCTITE 572

Lip: Grease

Threaded part: LOCTITE 262

Mating surfaces: LOCTITE 509

1. Oil seal - 2. Axle shaft - 3. Final drive - 4. Differential housing - 5. Differential - 6. Crown gear hub - 7. Pin - 8. Dowel 9. Axle shaft housing - 10. Dipstick - 11. Bleeding screw - 12. Bleeding screw - 13. Cover - 14. Draining plug

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Fig. 2-242

Brake piping connection


ports, 2 points

W190

10

11

13

14

12

15

5
2

Rear axle

Note - 1

230 Nm

230 Nm

Threaded parts: LOCTITE 572

Lip: Grease

Mating surfaces: LOCTITE 509

Threaded part: LOCTITE 262


Threaded part: LOCTITE 262

1. Oil seal - 2. Axle shaft - 3. Final drive - 4. Housing - 5. Differential - 6. Pin - 7. Crown wheel - 8. Dowel - 9. Axle housing
- 10. Bleeding screw - 11. Bleeding screw - 12. Cover - 13. Plug (level check) - 14. Draining - 15. Dipstick

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2.10.2 DIFFERENTIAL DESCRIPTION

Operation of the differential

The differential forms a single body with the reduction


unit.
The power is driven from the prop shafts to the differential gear housing through the pinion/bevel gear group.
Thus, it is driven through the right and left gears, to
the final drives. The reduction of r.p.m. is obtained by
the pinion/bevel gear ratio. The turn reduction is obtained by the bevel pinion/crown set.

When the loader is moving straight, the bevel ring


gear, the differential gear cage and the differential side
gears rotating together; the idle pinions inside the gear
cage do not rotate. Thus the right and left planetary
gears transfer the motion to the wheels at the same
speed, through the half-shafts. When the loader turns,
the right and left wheels turn at different speeds, the
planetary gears in the differential housing turn around
their pin proportionally with the speed difference between the right and left side gears.

While travelling straight


1
2

While making turns

High
speed

5
6

Fig. 2-243

Low
speed

Operation of differential

1. Idle gear - 2. Side gear - 3. Axle shaft - 4. Differential gear cage - 5. Idle pinion spider - 6. Bevel drive pinion - 7. Bevel
drive ring gear

Proportional torque differential


Wheel loaders often operate under severe terrain conditions, such as sandy or muddy grounds. Under such
unfavourable terrain conditions, a loader equipped with
a standard differential could experience a spinning of
the wheels, thus making difficult to exploit fully its
potential performance. Also, the tyres could wear
quickly. To avoid this, some models are equipped with
a proportional torque type differential, limiting its function.

A proportional torque differential design is almost identical to a normal differential, with the exception of the
idle pinions, having an odd number of teeth with a
special profile. When the tyres start slipping in soft
ground, the planetary gears continue transferring
power to both side gears, until the adhesion difference on the ground of the right and left tyre reach a
low value; thus the tyres are prevented from slipping.

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12

13

14

10

15

11
Fig. 2-244

20

19

18

17

16

Differential

Note -

90 Nm (66.4 ft-lbs)

150 Nm (110.6 ft-lbs)

230 Nm (169.6 ft-lbs)

670 Nm (494.2 ft-lbs)

Outer diameter: LOCTITE 262

Threaded Part: LOCTITE 262

___

Lip: Grease

Bevel pinion/crown gear teeth backlash. 0.25 0.36 mm.

After reassembling the differential, set the spacer so that the rolling torque is
0.1 0.4 Nm, without seal.

1. Adjusting nut - 2. Bearing retainer - 3. Half-housing (B) - 4. Bevel crown gear - 5. Half-housing (A) - 6. Locking plate 7. Thrust washer - 8. Thrust washer - 9. Spider - 10. Drive pinion - 11. Bearing holder housing - 12. Idle gear - 13. Pin 14. Planet gear - 15. Shim - 16. Spacer - 17. Spacer - 18. Nut - 19. Flange - 20. Oil seal

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2.10.3 "LSD" DIFFERENTIAL

2
10
11

1
1

Fig. 2-245

Limited Slip differential

270-300 Nm

Threaded part: LOCTITE 262

1. Reaction disc - 2. Clutch disc - 3. Thrust washer - 4. Semi-housing connection screw - 5. Half housing - 6. Flange halfhousing - 7. Spider - 8. Side gear - 9. Planetary gear - 10. Spacer - 11. Shim.

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2.10.4 FINAL DRIVES DESCRIPTION


The final drive units are of a planetary type and create the final rpm reduction in the power train.

6
8

The power driven by the differential to the sun gear


shaft rotates the three planet gears inside the toothed
drum, thus driving the axle shaft through the planet
gear carrier.

1
Section A-A
(Operation of planet gears)
4
6

5
Power drive

Fig. 2-246

Drive of power

1. Pinion - 2. Differential - 3. Sun gear shaft - 4. Planet gear pin - 5. Planet gear - 6. Toothed drum - 7. Planet carrier - 8. Axle
shaft

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13

Fig. 2-247

Note -

1
2

14

15 16

6 7

2 - 119

10

17 18

11

12

19 20

Final drive

50 Nm

Threaded part: LOCTITE 262

Procedure for the setting of shims


1) Tighten screw (1) to a torque of 50 Nm and set inward the taper bearing, by rotating the axle shaft.
2) Loosen screw (1) without turning the shaft.
3) Measure the gap between thrust ring (3) and axle shaft. Value measured = Y.
4) Select the adjusting shims to form a stack no thicker than 0.03 to 0.10 mm than value Y.
5) Install the shim pack, the retaining ring and the screw.
1110 Nm

Threaded part: LOCTITE 262

The rolling torque of the bearing must be included between 20 and 40 Nm

1. Screw - 2. Spacer - 3. Retaining plate - 4. Thrust ring - 5. Lock pin - 6. Brake disc (outer toothed) - 7. Brake disc (inner
toothed) - 8. Adapter - 9. O-ring - 10. Spring - 11. O-ring - 12. Piston - 13. Planet carrier - 14. Pin - 15. Ball - 16. Thrust ring 17. Needle bearing - 18. Planet gear - 19. Disc hub - 20. Sun gear

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2.10.5 DISASSEMBLY OF THE AXLE


Precautions to be implemented during the disassembly
During the disassembly and reassembly of the axle, it is good practice to install it on an overhaul stand and to
Weight of unit:
front: ........................................ 950 kg (2094 lbs)
rear: ......................................... 930 kg (2050 lbs)

1)

Removal of the axle housing

1.

Remove the draining plug and drain the gear oil.


Quantity of oil:
front ..................................... 30 l (7.92 US/gal)
rear ...................................... 30 l (7.92 US/gal)

Fig. 2-248
2.

Remove the screws securing the axle housing.


Q.ty of screws: 20

Fig. 2-249
3.

Sling and hold the axle housing with a hoist and


support it on the opposite side to prevent that it
lowers.

Fig. 2-250

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4.

Remove the axle tube from the differential body.


If they are joined, separate one from the other
using a screwdriver and soft mallet.

5.

Remove the sun gear and shaft from the differential.

6.

Remove the snap ring and disk hub from the


splines. Then, remove the snap ring.
Remove the axle tube and shaft at the opposite
side, using the same procedure as above.

Fig. 2-251

Fig. 2-252

7.

Fig. 2-253

2)

Disassembling axle tube

1.

Put the axle tube with the differential mounting


side upward. Using a nut runner (special tool),
loosen the retainer plate mounting bolt and remove it from the axle shaft.

Fig. 2-254

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2.

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Using a prying tool, separate the final reduction


gear assembly (planet carrier) from the shaft
splines, and remove it with a crane.
Remove any shim, if attached to the axle shaft.

Fig. 2-255

3.

Lay the axle tube on the bench. Using a screwdriver, remove the oil seal from the axle tube.

Fig. 2-256
4.

Remove the bearing cone from the differential


side of the axle tube.

Fig. 2-257
5.

Using a crane, lift the axle tube with its differential side upward to let the axle shaft drop from
opposite side.

Fig. 2-258

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6.

2 - 123

Using a gas burner, heat up the bearing cone


attached to the shaft, and remove the bearing
come from the shaft.

Note Make sure to replace the bearings with a new


one.
7.

Remove the oil seal from the axle shaft.

8.

Remove the bearing cups from the differential


and wheel sides of the axle tube by tapping their
outer diameter evenly.

9.

Using a portal jig, remove the ring gear from the


axle tube.

3)

Disassembling final reduction gear assembly

1.

Remove the snap ring from the planet gear shaft.

Fig. 2-259

Fig. 2-260

Thrust bolt
Portal jig

Plate

Ring gear

Fig. 2-261

Fig. 2-262

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Drive the shaft from the gear.


Use caution not to lose the lock ball that the shaft
has.

Fig. 2-263
3.

Remove the planet gear and the (2) thrust washers.

Note Use caution not to lose the needle roller because they may come off with the planet gear.

Fig. 2-264
4.

Remove the needle rollers and the spacer from


inside the gear.
Number of needle rollers: 50

5.

Remove the (2) other planet gear shafts, using


the same procedure as above.

Fig. 2-265
6.

Remove the retainer plate from inside the planet


carrier. Keep any shim, if attached.

Fig. 2-266

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4)

Removing brake unit

1.

Remove the end plate, brake ring, brake disk,


brake ring, brake disk and brake ring in this order
from the differential body. Then, remove the 8
pins.

2.

Remove the bolt (3), adapter (2) and spring (1)


from the brake piston.
Remove the bolts, adapters and springs from
other five positions in the same way.

3.

Then install three screws (3) previously removed


complete with adapter (2) on the mounting face
of the differential body housing to prevent the
piston from getting out accidentally.
Supply compressed air through the oil pressure
port to remove the piston from the differential
body.

Fig. 2-267

2 1

Fig. 2-268

2
4.

W190-2R004

Fig. 2-269
5.

6.

Remove the O-rings respectively from the larger


diameter and smaller diameter of the brake piston.
Remove the brake unit at the opposite side, using the same procedure.

Fig. 2-270

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5)

Removing drive pinion (bearing cage)

1.

Remove the bolts securing the cover from the


differential body, and remove the cover.
Number of bolts: 28

W190

Fig. 2-271
2.

3.

Check the ring gear for tooth surface contact pattern and backlash. Refer to steps (5) and (6) in
"2. Reassembly".
Remove the bolts securing the bearing cage.
Number of bolts:
8 for front axle
10 for rear axle

Fig. 2-272
4.

5.

Install two of the bolts removed at step (3), into


the puller screw holes in the bearing cage. Tighten
both evenly to separate the seating surface. Holding the bolts, remove the bearing cage and the
drive pinion as a unit.
Remove the half shim from between the differential body and bearing cage.

Fig. 2-273
6)

Disassembling drive pinion

1.

Put the drive pinion with the flange side upward.


Using a nut runner (special tool), loosen the flange
lock nut.

Fig. 2-274

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2.
3.

2 - 127

Remove the nut and detach the washer ring and


O-ring.
Remove the flange from the drive pinion.

Fig. 2-275
4.

Using a press, push down the drive pinion and


remove it from the bearing cage.

5.
6.

Remove the two spacers from the pinion shaft.


Using a separator, remove the bearing cone from
the pinion shaft.

7.

Break the oil seal on the bearing cage with a screwdriver and remove it.

Fig. 2-276

Fig. 2-277

Fig. 2-278

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8.

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Remove the other bearing cone.

Fig. 2-279
9.

Remove the two bearing cups from inside the


bearing cage, tapping their outer diameter evenly.
10. Remove the O-ring from the outer diameter of
the bearing cage.

Fig. 2-280
7)

Removing differential case

1.
2.

Lift the differential case with a crane temporarily.


Remove the bolts securing the bearing retainer,
along with the lock plate.
Number of bolts: 10

Fig. 2-281
3.

Install two of the bolts removed at step 2, into


the puller screw holes in the bearing retainer and
tighten both evenly. Remove the bearing retainer,
holding the bolts.

Fig. 2-282

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4.

5.

2 - 129

Remove the adjusting nut from the retainer. Then


turn the retainer upside down and remove the
bearing cup.
Remove the bearing retainer at the opposite side,
using the same procedure as above.

Fig. 2-283
6.

Remove the ring gear and differential case assembly from the differential body.

8)

Disassembling differential case

1.

Loosen the bolts securing the ring gear and remove the ring gear.
Number of bolts: 20

2.

Turn the differential case upside down and remove the 12 bolts securing the case from the
plane half case side.

Fig. 2-284

Fig. 2-285

Fig. 2-286

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Tap the center of the spider with a rod to separate the case into two halves.

Fig. 2-287
4.

Remove the 2 side gears, spider, 4 pinion gears


and 6 thrust washers from inside the differential
case.

Fig. 2-288
5.

Using the bearing puller, remove the bearing cone


from the plane half case and flange half case.

Fig. 2-289

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9)

Disassembly of the "LSD" differential housing

1.

Mark the two differential half-housings and remove the 12 connecting screws.
To separate the two halves of the differential, tap
the centre of the spider using a soft metal bar.

2.

Extract five discs (A) four clutch discs (B) and


the relevant pack.
Remove side gear (C).

3.

Then extract the spider (D) complete with thrust


washers (E).

4.

Remove the other side gear and the relevant


clutch pack.

Fig. 2-290
A
B
C

Fig. 2-291

Fig. 2-292

If required, remove the bearings from the halfhousings with a double jaw puller.

Fig. 2-293

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2.10.6 AXLE REASSEMBLY


Precautions to be implemented during the re-assembly
Wash disassembled parts with a clean washing oil and dry by blowing air.
Handle the washed parts, with care not to damage or contaminate them.
Check the disassembled parts for wear or damage and replace any worn or damaged part with a new one.
Refer to "2.13 VALUES OF REFERENCE FOR THE MAINTENANCE".
Replace all the seals with new ones.

1)

Reassembling differential case

1.

Place the flanged half case (differential case A)


on a work bench, and press the bearing cone
using a press or soft mallet.

Fig. 2-294
2.

Make sure the 2 dowel pins in the differential case.


Align the 2 holes in the thrust washer with the
dowel pins and install the thrust washer into the
case.

Fig. 2-295
3.

Install the side gear.

Fig. 2-296

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4.

Install the 4 pinion gears and 4 thrust washers


onto the spider, and install them as a unit on the
side gear, engaging the gears.

5.

Use a rubber mallet to arrange the spider in the


housing.

6.

Place the half housing (differential housing B) on


a work bench and press the taper bearing with a
press or a rubber headed hammer.

7.

Turn the plane half case upside down and align


the thrust washer with the pins and paste it with
grease.

Fig. 2-297

Fig. 2-298

Fig. 2-299

Fig. 2-300

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8.

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Engage the other side gear with the pinion gears


and install the plane half case, matching the
marks. Tap the case with a soft mallet to make
sure that the two case halves are closely fitted
to each other.

Fig. 2-301
9.

Apply LOCTITE 262 to the threaded area of each


of 12 case bolts. Install the bolts and tighten them
in a diagonal order.

Fig. 2-302
10. Install the ring gear from upward. Using a soft
mallet, bring it into close contact with the flange
surface of the case. Tighten the mounting bolts
from downward temporarily.

Fig. 2-303
11. Turn the differential case upside down. Apply
LOCTITE 262 to the threaded area of each of the
ring gear mounting bolts and tighten them.
Number of bolts: 20

Fig. 2-304

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3)

Reinstallation of "LSD" differential housing

1.

Place the flanged half housing on a workbench


and press the taper bearing with a press or a soft
metal mallet after warming-up the bearing inner
race.

Note Clean accurately all the parts before assembling them using non-flammable and non-toxic solvents.
Fig. 2-305
2.

Turn the flanged half-housing upside down and


insert, in sequence:
- an outer lobe counter-disc (A), a inner toothed
disc (B), an outer lobe counter-disc (A), and so
on, completing the clutch pack with spacer (C).

Fig. 2-306
A clutch pack complete with:
q.ty 4 clutch discs (inner toothed)
q.ty 5 reaction discs (outer lobes)
q.ty 1 spacer
plus possible shim discs.

C
A
Fig. 2-307
3.

Insert the shim/s on spacer (C) smearing a film


of grease between the contact faces before installing them.

Fig. 2-308

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Install side gear (P) making sure that the splines


engage the inner teeth of the discs.

Fig. 2-309
5.

Install the 4 planetary gears and the 4 thrust


washers on the spider and install them on the
side gear, engaging the teeth.
Use a soft material mallet to set the spider in the
mounting seats of the half-housing.

Fig. 2-310
6.

Engage the second side gear on the planetary


gears, then inset the second disc pack in a reversed sequence with respect to what described
in items "2" and "3". Insert shims, if any, smearing some grease on the contact faces. Continue
inserting the spacer, then an outer lobe disc, an
inner toothed disc etc.

Fig. 2-311
7.

Align carefully the lobes of the reaction discs.

8.

Install the two differential half housings matching the marks made before the disassembly and
tighten the screws indicated to a torque of 90
Nm.

Fig. 2-312

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9.

0.05-0.15

2 - 137

Check using a feeler gauge on both sides of the


differential in two points at spaced 180 that each
clutch pack has a play 0.05 to 0.15 mm (condition required for a correct operation of the L.S.D.
differential)
Prior to measuring, make sure that the planetary
and side gears are well set.
Measure the tolerance through the holes on each
one of the two half-housing.
In the event the clutch pack play is different from
the prescribed value, disassemble the differential and rebuild the clutch packs using shims of
appropriate thickness.
Value of the shims available in mm:
0.1 - 0.2 - 0.25 - 0.5.

10. Close the differential and check again the correct operation.

Fig. 2-313

Fig. 2-314

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3)

Reassembling drive pinion (bearing cage)

1.

Press the smaller-diameter bearing cup into the


bearing cage. Turn the bearing cage upside down
and using a press the larger-diameter bearing cup.

W190

Fig. 2-315
2.

Apply grease to the O-ring and install into the


groove at the outer diameter of the bearing cage.

Fig. 2-316
3.

Press the bearing cone into the drive pinion.

4.

Install the longer spacer into the bearing cone


with the chamfered area at the inner periphery
pointed downward, and install the shorter spacer.

Fig. 2-317

Fig. 2-318

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5.

Insert the pinion shaft into the support, then install the bearing race on the drive pinion.

6.

Press the bearing on the drive pinion using a


normal puncher.

7.

After pressing, give a load to the bearing cone


using a hydraulic press. Measure the rotational
resistance torque 0.20 - 0.30 Nm with a spring
balancer.
The capacity of the press should be high enough
to give a load of about 9500 kg (21000 lbs).

Fig. 2-319

Fig. 2-320

Reference - Instead of giving a load using a press,


the rotational torque may be measured after installing
the companion flange temporarily; putting the washer
on it and tightening the flange nut to the specified
torque value.

8.

If the rotational resistance torque is lower than


the standard value, remove the drive pinion and
grind the shorter spacer properly.

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9.

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Apply a thin coat of LOCTITE on the outer diameter of the oil seal.

Fig. 2-321
10. Using a jig, press the oil seal into the cage.

Fig. 2-322
11. Apply grease to the oil seal lip.

Fig. 2-323
12. Install the companion flange onto the drive pinion splines. Slide the flange several times to eliminate strain on the seal lip.

Fig. 2-324

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13. Then put the O-ring into the groove between the
flange and pinion, and put the washer on it.

Fig. 2-325
14. Apply LOCTITE 262 to the threaded area of the
lock nut and tight the lock nut using a nut runner.
Make sure that the drive pinion turns smoothly
without binding.

Fig. 2-326
4)

Installing differential case

1.

Install the bearing cup to the 2 bearing retainers.

2.

Screw in the adjust nut until it comes in contact


with the cup.

Fig. 2-327

Fig. 2-328

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3.

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Lift the reassembled differential case with a crane


and put the case in the differential body, aligning
the ring gear with the notch in the differential body.

Fig. 2-329
4.

Install the bearing retainers at the right and left


sides of the differential body to hold the differential case. Tighten the mounting bolts.
Number of bolts (at one side): 10

Fig. 2-330
5)

Installing drive pinion (bearing cage)

1.

Putting shims between the bearing cage and the


differential body, install the drive pinion (bearing
cage) to the differential body.

Fig. 2-331
2.

Tighten the bearing cage with the mounting bolts.


Number of bolts: 8 for front axle
10 for rear axle

Fig. 2-332

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3.

Use special tool 380002499 (1) and tighten the


right and left setting ring gears to 100 - 120 Nm
(72 to 87 Ft.lbs).

4.

Carry out steps "(5) Adjusting backlash of ring


gear" and "(6) Adjusting the tooth surface contact pattern of ring gear". After that, install the
lock plate and lock the adjusting nut.

6)

Adjusting backlash of ring gear

1.

Set a dial gauge on the tooth profile outer edge


of the ring gear.
Fix the drive pinion, and turn the ring gear back
and forth to measure the backlash.

Fig. 2-333

Fig. 2-334

2.

Fig. 2-335
3.

Ring gear backlash


Standard value: 0.25 - 0.36 mm
(0.0098 - 0.0142 in)

If the backlash is too large, loosen the adjusting


nut on the plane half case, tighten the adjusting
nut on the flange half case and bring the ring
gear closer to the drive pinion.
If the backlash is too small, adjust it in the opposite procedure as above.

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7)

Adjusting the tooth surface contact pattern of


ring gear

1.

Apply a thin coat of red lead to several ring gear


teeth and turn the ring gear back and forth with a
hand to check the tooth surface contact pattern.

Fig. 2-336
2.
3.

Adjust the tooth surface contact pattern, referring to the following steps a. to e.
After acquiring the normal tooth surface contact
pattern, check the backlash again.

Toe (small end)


Heel (big end)

Face
Frank

Fig. 2-337
a.

Normal contact pattern (Fig. 2-338)


The normal contact pattern of the tooth surface
is from the toe to the heel and its length is approx.
80% of the total tooth length.

Note - The following adjustment items (b. to e.) show


the procedures for checking the convex surface side
of the tooth. Remember that the concave surface side
has opposite contact conditions.

Ring gear

Fig. 2-338
b.

Adjusting contact condition at toe (Fig. 2-339)


Loosen the adjusting nuts on the flange half case,
tighten the adjusting nuts on the plane half case
and shift the ring gear away from the drive pinion. Then, reduce the shim thickness of the bearing cage and bring the drive pinion closer to the
ring gear.

Ring gear
Drive pinion

Fig. 2-339

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c.

2 - 145

Adjusting contact condition at heel (Fig. 2340)


Loosen the adjusting nuts on the plane half case
side, tighten the adjusting nuts on the flange half
case, bring the ring gear closer to the drive pinion. Then, increase the shim thickness of the
bearing cage and shift the drive pinion away from
the drive gear.

Ring gear
Drive pinion

Fig. 2-340

d.

Adjusting contact condition at face (Fig. 2-341)


Reduce the shim thickness of the bearing cage
and bring the drive pinion closer to the ring gear.
Then, loosen the adjusting nuts on the flange half
case, tighten the adjusting nuts on the plane half
case and shift the ring gear away from the drive
pinion.

Ring gear
Drive pinion

Fig. 2-341

e.

Adjusting contact condition at frank


(Fig. 2-342)
Increase the shim thickness of the bearing cage
and shift the drive pinion away from the ring gear.
Then, loosen the adjusting nuts on the plane half
case, tighten the adjusting nuts on the flange half
case and bring the ring gear closer to the drive
pinion.

Ring gear
Drive pinion

Fig. 2-342
8)

Installing brake unit

1.

Install O-rings at the 2 grooves at the outer diameter of the brake piston. After that, apply
grease.

Fig. 2-343

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2.

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Press the piston into the differential body, using


three screws (3) and adapter (2) previously removed (see illustration on the right).
3

W190-2R005

Fig. 2-344
3.

Install the spring (1), adapter (2) and bolt (3) of


the piston return mechanism onto the differential
body passing through each of the piston holes.
Then loosen the screws with the relevant adapter
used to press the piston into the differential body
and insert spring (1). Retighten the screws.

Fig. 2-345
4.

Install the snap ring, disk hub and snap ring onto
the sun gear and shaft.

Note Direct the stepped area of the disk hub upward.

Fig. 2-346
5.

6.

Install the sun gear and shaft which has the disk
hub, onto the side gear splines installed in the
differential case.
Install the 2 lock pins into the lower part of the
differential body. Install the brake ring aligning
them.

Fig. 2-347

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7.

Install the brake disk onto the disk hub splines,


and then install the brake ring.

8.

Install the second brake disk, aligning with the


first disk.
Then, install the brake ring and end plate in this
order.

Fig. 2-348

9.

Fig. 2-349
10. Install the other 6 lock pins using a soft mallet.
11. Install the brake unit at the opposite side, using
the same procedure as above.

Fig. 2-350
9)

Reassembling axle tube

1.

If the ring gear was replaced with a new one,


press the ring gear onto the axle tube using a
press or soft mallet and secure with 4 pins.

Fig. 2-351

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2.

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Turn the tube upside down, press the bearing cup


from the wheel side and install the bearing cone.

Fig. 2-352
3.

Then press the oil seal and apply grease to the


lip.

Note Install the inner sleeve to the oil seal.

Fig. 2-353
4.

Turn the tube upside down and lift it by the differential side with a crane. Lower it onto the standing axle shaft.

Fig. 2-354
5.

Place the tool (item 1 Fig. 2-354) on the axle shaft


and press the oil seal and the wheel bearing on
the shaft.

Fig. 2-355

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6.

Install the bearing (cup and cone) onto the axle


tube.

7.

Use a normal puncher to install the bearing between the shaft and the differential body.

Fig. 2-356

W190-2R006

Fig. 2-357
10) Adjusting the preload of axle shaft bearing
(shim adjustment)
1.

Install the planet carrier without gear on the axle


shaft splines.

2.

Put the retainer plate in the planet carrier.


Turning the axle tube, tighten the retainer plate
mounting bolt to the torque of 50 Nm.

Fig. 2-358

Fig. 2-359

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2 - 150
3.

W190

TRANSMISSION

Loosen the retainer plate mounting bolt and remove the retainer plate. Measure the difference
in height (Y in Fig. 2-361) between the axle shaft
end surface and the planet carrier.

Fig. 2-360
4.

Select a shim which is 0.03 to 0.10 mm (0.0012


to 0.0039 in) thicker than the height difference
(Y).
(Y)

Note - The measurement position of the height difference (Y) is shown in Fig. 2-361.

Fig. 2-361
5.

Install the selected shim on the axle shaft and


the retainer plate in this order. Tighten the bolt.

Fig. 2-362
6.

7.

Hook a spring balancer on the knock pin of the


axle tube, and measure the bearing's rotational
resistance torque by pulling it along the fitting
pitch circle.
If the measurement is not within the range 2 to 4
kg (4.4 to 8.8 lbs), readjust the shim. If the value
is smaller, reduce the shim thickness, and if it is
larger, increase the shim thickness.

Fig. 2-363

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W190

TRANSMISSION
8.

2 - 151

After the shim thickness is determined, loosen


the bolt securing the retainer plate and remove
the planet carrier which was temporarily installed.

Fig. 2-364
11) Reassembling and installing final reduction
gear assembly
1.

Install the needle bearing on the planet gear. Needle rollers are arranged in two rows with (1) spacer
at the center. Apply grease properly to prevent
the rollers from dropping off.
Number of needle rollers: 50

2.

Install the 2 thrust washers in the planet carrier.

Fig. 2-365

Note - Set the washer's torque in the groove of the


carrier.

Fig. 2-366
3.

Insert the planet gear between the thrust washers.

Fig. 2-367

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2 - 152
4.

TRANSMISSION

W190

Install the lock ball on the planet shaft and press


the planet shaft into the planet carrier.

Fig. 2-368
5.

Install the snap ring in the groove of the carrier to


lock the shaft.

Fig. 2-369
6.
7.

Put the retainer plate into the planet carrier.


Reassemble the other 2 planet gears and install
them in the planet carrier, using the same procedure as above.

Fig. 2-370
8.

Put the selected shim on the axle shaft and install the reassembled planet carrier on the shaft.

Fig. 2-371

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TRANSMISSION

2 - 153

9.

Apply LOCTITE 262 to the threaded area of the


retainer plate mounting bolt and tighten the bolt
to 1110 Nm torque to secure the planet carrier.
Fig. 2-374 shows the planet carrier being installed
with the nut runner.
10. Reassemble the other axle tube, using the same
procedure as above. Refer to the (8) to (9).

Fig. 2-372
12) Installing axle tube
1.

Apply LOCTITE 509 to the differential body surface which will mate with the axle tube.
Make sure that the beads of LOCTITE are applied, without a break, on the differential body
surface inside row of the bolt holes.
The bead width is 2 to 3 mm (0.08 to 0.12 in)
each.

2.

Lift axle tube horizontally and install it onto the


differential body, aligning with the sun gear and
mounting bolt holes. Apply LOCTITE 262 to the
threaded area of mounting bolts and tighten them.
Number of bolts: 20
Install the axle tube at the opposite side, using
the same procedure as above.

Fig. 2-373

3.

Fig. 2-374
4.

Apply LOCTITE 509 to the cover mounting area


of the differential body. Make sure that the beads
of LOCTITE are applied, without a break, on the
body surface inside row of the bolt holes.

Fig. 2-375

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2 - 154
5.

TRANSMISSION

W190

Fill the differential with gear oil before mounting


the cover.
Oil capacity
Unit: l (US/gal)
Axle (front):
31 (8.2)
Axle (rear):
31 (8.2)

Fig. 2-376
6.

Install the differential body cover and tighten the


securing screws to 100 Nm.
Q.ty of screws: 28

Fig. 2-377

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TRANSMISSION

2 - 155

2.10.7 INSTALLATION AND INSPECTION OF THE PINION BEARINGS PRE-LOAD


1. Measure the dimension between the inner and outer
race of the bearing.
a. Zero caliper A 380002600 after positioning over
measuring plane.
b. After positioning the bearing on the measuring table
as indicated in the figure, measure with caliper
A 380002600 dimension X of the pinion bearing
dimension after placing the outer race flat and
turning the bearing. Record dimension X.
W190-2R007

2. Measure the dimension between spacer and


bearing seat.
a. Insert the pinion head bearing on the pinion using
press.
b. Insert the outer race on the pinion support.
c. Install the outer support complete with pinion
bearing race, install the long spacer and turn to
settle the rollers (ten turns with a weigh equal to
10 kg).
d. Install temporary calibrated spacer (d) (d=13 mm)
and measure with caliper A 380002600 (after
zeroing it) dimension Y between spacer and bearing
seat (contact on pinion tail bearing support).

W190-2R008

3. Determine final spacer L to be installed, being


equal to calibrated spacer D minus dimension Y
measured plus dimension X measured at point 1b
plus theoretical bearing play Z (Z=2,20 mm);
thus L= (d-Y) + X + Z
example: x=2,60
y=2,83
L= (13-2,83)+2,60+0,20 L=10,17+2,60+0,20
L=12,97 spacer to be installed

4. Install the spacer measured at point (3), install the


bearing and turn the pinion support (4/5 turns) under
load. Install flange B without seal, install nut C
and tighten to torque: 67 da Nm.

5. Check that the rolling torque must be included


within 0,20-0,30 da Nm.
If required, repeat the operations of point (3)
increasing or decreasing the value of spacer L to
be installed.

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W190-2R009

Copyright New Holland

2 - 156

TRANSMISSION

W190

2.10.8 CORRECT MOUNTING POSITION OF THE PINION


1. Install the pinion assembly on the axle body and
secure it with four screws tightened to the
prescribed torque.
2. Install the calibrated tool on the body.
3. Define shims s to be installed between the axle
body and the pinion support:
- S = X dimension stamped on the pinion;
- dimension stamped on the pinion = 136,725
dimension obtained by supplier.
Example:
- dimension stamped on the pinion 152,7mm;
- Q = 153 - 152,7 = 0,3mm;
- X = 0,95mm (dimesnion measured with digital dial
gauge);
- S = 0,95 0,3 = 0,65mm shims to be installed.

W190-2R010

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W190

2 - 157

TRANSMISSION

2.11 WHEELS/TYRES
Wheels

Tyres

The wheel is composed of rim and disc.


The wheel disc is bolted to the axle shaft. The tyre is
mounted on the rim forming a single body with it. Consequently, it is of the utmost importance that the correct rim is used, based upon the type of tyre to be
mounted. The use os a inappropriate rim could shorten
the life of the tyre and, in the worst cases, cause
serious accidents.
Also, the dimensions of the rim is provided in inches.
The first number indicates the width of the rim and
the second indicates the diameter.

In a standard configuration, the loader is equipped


with radial type tyres with tread type L3, having high
traction characteristics. It is recommended that the
most appropriate tyres are selected, since a large
variety of types is available, based upon the type of
operation and working requirements.
Example:
23.5
R
25
XHA
TL

=
=
=
=
=

23.5 R 25 XHA TL
Width of the tyre (~ 600 mm)
Radial
Diameter of rim (~ 635 mm)
Type of tread
Tubeless

Fig. 2-378

Rim for mod. W190 - Q.ty 5 pieces


Fig. 2-379

Thread of XHA tyre

Wheel securing screws tightening torque 788 nm


TYRE NORMAL INFLATING PRESSURE
WORK bar (psi)
TYRE

TRAVEL bar (psi)

FRONT

REAR

FRONT

REAR

Good Year

3.75 (54.3)

2.50 (36.2)

2.75 (39.8)

2.75 (39.8)

23.5 R25 XHA

Michelin

3.00 (43.5)

2.00 (29)

2.00 (29)

2.00 (29)

23.5 R25 XRD 1A

Michelin

3.25 (47)

2.00 (29)

2.00 (29)

2.00 (29)

23.5 R25 XLD-D2

Michelin

3.00 (43.5)

2.00 (29)

2.00 (29)

3.00 (43.5)

650/65 R25

Michelin

3.00 (43.5)

2.00 (29)

2.00 (29)

2.00 (29)

23.5 R25 XRD 1A

Michelin

3.25 (47)

2.00 (29)

2.00 (29)

2.00 (29)

23.5 R25 MINE D2


YELLOW COLOR

Michelin

3.25 (47)

2.00 (29)

2.00 (29)

2.00 (29)

23.5 R25 RL 5K (*)

Good Year

3.75 (54.3)

2.50 (36.2)

23.5 R25 RT 3B

Good Year

3.75 (54.3)

2.50 (36.2)

2.75 (39.8)

2.75 (39.8)

23.5 R25 RT 5C L5

Good Year

3.75 (54.3)

2.50 (36.2)

2.50 (36.2)

2.50 (36.2)

23.5 R25 GP 4B

Good Year

3.75 (54.3)

2.50 (36.2)

2.72 (34.9)

2.75 (39.8)

23.5 R25 20PR L3

Galaxy

2.50 (36.2)

2.25 (32.6)

23.5 R25 16PR L3

Alliance

2.50 (36.2)

1.50 (21.7)

23.5 R25 GP-2B

(*) It is suggested to load the machine on a trailer for road transit.


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2 - 158

W190

TRANSMISSION

2.12 TROUBLESHOOTING
Trouble

Problem Cause

Noisy differential.

Remedy

Gear worn, damaged or broken.

Replace.

Excessive backlash of each gear.

Adjust or replace.

Bearing worn, damaged or broken.

Replace bearing.

Loose engagement of side gear and shaft splines.

Replace.

Loose bolts.

Retighten.

Low gear oil.

Add oil to specified level.

Gear (final reduction gear) worn, damaged or broken. Replace.

Noisy axle tube.

Oil leakage from


differential

Oil leakage from


axle shaft.

Excessive backlash of each gear.

Replace.

Bearing worn, damaged or broken.

Replace bearing.

Loose planet carrier holding bolt (retainer plate


mounting bolt).

Retighten (Adjust shims).

Improper preload of axle shaft bearing.

Adjust shims.

Low gear oil.

Add oil to specified level.

Broken liquid packing of differential cover.

Apply liquid packing.

Broken liquid packing of axle tube.

Apply liquid packing.

Worn or damaged O-ring of bearing cage.

Replace O-ring.

Oil seal worn or damaged.

Replace oil seal.

Loose bolt.

Retighten.

Oil seal worn or damaged.

Replace oil seal.

Oil seal installed improperly.

Repair or replace.

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W190

2 - 159

TRANSMISSION

Trouble

Problem Cause

Remedy

Brake piston seal (O-ring) deteriorated or damaged.


Brake disk or brake ring worn or damaged.
Poor braking.

Overhaul and replace.

Brake piston rusted.


Foreign matter caught on brake disk.
Loose or damaged bleeder screw of disk brake.

Erratic braking.

Brake disk or brake ring run-out or worn unevenly.

Retighten or replace.
Overhaul and replace.

Wornparallel pin of disk brake.


Dragging brake.

Rusted brake piston.

Overhaul and replace.

Brake disk and brake ring seized.

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Copyright New Holland

2 - 160

W190

TRANSMISSION

2.13 VALUES OF REFERENCE FOR THE MAINTENANCE


Values in mm
Item
Thickness of bearing cage
Inner diameter of differential
pinion gear

Standard dimension

Allowable
limit

0.1 - 0.2 - 0.3

35.05 through 35.13


Tolerance
0.2

Diameter of differential spider pin


Thickness of differential pinion gear
thrust washer

Remarks

1.562 through 1.613

1.41

Thickness of differential side gear


thrust washer

2.31 through 2.36

2.24

Backlash between bevel pinion/crown gear teeth

0.25 through 0.36

Set by nut

Turning resistance torque of bevel pinion Nm

0.20 through 0.30

Set by spacer

Outer diameter of mating flange in the oil seal


rotation area

89.913 through 90.000

89.863

Turning resistance torque of axle shaft bearing


bearing (pitch line housing securing screws)
Nm

from 2.0 through 4.0

Value of shaft shims

0.1 - 0.2 - 0.25 - 0.5

Setting shims

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W190

2 - 161

TRANSMISSION

Values in mm
Item

Standard Size

Useful limit

Brake disk thickness

5.9 to 6.5 mm
(0.232 to 0.256 inch)

5.58 mm
(0.220 inch)

Brake ring thickness

4.9 to 5.1 mm
(0.193 to 0.201 inch)

4.5 mm
(0.177 inch)

Free height

33 mm (1.30 inch)

31.7 mm
(1.25 inch)

Settings load
kg (lbs)

20.8 kg (45.9 lbs)

18.8 kg (41.4 lbs)

20.0 mm (0.787 inch)

Brake piston riturn spring

Setting
height

Remarks

2.13.1 TIGHTENING TORQUE VALUES FOR MAIN BOLTS


Item

Tightening torque
Nm (lbs.ft)

Remarks

Ring gear mounting bolt

230 (170)

Apply LOCTITE 262

Differential case mounting bolt

150 (110)

Apply LOCTITE 262

90 (66)

Apply LOCTITE 262

Bearing cage mounting bolt

230 (170)

Apply LOCTITE 262

Flange nut

670 (494)

Apply LOCTITE 262

50 (37)

Apply LOCTITE 262

Planet carrier holding bolt


(Retainer plate mounting bolt)

1110 (818)

Apply LOCTITE 262

Axle tube mounting bolt

230 (170)

Apply LOCTITE 262

Differential bearing retainer mounting bolt

Brake piston return spring mounting bolt

Differential cover mounting bolt

50 (37)

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2 - 162

TRANSMISSION

2.14 LIST OF OVERHAUL SPECIAL TOOLS


TOOL NUMBER

DESIGNATION

380001274

Control valve screws (M10) adjusting tool

380001275

Control valve screws (M8) adjusting tool

380001276

Control valve screws (M5) adjusting tool

380001277

Control valve screws (M6) adjusting tool

380001280

Clutch pack spring removal and assembly tool

380001281

Transmission overhaul rotary stand

380001288

Shaft bearing puller

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W190

Copyright New Holland

W190

TRANSMISSION

2 - 163

TOOLING
TOOL NUMBER

DESIGNATION

380001291

Shaft bearing puller

380001295

Control valve tightening screw wrench (TX27)

380001296

Control valve tightening screw wrench (TX40)

380001292

Primary shaft bearing mounting tool

380001269

Bearing half-ring holder tool

380001283

Bracket supporting the transmission on rotary stand to be used with


380001281

380001271

Primary shaft bearing mounting tool To be used with 380001278

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2 - 164

TRANSMISSION

TOOLING
TOOL NUMBER

DESIGNATION

380001272

Bearing mounting tool on transmission housing

380001273

Bearing mounting tool on transmission housing

380001290

Adapter for bearing pulling

380001294

Adapter for bearing pulling

380001289

Adapter for bearing pulling

380001293

Adapter for bearing pulling

380001278

Handle for mounting tool

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W190

Copyright New Holland

W190

TRANSMISSION

2 - 165

TOOLING
TOOL NUMBER

DESIGNATION

380001279

Mounting tool for primary shaft oil seal To be used with 380001278

380001270

Bearing puller bridge

380001284

Hydraulic pipe rolling tool

380001285

Hydraulic pipe rolling tool

380001286

Hydraulic pipe rolling tool

380001287

Hydraulic pipe rolling tool

380000818

AEB Starter

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2 - 166

TRANSMISSION

TOOLING
TOOL NUMBER

DESIGNATION

380001217

Pag 2-161DPA 04 Testman kit assembly composed of:


380001224, 380001225, 380001226, 380001227

380001219

Diagnostic software English

380001221

Diagnostic software German

380001222

Diagnostic software French

380001224

DPA 04 interface

380001226

Testman basic software

380001225

Cable RS 232 connecting Sartor and DPA-04 interface

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

W190

TRANSMISSION

TOOLING
TOOL NUMBER

DESIGNATION

380001227

Connecting cable DPA-04 Interface to transmission

380001297

Display assembly

380002499

Differential ring nut removal tool

380002600

Caliper inspection of the pinion bearings pre-load

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 167

Copyright New Holland

2 - 168

W190

TRANSMISSION
380060208 CE - EST DIAGNOSTIC KIT KEYBOARD version
380060157 CE - EST DIAGNOSTIC KIT TABLET version

A.
A.
A.
A.
B.
C.
D.
E.
F.
F.
G.
H.
K.
I.
L.

STHP HDD 80 GB
DVD 8x
Battery for PC
STHPX Computer English
Vehicle interface module DPA-3
DPA-3 to multibrand interface cable
PC to DPA-3 interface cable
STHP Computer Docking Station
"SMS key" application software
12V Vehicle Power Supply
Bag
PC to vehicle interface
Cable PC to vehicle
Cable PC to vehicle interface
Cable PC to vehicle

M.
N.
O.
P.
Q.
R.
S.
T.
T.
U.
V.

Engine diagnosis cable


Cable from multibrand interface
to ZF AEB starter.
Grader diagnosis cable
Cable motor
BB3 diagnosis cable
Special keyboard
I/O Stick
Excavator connecting cable
3,5 FDD
24V Vehicle Power Supply
Printer
Printer cable
1850-2R520

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W190

TRANSMISSION

380001594 PFT-8 HYDRAUIC TEST KIT

1850-2R521

A.
B.
C.
D.
D.
E.
F.

750L/M Flow block


700 bar pressure sensors
Temperature sensors 150 C
Sensor cables
Cable temperature sensors
Suitcase
Module PFT-8

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 - 169

Copyright New Holland

2 - 170

W190

TRANSMISSION
380060209 CE - EST KIT COMPLETE KEYBOARD version
380060165 CE - EST KIT COMPLETE TABLET version

KIT Hydraulic PFT-8


380001594

CE - EST KIT DIAGNOSTIC


380060209

KIT Hydraulic PFT-8


380001594

CE - EST KIT DIAGNOSTIC


380060165
W190-2R003

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Copyright New Holland

W190 EVOLUTION

BRAKE SYSTEM

3-1

SECTION 3

BRAKE SYSTEM
INDEX

PARAGRAPH

SUBJECT

3.1

GENERAL DESCRIPTION ...................................................................................... 3-1

3.2
3.2.1
3.2.2

OPERATION ........................................................................................................... 3-3


Generalities ............................................................................................................. 3-3
Operating conditions ............................................................................................... 3-3

3.3
3.3.1

DISC BRAKE .......................................................................................................... 3-5


Operation ................................................................................................................ 3-5

3.4

BRAKE PEDAL VALVE ........................................................................................... 3-6

3.5

BRAKES/POWER SYSTEM PUMP ....................................................................... 3-7

3.6
3.6.1
3.6.2

PARKING BRAKE CONTROL ................................................................................. 3-8


Checking the wear of the parking brake ................................................................... 3-9
Setting the parking brake ........................................................................................ 3-9

3.7
3.7.1
3.7.2
3.7.3

PARKING BRAKE ..................................................................................................


Releasing the parking brake ....................................................................................
Operation of the disc parking brake .........................................................................
Brake disengagement .............................................................................................

3.8
3.8.1

OTHER COMPONENTS ......................................................................................... 3-12


Service brakes accumulator .................................................................................... 3-12

3.9

BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS .......................................... 3-13

3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
3.10.6

DIAGNOSTICS AND TESTING ..............................................................................


Brake control pressure testing .................................................................................
Minimum and maximum accumulator recharge pressure adjustment .......................
Accumulator pre-charge test ...................................................................................
Instructions for the restoration of the service brakes accumulators pre-charge .......
Bleeding the brake system ......................................................................................
Brake disc wear check ............................................................................................

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

PAGE

3-10
3-10
3-11
3-11

3-14
3-14
3-15
3-16
3-17
3-18
3-19

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Copyright New Holland

W190

BRAKE SYSTEM

3-1

3.1 GENERAL DESCRIPTION


The braking system includes:

The parking brake circuit is composed of:

- a two stage gear type powering pump (8) flanged on


the torque converter cover;

- solenoid valve (14) controlling the engagement and


disengagement of parking brake (6);

- filter (7) on the pump delivery;

- the parking brake group (6) is composed of a few


springs and a reaction hydraulic cylinder. The
springs provide the force locking the discs of the
parking brake when, through the solenoid valve,
pressurised oil in the cylinder is discharged. The
hydraulic cylinder, when activated by pressurised
oil, (by the solenoid valve) neutralises the action of
the springs, thus disengaging the brake;

- brake pedal valve (15) controlling simultaneously


front (1) and rear (9) brakes located inside the axles;
- two accumulators (4 and 13) that during normal
operation stabilise the pressure in the circuit and, in
case of emergency, with engine inoperative, allow
the actuation of the brakes for a certain number of
times;

- accumulator (11) installed on the parking brake power


line, during normal operation stabilises the pressure
in the circuit and, with engine inoperative, allows the
disengagement of the parking brake, a few times.

- the oil used by the circuit is the same of the equipment hydraulic system and it is taken from hydraulic tank (S).

4
R

13
R1

R2

15

T2

TO STEERING/EQUIPMENT
CIRCUIT

TO PILOTED SYSTEM CIRCUIT

M
T1

14
N

11
8
6
S

Fig. 3-1

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Copyright New Holland

3-2

BRAKE SYSTEM

W190

2
16

15

14

5
6

13

12
M

7
8
S

11

17

10

Fig. 3-2 Brake system


S. Tank - M. Pilot system circuit - 1. Front brakes - 2. Stop light pressure switch - 3. Accumulators control pressure switch 4 and 13. Brake system accumulators - 5 and 12. Quick release pressure pick-ups - 6. Parking brake - 7. Oil delivery filter 8. Brake oil pump - 9. Rear brakes - 10. Parking brake pressure switch - 11. Parking brake accumulator - 14. Parking brake
control solenoid switch - 15. Brake pedal valve - 16. Transmission cut-off pressure switch - 17. Quick release pressure
pick-up point.

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Copyright New Holland


BRAKE SYSTEM

W190

3-3

3.2 OPERATION

3.2.1 GENERALITIES

3.2.2 OPERATING CONDITIONS

Brake system

Conditions of:

The brake system is powered by pump (8) sucking oil


from oil tank (S) and forwards it to flow regulation valve
(18), filtered by filter (7).
Two hydraulic accumulators (4 and 13) and two check
valves provide the accumulation of a quantity of oil
under pressure sufficient to actuate the brakes a limited amount of times, even with the engine inoperative, thus when the flow of pump (8) is nil.

Parking brake
Parking brake (6) is composed of a disc brake operating on the output shaft of the transmission.
The equipment receives oil under pressure from the
regulation valve.
Pressure switch (10) closes the "parking brake engaged" signal electric circuit when the pressure drops
below the value of 15 bar, with the consequent engagement of the parking brake.

Service brakes
Of an oil-bath, disc type, they are located inside the
final drives of the axles (1 and 9). When pressing the
brake pedal, valve (15) supplies the braking circuit
with a controlling pressure (thus a braking force) proportional to the stroke of the brake pedal (Pf Max =
45 bar).
When releasing the pedal, valve (15) discharges the
brake circuit oil zeroing the braking action on discs
(1 and 9).
During the braking phase pressure switch (2) activates
the electric circuit of the stoplights. Pressure switch
(16) controls the transmission cut-off device.

13

12

5
R1

R2

15

22

engine running
service brakes disengaged
parking brake engaged
accumulators during recharging phase

19

The delivery of pump (8) reaches flow regulation valve


(18). The oil flow opens and passes main check valve
(19) then opens and passes check valves (22 and 23)
charging the accumulators of service brakes (4 and
14) and parking brake accumulator (11).
Controlling spools (20 and 21) when brake pedal (P)
is released, block the flow of the oil coming from the
pump and keep the brake disc actuating pistons
(1 and 9) in discharge. Thus the service brakes are
disengaged.
Solenoid valve (14) controlling parking brake (6) is
positioned so that the oil flowing from the parking brake
chamber is discharged thus parking brake (6) is actuated by the action of the springs.

21

18

T2

16

T1

20
2

7
23
14
N

Conditions of:
-

10

engine running
service brakes engaged
parking brake disengaged
accumulators charged.

This condition occurs when braking while the machine


is operating.
The parking brake is disengaged since solenoid valve
(14) forwarding oil under pressure to the brake piston
neutralises the action of the springs.
Brake pedal (P), when pressed, presses the springs
actuating controlling spools (20 and 21) determining
the opening of the delivery gaps to the brakes (1 and
9).
In the lower part of controlling spool (21) the barking
pressure starts operating, pushing the disc pack of
brakes (1 and 9). In this manner, while the pressure
on the discs increases, controlling spools (20 and 21)
are pushed upward and close the delivery gaps. In
this manner a pressure is obtained on brake discs
(1 and 9) thus a braking force proportional to the pressure on pedal (P).
The presence of two accumulators (4 and 13) and two
controlling spools (20 and 21) allow the operation of
two separate circuits for the front and rear brakes.
The failure of one circuit does not influence the operation of the other one.

17
V = 0,71
Po = 19 bar

11

TO ENGINE
HYDRAULIC FAN

V = 1,41
Po = 70 bar

T
30 bar
PV

Fig. 3-3 Brakes hydraulic system circuit


Steering/Equipment
Q=162 l/min

Brakes/Pilot valves
Q=32 l/min

8
63 cc/rev.

13 cc/rev.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

P. Brakes pedal - S. Tank - M. Pilot system circuit - 1. Front


brakes - 2. Stop light pressure switch - 3. Accumulators
control pressure switch - 4. and 13. Brake system accumulators - 5. and 12. Quick release pressure pick-ups 6. Parking brake - 7. Oil delivery filter - 8. Brake oil pump 9. Rear brakes - 10. Parking brake pressure switch 11. Parking brake accumulator - 14. Parking brake control solenoid switch - 15. Brake pedal valve - 16. Transmission cut-off pressure switch - 17. Quick release pressure pick-up point - 18. Flow regulation valve - 19. Main
check valve - 20. Front axle brakes control spool 21. Rear brake control spool - 22. and 23. Check valves.

Copyright New Holland

3-4

BRAKE SYSTEM

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

W190

BRAKE SYSTEM

3-5

3.3 DISC BRAKE


The disc brake is composed of two oil-bath, discs
and it is mounted inside the axle housing. On this
loader, four brake groups are mounted in the axles,
one on each axle shaft.
The structure of the disc brake is described in the
TRANSMISSION section.

The inner circumference of the discs is splined


and it is keyed to the axle shaft. The outer circumferences of the pressure plate and reaction plate
are secured to the axle housing by dowels, so that,
the locking of the brake discs causes the stopping of the axle, thus braking.

2) Releasing the brakes


When oil pressure is relieved from the brake piston, this moves slightly rearwards to release the
brake disc and the the braking action stops.

3.3.1 OPERATION
1) Actuation of the brake
The pressure of the brake oil acts on the rear face
of the brake piston and locks the brake discs between the disc pressure plate and the reaction plate.

8
Brake
pressure oil

11
9
10

3
2
1

12

13
14

Fig. 3-4 Operation of disc brake


1. Axle shaft - 2. Planetary carrier - 3. Solar shaft - 4. Disc hub - 5. Reaction plate - 6. Pin - 7. Disc brake - 8. Disc pressure
plate - 9. Piston - 10 and 11. Sealing ring - 12. Spring - 13. Piston guide - 14. Screw.

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3-6

BRAKE SYSTEM

W190

3.4 BRAKE PEDAL VALVE

max 19

To dump
To other users
or dump

T1
Rear brake feed
port (45 bar)

T2
Front brake feed port
(45 bar)

Accumulator pressure
adjustment

Fig. 3-5 Brake pedal valve

Angle adjustment with pedal


released 40 to 60
Min. angle from released position
to start sending pressure oil to
the brakes
Max working angle 16

Pedal angle adjust


screw

Backlash
take-up screw

Brake oil delivery


spools

Brake feed ports


Brake pressure adjustment stop
screw = Pf Max.

Fig. 3-6 Section view of oil delivery spools to users

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Copyright New Holland

W190

BRAKE SYSTEM

3-7

3.5 BRAKES/POWER SYSTEM PUMP


The brakes circuit is powered by the hydraulic oil delivered by the pump keyed on the transmission housing, together with the steering pump. The same pump
powers the power system.

BRAKES PUMP (AND POWER SYSTEM)


Designation: ........................................................................................................... Kajaba KP1013ABGH
Type: ........................................................................................................................................ Gear type
Drive: .............................................................................................................. mounted on steering pump
Delivery ............................................................................................................ 32 lt/min (7.03 USG/min.)
Maximum pressure: ..................................................................................................... 170 bar (2465 psi)

10

Item "C"

13

12

11

Fig. 3-7 Brakes/power steering pump sections

1. Driven gear - 2. Mounting flange - 3. Gear plate - 4. Centering dowel - 5. Closing plate - 6. Oil seal - 7. Driving gear 8. Side plate - 9. Side plate - 10. O-Ring - 11. Sealing device - 12. Gasket B - 13. Gasket A

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Copyright New Holland

3-8

BRAKE SYSTEM

W190

3.6 PARKING BRAKE CONTROL


WARNING
To prevent possible damages to mechanical
components, do not engage the parking brake
while the machine is moving.
The parking brake (button B) operates on the
transmission output shaft blocking the machine when
parking.
Every time the machine is parked, move the gearshift
lever into neutral and engage the parking brake.
Brake engaged
= ON
Brake disengaged = OFF

W190-3R001

Fig. 3-8

ON

OFF

Note When the engine is cut-off the parking brake is


automatically engaged.

If during a stoppage the engine has been cut-off and


the switch was left in position "OFF", it is necessary
to move the switch into position "ON" first and then into
"OFF" to re-start the machine.

P
Fig. 3-9

Hazard light switch


In the event of a failure or a forced stoppage, actuate
hazard light switch "C" as well as the parking brake.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

BRAKE SYSTEM

3-9

3.6.1 CHECKING THE WEAR OF THE


PARKING BRAKE
Check that the minimum thickness of the friction
material is not less than 2 mm (0.07 in) for each braking
element F.
If not, replace the braking elements following this
procedure:
1. Block the wheels of the loader with wedges;
2. After cleaning the surrounding area, remove piping
T;
3. Remove cover C and unlock locknut D;
4. Turn screw E anticlockwise until pressure
cylinder P is fully retracted. Under this condition,
the brakes can be replaced;
5. Install the oil piping previously disconnected and
apply the pressure required to pre-charge spring
M (about 85 bar - 1232 psi);
6. Turn screw E clockwise until the braking
elements touch disc G then unscrew screw E
4/5 turn. Under this condition, the play between
disc and braking elements is 2 mm (0.07 in).
7. Tighten locknut D holding screw E in its position.
8. Reinstall cover C tightening manually with a
filter wrench as much as possible;
9. If required, bleed the air through valve S.

B
T

Fig. 3-10
P

S
M

3.6.2 SETTING THE PARKING BRAKE


To set the parking brake, follow points 1 through 3 and
6 through 8 of the procedure described here above.

F
G

Fig. 3-11

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Copyright New Holland

3 - 10

BRAKE SYSTEM

W190

3.7 PARKING BRAKE


Parking brake manual disengagement (in case of
emergency).
B
WARNING

Disengage the parking brake manually only if it is


absolutely necessary. Namely, this should be done
only when towing a failed loader to traffic-free areas. If the loader is on an incline, check that the
wheels are securely blocked with wedges or
stones prior to releasing the parking brake.

Fig. 3-12

3.7.1 RELEASING THE PARKING BRAKE


P

F
G

Fig. 3-13

D C
E

Parking brake "A" operates on disc "B" keyed on the


transmission output shaft.
In the event the engine fails to start or the hydraulic
pumps fail, or other troubles occur blocking the machine,
proceed as follows:
Block the wheels of the loader with wedges.
After cleaning the surrounding area, loosen cover
"C".
Unlock locknut "D" and loosen setting screw "E"
anticlockwise, until the brake is released.
Reinstall nut "D" and cover "C" tightening manually
as far as possible with a filter tool.
The parking brake is of an oil-bath, multiple disc type
and it is mounted on the intermediate shaft of the
transmission.
The brake is actuated by a series of inner springs and
it is disengaged by the oil pressure controlled by the
parking brake valve.
Its structure is described in the section 2 TORQUE
CONVERTER - TRANSMISSION.

Fig. 3-14

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Copyright New Holland

W190

BRAKE SYSTEM

3 - 11

3.7.2 OPERATION OF THE DISC PARKING


BRAKE
When the oil under pressure actuating brake piston
(1) is discharged, this is pushed by the force of spring
(2) closing the brake rotary discs against transmission output disc (4).

5
4

Fig. 3-15

Parking brake

1. Brake piston - 2. Springs - 3. Support plate - 4. Transmission output shaft disc - 5. Brake discs.

3.7.3 BRAKE DISENGAGEMENT


1. When pressure oil is sent to the rear surface of
the brake piston, this overcomes the spring action
and moves.
2. A clearance is established between each brake
disc and fixed plate, the brake discs are released
and the brake is disengaged.

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Copyright New Holland

3 - 12

BRAKE SYSTEM

W190

3.8 OTHER COMPONENTS


3.8.1 SERVICE BRAKES ACCUMULATOR
The membrane accumulator is used to store pressure oil to release the parking brake.
Oil from the charge pump is diverted by the check

valve to the accumulator which maintains the pressure at a certain value.

CAPACITY ...................................................................... 1.4 l (0.36 gal)


MAX. WORKING PRESSURE FOR
ACCUMULATOR .................................................... 210 bar (3045 psi)

Fig. 3-16

GAS TO BE USED ............................................................ NITROGEN


GAS PRE-CHARGE PRESSURE .............................. 45 bar (652 psi)
WEIGHT ............................................................. 5.4 kg abt (11.90 lbs)

Accumulator

1. Gas filling plug - 2. Accumulator body - 3. Oil inlet connection.

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Copyright New Holland

W190

BRAKE SYSTEM

3 - 13

3.9 BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS

max 19

N
M
T1
F

R2

R1

T2

R3

TI2
P
T1

R1

R2

B
T2

TI1
X

Fig. 3-17

Brake pedal valve hydraulic connections

F. Accumulator control pressure switch - M. Other users or to dump - N. Dump - P. Inlet - R1-2. Accumulator - T1-2. To the
brakes - TI1-2. Brake control pressure switch.

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Copyright New Holland

3 - 14

BRAKE SYSTEM

W190

3.10 DIAGNOSTICS AND TESTING


3.10.1 BRAKE CONTROL PRESSURE TESTING
Connect two pressure gauges (end of scale 100 bar
(1450 psi)) to the pressure ports shown in Fig. 3-18.

Release the lock-nut (E, Fig. 3-18) and turn the screw
in or out if pressure values are not within the rated
range.

Apply the parking brake.


Start machine engine and wait until it settles to maximum torque speed.

Such a pressure must be measured after a pedal stroke


of about 70 mm (2.79 in).
Seal the screw after adjustment.

With the engine idling, press the brake pedal and check
that pressure reading on the gauges is approximately
45 bar (652 psi).

Rear axle
pressure port
Front axle
pressure port

Fig. 3-18

Braking pressure adjustment

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Copyright New Holland

W190

BRAKE SYSTEM

3 - 15

3.10.2 MINIMUM AND MAXIMUM ACCUMULATOR RECHARGE PRESSURE ADJUSTMENT


Connect two pressure gauges (end of scale 200 bar
(2900 psi)) to the quick coupling pressure ports
(7 and 8, Fig. 3-19) on the accumulators.
Start machine engine and bring oil temperature to
approximately 40 to 50 C (104 to 122 F) by means
of the attachment control lever. Cycle the brake pedal
several times to make oil temperature even.

different from the rated value, remove the plug (1),


release the lock-nut (5) and turn the screw (4) with
micrometric variations until obtaining correct value.
Check pressure again before tightening the lock-nut
(5).
Maximum recharge value
With the engine idling and the parking brake applied,
observe maximum recharge pressure on pressure
gauges M1 and M2.
Pressure should be 130 5 bar (188 72 psi).
If maximum recharge pressure is different from the
rated value, remove the plug (1), release the lock-nut
(3) and turn the screw (2) out to increase the accumulator maximum recharge pressure.

Minimum recharge value


With the engine idling and machine at a standstill,
brake slowly 4 or 5 times.
Observe minimum pressure values on pressure
gauges M1 and M2 before recharge starts.
The pressure gauges should momentarily read 80 5
bars (1160 72 psi). If minimum recharge pressure is

M1
M2

7
8

Fig. 3-19

34

Minimum and maximum accumulator recharge pressure adjustment

M1 & M2. Pressure gauges - 1. Plug - 2. Maximum pressure adjust screw - 3. Lock-nut - 4. Minimum pressure adjust screw 5. Lock-nut - 6. Accumulators - 7 & 8. Pressure ports.

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Copyright New Holland

3 - 16

BRAKE SYSTEM

W190

3.10.3 ACCUMULATOR PRE-CHARGE TEST


Accumulators fitted to the braking system are membrane type, pre-charged using nitrogen.
Normal minimum membrane porosity and continued
use reduce pre-charge pressure in time and limit accumulator efficiency.
It is advised to check the nitrogen pre-charge every
six months and restore it, if necessary.
Pre-charge pressure should never drop below approximately 90% of the rated value.
Check is to be carried out with the accumulators
drained of hydraulic oil. This condition is obtained as
follows:
- as regards accumulators (4 and 13, Fig. 3-3) by
pressing the brake pedal slowly several times;
- as regards the parking brake release accumulator
(11, Fig. 3-2) by operating repeatedly the diverter
valve (14) with the engine stopped.

Check the pre-charge as follows:


1. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake
circuit.
2. Close valves (B) and (C) on the nitrogen charging
kit, refer to the illustration 3-20.

3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumulator.
5. Remove the cap from the accumulator valve stem.
6. Connect valve (F) to the accumulator valve stem.

Fig. 3-20 Nitrogen charging kit 380001737

7. Make sure that valve (D) is open.


8. Turn the stem into valve (F) and read the pressure
gauge (E).
9. The pressure must result 45 bar (652.6 psi). If the
pressure is too low, charge the accumulator with
dry nitrogen.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

94L95

Copyright New Holland

W190

BRAKE SYSTEM

3.10.4 INSTRUCTIONS FOR THE


RESTORATION OF THE SERVICE
BRAKES ACCUMULATORS PRECHARGE
Note Check the pressure of the accumulator ion accordance with the instructions listed in "Check the accumulator
pre-load". Keep the nitrogen charging kit connected to the
accumulator.

3 - 17

1. Close (turn counterclockwise) valve (A) and open


valve (B). Close valves (C) and (D).
2. Turn the stem out of valve (F) until the stem stops
moving. Disconnect valve (F) from the accumulator valve stem.

Fig. 3-21 Nitrogen charging kit 380001737

3. Connect the nitrogen charging kit to a dry nitrogen


tank.
4. Slowly turn valve (A) clockwise and read gauge (E)
until the pressure is 45 bar (652.6 psi). Stop turning
valve (A).
5. If the pressure increases above 45 bar
(652.6 psi), quickly open and close valve (D) and
read gauge (E). If the pressure is still too high, close
valve (A) (turn counterclockwise) a small amount
and quickly open and close valve (D). The pressure shown on gauge (E) is the charge pressure.
6. Connect valve (F) to the accumulator valve stem.
Turn the stem into valve (F) until the stem stops
moving and open valve (D) to charge the accumulator.
7. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
8. Close valve (B) and disconnect the nitrogen charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem. Install the guard and cap screws on the accumulator.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

94L95

Copyright New Holland

3 - 18

BRAKE SYSTEM

W190

3.10.5 BLEEDING THE BRAKE SYSTEM


It is necessary to bleed the brake system when anyone of the conditions here below occurs:
- after replacing hydraulic oil in the attachment oil
reservoir;
- when air has entered the system because of poor
sealing of hoses or charge pump;
- after disconnecting or replacing any of the system
parts.

Bleed the system as detailed below (this is a twoman operation):


- position the machine on a level surface and start
the engine;
- with the engine idling, one operator should release
the bleed screw (two on each axle) while the other
is pressing the brake valve pedal. Tighten the bleed
screw before releasing the brake pedal;
- repeat this operation until bleeding all air from the
system (fluid should come out of the bleed screw
free of bubbles);
- repeat for the other axle.

Fig. 3-22

Brake oil bleed screw (S) locations on the axle (1 per brake)

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Copyright New Holland

W190

BRAKE SYSTEM

3 - 19

3.10.6 BRAKE DISC WEAR CHECK

Fig. 3-23

Brake disc wear check hole locations

Threads: LOCTITE 572

The control of the wear on the 4 brake discs (for each


axle) is carried out after draining the oil from the group.
Remove inspection plugs (A) and (B);
The brake discs are to be replaced if a thickness gauge
blade of the 5.3 mm can be made to pass through the
steel discs.

Note The check of the operation play must be performed using air pistols.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

3 - 20

BRAKE SYSTEM

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

SECTION 4

STEERING SYSTEM
INDEX

PAGE

PARAGRAPH

SUBJECT

4.1
4.1.1

GENERAL DESCRIPTION ...................................................................................... 4-1


Description of the steering system operation ........................................................... 4-2

4.2
4.2.1
4.2.2
4.2.3
4.2.4

MAIN AND SECONDARY PRIORITY VALVES ......................................................


Description of operation of main priority valve .........................................................
Main priority valve diagram .....................................................................................
Steering emergency circuit ......................................................................................
Secondary priority valve ..........................................................................................

4-6
4-6
4-8
4-9
4-9

4.3
4.3.1
4.3.2
4.3.3
4.3.4

POWER STEERING ...............................................................................................


Power steering (removal) .........................................................................................
Disassembly of power steering ...............................................................................
Assembly of the power steering ..............................................................................
Disassembly of the valve block ..............................................................................

4-10
4-11
4-12
4-14
4-16

4.4

TEST OF THE STEERING SYSTEM ..................................................................... 4-17

4.5

EMERGENCY STEERING PUMP .......................................................................... 4-20

4.6
4.6.1
4.6.2
4.6.3

STEERING CYLINDERS ........................................................................................


Removal .................................................................................................................
Disassembly and reassembly .................................................................................
Installation ..............................................................................................................

4-21
4-21
4-22
4-22

Copyright New Holland

Copyright New Holland

W190

4-1

STEERING SYSTEM

4.1 GENERAL DESCRIPTION


Type: ............................................................. hydraulically controlled by orbitrol actuated by the steering wheel
Angle of articulation of the frames .............................................................................. 40 rightward and leftward
Number of turns of steering wheel: ................................................................................................................ 3.7
Setting of pressure relief valve ............................................................................................... 210 bar (3045 psi)
Setting of safety valve pressure ............................................................................................. 280 bar (4061 psi)
Steering pump: ..................................................................................................................................... gear type
Steering cylinder:
Type: ................................................................................................................ Stantuffo a doppia azione
Q.ty: ...................................................................................................................................................... 2
Cylinder stroke: ...................................................................................................................... 422 mm (16.61 in)
Weight (each): ............................................................................................................................ 31 kg (68.4 lbs)
The loader is of an articulated frame type. The steering
force is applied between the front and rear modules by
a couple of double stroke cylinders actuated by an
orbitrol, directly connected to the steering column. The
loader is also equipped with an emergency steering system.
The steering system uses the same oil of the equipment system. The two systems are combined, since
the oil in excess of the steering pump is forwarded to
the equipment system. The system is made of hydraulic tank (S) pump (1) main priority valve (2) steering unit

(orbitrol 5) complete with check valves and steering


cylinders (4).
The emergency steering system is composed of the
following components:
- emergency pump (14);
- secondary priority pump (12);
- two check valves on main and secondary priority
valve;
- one check valve (8) with pressure switch (7) installed
on the oil return pipe to the tank.

4
5
4

To equipment control
valve

12

To brakes
circuit

14
Hydraulic tank (S)

Fig. 4-1 Steering system


1. Main pump - 2. Main priority valve - 4. Steering cylinders - 5. Orbitrol - 12. Secondary priority valve - 14. Emergency pump.

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Copyright New Holland

4-2

STEERING SYSTEM

W190

4.1.1 DESCRIPTION OF THE STEERING


SYSTEM OPERATION
The oil in tank (S) is sucked by pump (1) composed
of two sections: one section powers the steering/
equipment system, the other powers the brake system.
The oil is directed toward priority valve (2) containing a spool that, in case of steering, sends the oil
directly to orbitrol (5).
The hydraulic oil pressure at input (P) of orbitrol (5)
is controlled by pressure relief valve (6) set at 210
bar (3045 psi), that discharges the oil in case the
said value is exceeded.
When required, the oil is directed to the steering
system and the equipment system. With the steering at rest, the oil at the end of the priority spool
upward, thus allowing the oil of the pump to flow to
the equipment system. The steering system has
priority and gets oil first. The priority valve together
with the orbitrol make the LOAD SENSING system.

Operation of the LOAD SENSING system


The load sensing system provides the powering of
the orbitrol with a quantity of oil (taken from the main
pump delivery) required by the steering action, letting
the residual flow of the pump into the equipment hydraulic system (equipment control valve).
As an example, when the steering wheel is in neutral
position, the majority of the pump oil flow is forwarded
to the hydraulic control valve operating the equipment
hydraulic system, so that the oil delivered by the main
pump is used in an efficient manner to achieve the
maximum saving of energy.
When the operator actuates the steering wheel, the
oil is directed to the steering control cylinders through
the orbitrol. Two safety and anti-cavitation valves (1)
located inside valve block (10) operate in the event of
shocks on the wheels, absorbing their effects.
The valve have also an anti cavitation function, ensuring that with the orbitrol in neutral, the cylinder
chambers are always filled with oil, thus preventing
oil vacuums in the circuit in case of intervention of
the safety (shockless) valves protecting against hard
shocks on the wheels.
Under normal operation conditions of supply pump (1)
the oil delivered by emergency steering pump (14)
flows through secondary priority valve (12) to hydraulic tank (S) with a pressure exceeding 1.5 bar (21.75
psi).
On the tank check valve (8) set at 1.5 bar (21.75 psi)
and pressure switch (7) are installed, that under normal conditions keep the emergency steering indicator light in the cab OFF.
In the event, while the wheels are moving, a sudden
cut-off of the engine or supply pump (1) (steering section) occur, orbitrol (5) sends a signal (LS) to secondary priority valve (12) that positions itself so that the
oil flow delivered by steering emergency pump (14) to
the orbitrol circuit.
The oil directed to the orbitrol is sufficient to ensure
the steering, even with engine inoperative.
Under these conditions, since the oil is diverted to
the orbitrol, pressure switch (7) monitors a pressure
drop (lower than 1.5 bar (21.75 psi)) and signals to the
operator the intervention of the emergency steering
pump (14) activating the relevant indicator light in the
cab.

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W190

4-3

STEERING SYSTEM

7
8
L

R
T LS

5-6

10

11
4

D
F
12
13
14

Fig. 4-2 Emergency steering circuit


D. To equipment control valve - F. To brake pedal valve - L. To left cylinder (bottom side) - LS. Load Sensing signal P. Supply form pump - R. To right cylinder (bottom side) - T. Discharge to tank - 1. Dual supply pump (steering/brakes) 2. Main priority valve - 3. Check valves - 4. Steering cylinders - 5. Orbitrol - 6. Pressure relief valve - 7. Pressure switch for
emergency steering pump low pressure - 8. Check valve on tank (from emergency steering pump) - 9. Check valve (from
orbitrol) - 10. Valve block - 11. Safety and anti-cavitation valve - 12. Secondary priority valve - 13. Check valves on LS (load
sensing) circuit - 14. Emergency steering pump

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Copyright New Holland

4-4

W190

STEERING SYSTEM

11

10
T

5 bar

5
LS

D
13

3
3

CF
PP

EF

EF
0.8

CF
PP

0.8

2
0.8

1.0

LS

12

0.8

1.0

7
14

1,5 bar

Fig. 4-3 Steering hydraulic system

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W190

STEERING SYSTEM

LEGENDA OF STEERING HYDRAULIC SYSTEM


D - To control valve
F - To brake pedal valve
L - To left cylinder (bottom side)
LS - Load-Sensing signal
P - Supply from pump
R - To right cylinder (bottom side)
T - Discharge to tank
1 - Dual supply pump
- Steering/equipment section
(max flow Q = 162 lt/min) (35.63 USG/min)
- Brakes/pilot system section
(max flow Q = 32 lt/min) (7.03 USG/min)
2 - Main priority valve (stand-by setting 12 bar)
(174 psi)
3 - Check valves
4 - Steering cylinders
5 - Orbitrol
6 - Pressure relief valve (setting 210 bar) (3045 psi)
7 - Pressure switch for emergency steering pump
low pressure
8 - Check valve on tank (emergency steering circuit
- setting 1.5 bar) (21.75 psi)
9 - Check valve (orbitrol circuit - setting 5 bar)
(21.75 psi)
10 - Valve block
11 - Safety and anti-cavitation valve (setting 280 bar)
(4061 psi)
12 - Secondary priority valve (setting stand by 4 bar)
(58.01 psi)
13 - Check valves on LS (Load Sensing) circuit

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4-5

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4-6

W190

STEERING SYSTEM

4.2 MAIN AND SECONDARY PRIORITY VALVES


4.2.1 DESCRIPTION OF OPERATION OF
MAIN PRIORITY VALVE
Item (g) represents the position of the spool under
the conditions of equipment (booms and bucket) operation only without intervention by the steering. Check
valve (1) is closed due to the lack of flow toward the
orbitrol, keeping the latter under pressure. This condition is maintained for a few instants, due to the dynamic leakage inside the orbitrol, from which an alternate closing and opening movement of supply duct
(CF) occurs.
If the steering is continued to stroke-end and the circuit pressure increases, the pressure relief valve inside the orbitrol opens discharging excess pressure
directly to the hydraulic oil tank.
Two orifices (S1 and S2) creating a pressure gradient
downstream, provide a gradual movement of spool
(2) during the various phases of operation.

Oil is sucked by the pump and forwarded directly to


the main priority valve. The oil powers the valve from
duct (P).
In the event the steering of the machine is required,
spool (2) is positioned as in detail a. This position is
maintained by the return spring and by the oil coming
from duct (LS).
Duct (LS) is connected to the orbitrol and the pressure is directly proportional to the steering speed. If
the steering is gradually zeroed (item b) the pressure
in the orbitrol decreases thus it decreases in duct (LS)
as well.
Being the delivery pressure to the orbitrol (duct CF)
higher, under these conditions, spool (2) moves and
presses the return spring gradually uncovering the
delivery to control valve (EF).

S2

EF

123456
123456
123456 Static oil

Oil to discharge

Oil under pressure

CF

EF

LS

CF

EF

CF

LS

LS
PP

PP

PP

S1
P

Fig. 4-4 Main priority valve operation phases


a. Full flow delivery phase to orbitrol - b. Simultaneous flow delivery to orbitrol and equipment control valve - c. Full cutting
-off to orbitrol and full delivery to control valve - S1 and S2. Orifices - 1. Check valve - LS. From orbitrol - CF. To orbitrol and
(upon request) to secondary priority valve - P. From hydraulic pump - 2. Spool.

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W190

4-7

STEERING SYSTEM

Removal

Disassembly

The valve is installed on the frame on the left side of


the machine, under the cab.

To disassemble the priority valve proceed as follows:

Drain the hydraulic oil from the tank, tagging and disconnecting the oil hoses. Remove the securing screws
and remove the valve.

1) remove plug (1) and relevant O-Ring (2) from port


(PP);
2) remove plug (6) and relevant O-Ring (2) from port
(LS) and extract spring (5);
3) extract spool (3) using a nylon rod pushing from
the opposite side of the valve.

1
2
3

5
2
6
4

Fig. 4-5 Main priority valve


1. Plug - 2. O-Ring - 3. Spool - 4. Valve body - 5. Spring - 6. Orifice plug

60 Nm

Reassembly and installation


The reassembly and installation are performed reversing the operations above.
Tighten the components to the prescribed torque indicated in Fig. 4-5.

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4-8

W190

STEERING SYSTEM

4.2.2 MAIN PRIORITY VALVE DIAGRAM


The priority valve is combined with the orbitrol to make
the "load sensing" system that distributes the flow of
the main pump to the steering and equipment hydraulic systems.

EF

CF
EF

CF
PP

PP

LS

LS

P
P

Fig. 4-6 Priority valve diagram


P:
LS:
EF:
CF:
PP:

PUMP (from main pump)


LOAD SENSING (from Orbitrol)
MAIN CIRCUIT (to equipment control valve)
STEERING CIRCUIT (to orbitrol)
PILOTING CIRCUIT (by-passed inside the valve)

Setting = 12 bar (174.04 psi)

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W190

4-9

STEERING SYSTEM

4.2.3 STEERING EMERGENCY CIRCUIT


General description
The configuration of the device includes a gear pipe
directly keyed on the transmission to ensure, when
the machine is moving (forward or reverse) the flow of
oil to the emergency system. Oil sucked by the emergency pump reaches the secondary priority valve that,
in case of operating failure of the steering pump, is
positioned in a manner to ensure the flow of oil toward
the orbitrol and the cylinders.

The emergency steering circuit has the purpose of


allowing the steering of the machine, in the event of
accidental cutting-off of the engine or in case of failure of the main steering pump.
Its intervention is signalled by the activation of an
indicator light located on the right of the dashboard.

TO ORBITROL
TO EQUIPMENT
CONTROL VALVE
TO ORBITROL

EF

TO MAIN
PRIORITY
VALVE

EF
0.8

0.8

CF

0.8

1.0

LS

1.0

PP

0.8

EMERGENCY
STEERING
PUMP

STEERING/
BRAKES POWER
PUMP

1.5 bar

CF
PP

TO SECONDARY
PRIORITY VALVE

TANK

CAB DASHBOARD
C

STEERING
EMERGENCY
INDICATOR LIGHT

Fig. 4-7 Emergency steering diagram

4.2.4 SECONDARY PRIORITY VALVE


The secondary priority valve is equal to the main priority valve, being the "stand-by" pressure different at
4 bar 58 psi, is installed on the frame, on the right
side, under the cab.

The removal/disassembly/reassembly and installation


are the same of the main priority valve.

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4 - 10

W190

STEERING SYSTEM

4.3 POWER STEERING


Its normal function is the one of a hydraulic motor to
perform dosing operations. In case of emergency, it
is made to operate as a manual pump for manual
steering (without hydraulic power).

The power steering is composed of the controlling valve


and rotor group. The controlling valve is a rotary valve
that, with its rotation changes the oil passages, thus
actuating the steering cylinders. The rotor group is
located under the controlling valve.

4
T

LS

DANFOSS

1
2

Fig. 4-8 Power steering


1. Valve block - 2. Power steering - 3. To main and secondary priority valves (unit with emergency steering) - 4. To tank - 5.
From pump - 6. To left steering cylinder - 7. To right steering cylinder.

PT L

R
OVPL 28

OSPL 1000 LS

LS

Fig. 4-9 Hydraulic diagram

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4 - 11

STEERING SYSTEM

4.3.1 POWER STEERING


Removal
The power steering is complete with valve block (2)
that is flanged on the steering.
It is suggested to mark the sections of the steering,
so that the same position is ensured when reassembling.
Remove the securing screws and remove valve block
(2) and power steering (1).

Drain the hydraulic oil from the tank, steer fully rightward or leftward to reach the zone under the cab. Tag
and disconnect the oil pipes from valve block (2). From
the inside of the cab, remove the steering column
guard, until the steering securing screws are reached,
then remove the four screws (5).
Remove the steering complete with valve block.

3
5

Fig. 4-10

Steering column complete

1. Power steering - 2. Valve block - 3. Steering column - 4. Steering wheel - 5. Power steering securing screws - 6. Valve
block securing screws.
Note -

65 Nm

20 Nm

35 - 45 Nm

65 Nm 0.5

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4 - 12

STEERING SYSTEM

4.3.2 DISASSEMBLY OF POWER STEERING


Remove securing screws (22) and remove cover (19).
Remove fixed ring (17) complete with inner rotor (15).
Pullout spacer (14) and O-Ring (13).
Extract the rotor drive shaft (12).
Remove threaded bush (4) and extract ball (3) from
the check valve.
To remove the springs, it is necessary to pullout
slightly the rotary valve from the sleeve, remove blade
springs (9), extract the valve pushing it out from the
sleeve, paying attention to rotate it slowly to facilitate
the operation.
Check carefully all the components.
Check that the sliding surfaces are free from scratches
and are not deformed.
Replace all damaged parts.
Replace all seals and possibly the blade springs as
well.
It is important that the assembly of the parts making
the power steering done with the maximum cleanliness.
Lubricate freely the parts with hydraulic oil.
Check that all oil ducts are unclogged.
Extract sleeve (11) complete with rotary valve (8).
Extract thrust bearing (6) and the sleeve return spring
retaining ring.
Disassemble the rotary valve from the sleeve, removing drive pin (10).

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W190

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W190

4 - 13

STEERING SYSTEM

23

24

7
3

10
11
12
9

13
14
15

16

17
19
18

20
21
22

W190-4R001

Fig. 4-11

Power steering parts

1. Seal - 2. Power steering body - 3. Check valve ball - 4. Treaded bush - 5. Seal - 6. Thrust bearing parts - 7. Ring
8. Rotary valve - 9. Sleeve (11) return springs - 10. Sleeve (11) and shaft (12) drive pin - 11. Valve (8) seat sleeve
12. Rotor (17) drive shaft - 13. O-Ring - 14. Ring - 15. Rotor - 16. O-Ring
17. Rotor (15) fixed ring - 18. O-Ring - 19. Cover - 20. Washers - 21. Screw with pin - 22. Cover (19) securing screws
23. Pressure relief valve - 24. Pressure relief valve seat.

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4 - 14

W190

STEERING SYSTEM

4.3.3 ASSEMBLY OF POWER STEERING


Install the seal in the power steering body.
Reinstall rotary valve (8) into sleeve (11) turning it
slowly while installing it.
Align the spring passage cuts and insert the springs
inside the sleeve and rotary valve.
Note In the event a tool is required to install the
springs, make it from a recessed head screw wrench
of appropriate size.
The long part of the wrench must be splined for a depth
of about 13 mm and a width of 3.2 mm.
Centre correctly the springs installed so that they result flush with the outer diameter of the sleeve.
Insert ring (7) retaining the springs.
Install pin (10) driving the sleeve/rotary valve.

Insert ball (3, Fig. 4-12) into its seat on the body and
install threaded bush (4).
To facilitate the operations to follow, before installing
the drive shaft, mark it with a sign parallel to the pin
cutting.
Install drive shaft (12) checking that the slot is inserted on the pin.
Note Mark (B) on the shaft must be parallel (C) to
the drive pin and surface (D) securing the valves block.
Arrange shoulder ring (14) with the relevant O-ring
seals.
Install fixed ring (17) complete with rotor (15).
Note Make sure that the two vanes of the rotor indicated
in the figure are parallel (A) to mark (B) made previously
on the shaft, thus to drive pin (C) and surface (D) securing
the valve block.

Install thrust bearing (6).


Insert the sleeve assembly into the orbitrol body,
making sure that all parts are free to turn.
Note During the installation of sleeve ( 11 ) in
the orbitrol body, make sure that the drive pin
remains horizontal.

Install the cover checking that the marks made prior


to the disassembly coincide.
Assemble the group tightening the screws to the torque
of 35 Nm. following the sequence indicated in
Fig. 4-12.
Note Screw w/ pin (21) must be inserted in the hole
where threaded bush (4) is.

B
C
A

B
C

7
5

Fig. 4-12

Timing of power steering

A - B - C - D. Surfaces that must result parallel among them at the reassembly.

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W190

4 - 15

STEERING SYSTEM

23

24

7
3

10
11
12
9

13
14
15

16

17
19
18

20
21
22

W190-4R001

Fig. 4-13

Power steering parts

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4 - 16

W190

STEERING SYSTEM

4.3.4 DISASSEMBLY OF THE VALVE


BLOCK
Remove plugs (8) from the valve block as well as the
multiple safety, shockless and anti-cavitation valves
(5).

Replace the O-Rings.

Extract from the block check valves (9).

Reassemble the component parts reversing the disassembly sequence.

Lubricate all parts.

Clean accurately all the components and check that


the sliding surfaces are free from scratches.

Install the valve block assembly on the orbitrol tightening the screws to a torque of 65 Nm.

1
C1

3
8
10
6

5
6
7
8
1

Fig. 4-14 Exploded view of the valve block


1 and 2. O-Rings - 3. Dowel - 4. Securing screws - 5. Multiple safety valves - 6. Springs - 7. O-Ring - 8. Plugs - 9. Check
valves - 10. Valve body.

Note -

37 - 43 Nm

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4 - 17

STEERING SYSTEM

4.4 TEST OF THE STEERING SYSTEM


The steering cylinder control circuit is powered by a
hydraulic pump in two sections.
One section of the pump powers, through a priority
valve, the steering system.
The other section powers the brakes system and the
pilot valve.

The pump sucks oil from the hydraulic tank and forwards it, with the steering inoperative, to the equipment control valve. The oil flow in the delivery circuit
is proportional to the performance required.
A main pressure relief valve set at 210 bar (3045 psi)
regulates the maximum pressure of the system, discharging the excess pressure.

Fig. 4-15 Installation of the steering pump on the transmission-torque converter group
1. Steering pump - 2. Brakes/pilot system pump - 3. Torque converter.
Note:

Mating surfaces:
LOCTITE 509

Steering section

Designation:
Type:
Drive:
Maximum delivery:
Maximum pressure:
Engine/pump speed ratio:

Kayaba KFP5163
gear
gear
162 lt/min (35.63 US/gal)
210 bar, 2300 rpm (3045 psi)
0.894 : 1

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4 - 18

W190

STEERING SYSTEM

Delivery side

Suction side

Delivery

IN

Suction

Rotation direction

Fig. 4-16 Steering and brakes/pilot valve pump

1. Front pump (steering) - 2. Rear pump (brakes-power system)

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W190

12

15

Section B-B

Fig. 4-17

4 - 19

STEERING SYSTEM

14

A
10 11

13

13

10

14

15

Section A-A

Steering pump section

1. Mounting flange - 2. Driven gear - 3. Intermediate plate - 4. Centering dowel - 5. Covering plate - 6. Adapter - 7. Brakes/
power system pump (see fig. 4.11) - 8. Seals - 9. Washer- 10. Plate - 11. Driving gear - 12. Coupling sleeve - 13. Plate 14. Back-up ring - 15. Seal.

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4 - 20

STEERING SYSTEM

W190

4.5 EMERGENCY STEERING PUMP


Designation: ......................................................................................................... ZF driven by the transmission
Type: ............................................................................................................................. bi-directional, gear type
Drive: .......................................................................................................................................................... gear
Delivery: ...................................................................................................................................... 32 cu cm /turn

2
1

Fig. 4-18

Removal

Reinstallation

Disconnect the hydraulic pipes from emergency steering pump (2) remove securing screws (1) and remove
the pump.
Recover spacer (4) and O-Ring (3).

Position correctly spacer (4) and O-Ring (3) then install steering emergency pump (2).
Tighten securing screws (1) and connect the hydraulic pipes.

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W190

4 - 21

STEERING SYSTEM

4.6 STEERING CYLINDERS


The two, double acting, steering cylinders, with rod
and cylinder sleeve mounted, respectively, to the front
and rear module of the frame.
The loader is steered by extracting or retracting the
rod.
Specifications:
Cylinder bore ................................... 80 mm (3.14 in)
Rod diameter ................................... 45 mm (1.77 in)
Piston stroke ............... 422 2 mm (1661 0.07 in)
Weight ............................................... 31 kg (68 lbs)

4.6.1 REMOVAL
Proceed as follows:
- drain the oil from the equipment reservoir;
- disconnect the oil pipes;
- from the rod side, loosen the retaining plate securing screw and extract the pin;
- disconnect the greasing pipe of the pivot pin from
the left cylinder;
- from the bottom side, loosen the retaining plate securing screw and extract the pin;
- remove the cylinder assembly.

10

11

12

13

17

14

Section

15

16

Fig. 4-19 Steering cylinder components


Notes - 1

451 Nm (333 ft-lbs)

1030 Nm (760 ft-lbs)

16 Nm (11.8 ft-lbs)

Pressure pick-up (PT 1/8)


Threaded area: LOCTITE 767

1. Cylinder head - 2. O-Ring - 3. Back-up ring - 4. O-Ring - 5. Mud scraper - 6. Bushing - 7. Seal - 8. Cylinder rod 9. Cylinder sleeve - 10. Piston seal - 11. O-Ring - 12. Piston - 13. Stop screw - 14. Steel ball - 15. Ball bushing - 16. Snap
ring - 17. Pressure pick-up plug.

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STEERING SYSTEM

W190

4.6.2 DISASSEMBLY AND REASSEMBLY

4.6.3 INSTALLATION

Loosen cylinder head (1) and extract rod (8) complete


with piston (12).

Reinstall the cylinder on the machine, reversing the


removal sequence.

Loosen the piston securing screw (13), then loosen it


from the cylinder rod (8).

After starting the engine, check, with repeated movements of the steering, that the cylinder rod does not
show signs of leakages.

In the event the ball bushing has an excessive play,


replace it as follows:
- remove retaining snap rings (16);
- using a punch or a press, extract bushing (15) from
its seat, taking care to push on the outer side of the
bushing only.

Handle all components with great care.


Do not place hands and fingers between parts. Wear
glasses, gloves and safety shoes.

Check that the rod is free from signs of denting, burring or wear.
Check, using a ruler or placing it on a flat surface,
that the rod is not bent.
Inspect the inside of the cylinder; in the case of
scratches or wear, it must be replaced.
Replace all damaged components.
Reassemble the cylinders, reversing the disassembly phases considering the following:
- lubricate all parts appropriately;
- install new seals, ensuring the correct position and
direction;
- tighten the piston to torque 2 ;
- tighten screw (13) to torque 3 and stake;
- tighten front head (1) to torque 1 .

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Copyright New Holland

SECTION 5

BUCKET BOOMS AND FRAME


INDEX

PARAGRAPH

SUBJECT

PAGE

5.1
5.1.1
5.1.2
5.1.3

GENERAL DESCRIPTION ......................................................................................


Bucket ....................................................................................................................
Bucket automatic positioner ....................................................................................
Setting the boom maximum height ..........................................................................

5-1
5-5
5-6
5-7

5.2
5.2.1
5.2.2

FRAME ................................................................................................................... 5-8


Frame central pivot ................................................................................................. 5-9
Removal-installation of frame central pivot ............................................................. 5-11

5.3

BUCKET STOPS .................................................................................................... 5-20

5.4

LIST OF OVERHAUL SPECIAL TOOLS ................................................................. 5-22

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W190

5-1

BUCKET BOOMS AND FRAME

5.1 GENERAL DESCRIPTION


The load handling system is composed of:
- booms
- strut
- link
- bucket
- bucket cylinder
- boom cylinders
- pins

Linkage
Bucket shape
Bucket capacity:
Heaped
Struck
Bucket positioner
Boom kick-out
Weight:
Booms
Strut
Link
DEB bucket (without cutting edge)

The bucket positioner device and the boom kick-out


ensure an optimised efficiency of the equipment.
All pivot pins of the handling system have dust seals
to prevent the entry of debris.
The three bucket pivot pins and the lower strut hinging pin are equipped with O-rings. All pivot pins are
mounted with securing screws.
For the part relative to bucket and boom cylinders,
please refer to Section 6 (Hydraulic system).

Zed
DEB, general purpose
3.4 cum
3.1 cum
Mounted (proximity type)
Mounted (proximity type)
1100 kg (2420 lbs)
275 kg (606 lbs)
58 kg (128 lbs)
1275 kg (2810 lbs)

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5-2

W190

BUCKET BOOMS AND FRAME

6
5

11

7
7

12
12

11
9

10

10
Detail of typical pin

Bucket pins

Fig. 5-1 Booms, strut and bucket

Note Apply grease to the inner surfaces of the bushings and dust seals, prior to inserting the pins. Apply rust
preventing oil to the inner surfaces of the bosses.

1. Bucket - 2. Strut - 3. Boom - 4. Bucket cylinder - 5. Link - 6. Boom cylinder - 7. Locking screw - 8. Dust seal - 9. Bushing 10. Pin - 11. Grease fitting - 12. O-Ring.

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W190

5-3

BUCKET BOOMS AND FRAME

Section A-A

Section B-B

Section C-C

1
1

Section D-D

Section G-G

Section E-E

Section H-H

Section F-F

Section I-I

Fig. 5-2 Booms, Strut and Bucket

Note -

Set a maximum play at 1.5 mm (0.059 in) or less.

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5-4

W190

BUCKET BOOMS AND FRAME

The 5 mm. diam. hole of the bush


must be aligned with centre line
of the link and cylinder ringes.

Section D-D

Duter lube
groove

Bush installation diagram

8 mm

Immer lube
groove

Fig. 5-3 Installation of equipment central hinging bushes


Note In the central hinging of the link (section D-D), the bushes must be oriented with the outer grooves directed
inword.

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W190

BUCKET BOOMS AND FRAME

5-5

5.1.1 BUCKET
A standard bucket, with a screw-on reversible cutting
edge, is supplied as a standard. Upon request, a
welded cutting edge and a bolted teeth version is available.

The choice of the type of bucket, as a function of the


material and the work conditions, is essential, to ensure an efficient performance

(Multiple purpose bucket with reversible cutting


edge, DEB)
Note -

1070 Nm (788 ft-lbs)

(Multiple purpose bucket with bolted teeth)


Note -

1940 Nm (1430 ft-lbs)

1070 Nm (788 ft-lbs)


2
1

Fig. 5-4 Bucket

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5-6

BUCKET BOOMS AND FRAME

W190

Removal of the bucket


Rest the bucket on the ground on a flat surface.
Position some wooden shims under the booms so
that, when the booms are separated, the position
remains unchanged, facilitating the reinstallation.
Remove the screws securing the link and boom pins,
pullout pins (1 and 2) paying attention that the grease
fittings are not damaged, recovering eventual shims in
place.

Sling a hoist to the bucket, using the two existing eyes,


then disconnect it from the booms and lift it carefully.
Reverse the operations to re-install the bucket.
1

Fig. 5-5

5.1.2 BUCKET AUTOMATIC POSITIONER


WARNING
Mark

Fig. 5-6

Fig. 5-7

Before setting the bucket automatic positioner,


engage the parking brake. Do not allow any bystander to linger near the loader.
The tilt circuit is equipped with a bucket automatic
positioner.
This device has the purpose of returning automatically
the bucket to a horizontal position, every time, after
dumping the material, the machine is going to return to
a new work cycle.
For this purpose, when the bucket is dumped forward,
move the bucket tilt lever backward, beyond strokeend (to the left in case of a single lever control). The
lever is held by an appropriate detent and returns by
itself into neutral position once the bucket reaches the
pre-established position, being when the two red mark
overlap (horizontal bucket). The horizontal positioning
of the bucket is set as follows:
start the engine and position the bucket parallel to
the ground;
cut-off the engine;
loosen nut A;
slide the device in the slot until the final end of rod
B is aligned with sensor C.
tighten nut A.
The maximum actuating distance of device C indicated
with respect to rod B is 5 mm (0.20 in). Comply with this
tolerance, using nut A as required.

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W190

5-7

BUCKET BOOMS AND FRAME

5.1.3 SETTING THE BOOM MAXIMUM


HEIGHT
Sensor "A" provides the automatic detent of the boom
raise control lever, with the subsequent return to
neutral of the same lever each time the booms reach
maximum height.
The maximum raise of the booms is set proceeding as
follows:
Start the engine and raise the booms to the highest
position desired;
Cut-off the engine;
Loosen securing screws "B" and move plate "C" as
required;
Fasten the securing screws;
Start the engine and operate the boom raising a few
times to verify the correct positioning.
The maximum actuating distance of the device with
respect to plate "E" is 5 mm (0.20 in). Comply with this
tolerance, positioning sensor "A" using the securing
nuts.

A
C

Fig. 5-8

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5-8

W190

BUCKET BOOMS AND FRAME

5.2 FRAME
The frame is of a type with welded steel plates with
two modules pivoting between them, and the equipment mounted on the front module and the enginetransmission on the rear one.

WARNING
Do not attempt any modification on the ROPS (Roll
over protection structure) if mounted, without the
previous authorisation by the Manufacturer. In the
event the ROPS is damaged or deformed as a
consequence of a roll over or a collision, it is
recommended that it is replaced with a new one,
since a damaged or deformed ROPS has a low
structural strength.

20
21
19
22

6
4
2
5
1
14
18
5
3
4
13

15

11
9

22
23
32
24
25

17
12
8

26
28

29
31
30
26
27

14
12
10
11

Fig. 5-9 Frame

1. Bearing - 2. Plug - 3. Cover - 4. Seal - 5. Shim - 6. Valve - 7. Split pin - 8. Bearing - 9. Plug - 10. Plug - 11. Seal - 12. Shim13. Screw 16x120 - 14. Grease fitting - 15. Front frame - 16. Pin - 17. Shim - 18. Shim - 19. Pin - 20. Screw 16x25 - 21. Flat
washer - 22. Bush - 23. Pin - 24. Bush - 25. Bush - 26. Flat washer 16x30x3 - 27. Screw 16x55 - 28. Screw 16x100 - 29. Shim 30. Flat washer - 31. Shim - 32. Rear frame

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Copyright New Holland

W190

5-9

BUCKET BOOMS AND FRAME

Fig. 5-10 Rear ballast installation

Note -

1510 Nm

Ballast weight: 1965 kg (4332 lbs)

5.2.1 FRAME CENTRAL PIVOT


The loader is of an articulated frames type: the front
frame is connected to the rear frame by two hinging
pins around which the loader is pivoting, when steering.

WARNING
The steering action could crush the body between
the two modules (front and rear) of the frame.
Block the articulation with the safety bar, prior to
transporting the machine or performing repair
interventions. On the other hand, relocate the
safety bar in its original position, prior to starting
operating the machine.

(With loader under repairs)

Fig. 5-11

Safety bar

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5 - 10

W190

BUCKET BOOMS AND FRAME

(Upper hinging)

6
7

1
2

13

(Lower hinging)

14

15
6
16
10

17

11

18

12
2

Fig. 5-12 Central hinging

Note -

88 Nm

Threaded area: LOCTITE 262

215 Nm

Ring outer area: LOCTITE 262

1. Cover - 2. Dust seal - 3. Bushing - 4. Cover - 5. Shim - 6. Grease fitting - 7. Bearing - 8. Pin - 9. Bushing - 10. Cover 11. Shim - 12. Washer - 13. Pin - 14. Cover - 15. Shim - 16. Bearing - 17. Dust seal - 18. Bushing

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W190

5 - 11

BUCKET BOOMS AND FRAME

5.2.2 REMOVAL-INSTALLATION OF
FRAME CENTRAL PIVOT
PREPARATION
Prior to removing the central pivot:
remove all the parts connected between the front
and rear frame, precisely:

propeller shaft;
steering cylinders;
hydraulic pipes;
brake pipes;
electric wires;
ATTENTION

Do not work under or near attachments of the


machine or any part of them that are not adequately
supported or blocked.
Insert under the front and rear frame adequate resting
supports providing conditions of stability and safety
during the disassembly phase.
W190-5R001

Fig. 5-13
ATTENTION
Do not allow unauthorised personnel to repair or
to maintain this machine. Read and head carefully
the Operation andMaintenance InstructionManual
prior to starting, operating, maintaining, refuelling
or repairing this machine.

DISASSEMBLY
2

Remove spacer (1) of the central pivot lower pin by


removing securing screws (2).

W190-5R002

Fig. 5-14
ATTENTION
Handle all parts with great care. Do not place hands
or fingers between pieces.Wear authorised
protective clothing/devices such as glasses, gloves
and safety shoes.

Recover shims (3).

3
W190-5R003

Fig. 5-15
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5 - 12

W190

BUCKET BOOMS AND FRAME

Then extract frame central pivot lover pin (1) using a


punch and a mallet.
1

W190-5R004

Fig. 5-16
Remove locking screw (2) complete with washer (3)
from flange (4) of the upper pin.

W190-5R005

Fig. 5-17
Extract frame central pivot upper pin (5).

W190-5R006

ATTENTION

Fig. 5-18

Do not work under or near attachments of the


machine or any part of them that are not adequately
supported or blocked.
Lift and handle all heavymaterials witha
liftingdevice with appropriate capacity. Make sure
that all items are properly secured by appropriate
slings and hooks. Use the lifting eyes provided
for this purpose. Beware of persons standing near
the load to be lifted.
Use a hoist and lifting chains to sling and extract the
front frame to separate it from the rear frame.

W190-5R007

Fig. 5-19

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W190

5 - 13

BUCKET BOOMS AND FRAME

Remove positioning bush (1) of the pivot pin from the


front frame lower support.

W190-5R008

Fig. 5-20
Remove covers (2) by removing screws (3).
3

2
W190-5R009

Fig. 5-21
Remove shims (4).

W190-5R010

Fig. 5-22
Extract the two seals (5) from lower pivot covers (2)
and proceed in the same manner for the upper pivot
seals.
2

5
W190-5R011

Fig. 5-23
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5 - 14

W190

BUCKET BOOMS AND FRAME

Use a punch of adequate dimensions to extract the


bearings pack assembly from the lower pin pivot seat.
Proceed in the same manner for the removal of the
bearing pack from the upper pivot.

W190-5R012

Fig. 5-24
REASSEMBLY
LOWER HINGING
Prior to re-assembly, clean thoroughly all parts. Check
the wear conditions of the bearings and replace them
if required.

2
1

Lubricate adequately the seats of front frame bearing


support (1) and the seats of the rear frame pins seats.
Install outer race (2) of the lower bearing.
W190-5R013

Fig. 5-25
ATTENTION
Handle all parts with great care. Do not place hands
or fingers between pieces.Wear authorised
protective clothing/devices such as glasses, gloves
and safety shoes.

Lubricate lower bearing (3).

W190-5R014

Fig. 5-26
ATTENTION
Do not allow unauthorised personnel to repair or
to maintain this machine. Read and head carefully
the Operation andMaintenance InstructionManual
prior to starting, operating, maintaining, refuelling
or repairing this machine.

Install bearing (3) and spacer (4).


W190-5R015

Fig. 5-27
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W190

5 - 15

BUCKET BOOMS AND FRAME

Install upper bearing (1).


1

W190-5R016

Fig. 5-28
Install outer race (2) of the upper bearing.
2

W190-5R017

Fig. 5-29
Apply LOCTITE 262 in the dust seal seat of lower
cover (3).

W190-5R018

Fig. 5-30
Place dust seal (4) on cover (3).
3
4

W190-5R019

Fig. 5-31
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5 - 16

W190

BUCKET BOOMS AND FRAME

Use punch (1) 380002594 to press dust seal (2) into


the relevant mounting seat of cover (3).

1
3

2
W190-5R020

Fig. 5-32
Proceed in the same manner for the installation of
dust seal (4) on upper cover (5).

4
W190-5R021

Fig. 5-33
Install the two covers and close the bearing pack
tightening the two screws to a torque of 88 Nm.
Measure the gap existing between upper cover (5)
and frame (6). The shim pack must be equivalent to
the gap measured + 0.2 mm, where 0.2 mm represents
the right tolerance for the correct rolling of the bearings.

6
W190-5R022

Fig. 5-34
Insert shims (7) corresponding to the value identified.

W190-5R023

Fig. 5-35
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W190

5 - 17

BUCKET BOOMS AND FRAME

Reinstall the covers using six securing screws (1) after


previously applying LOCTITE 262 on the threaded part.
Use a torque wrench to tighten the screws o a torque
of 88 Nm.

W190-5R024

Fig. 5-36
Install grease nipple (2).
Proceed in the same manner for the installation
of the bearings on the upper pivot.

W190-5R025

Fig. 5-37
Insert positioning bush (3) on the front frame lower
support.

ATTENTION

W190-5R026

Fig. 5-38

Do not work under or near attachments of the


machine or any part of them that are not adequately
supported or blocked.
Lift and handle all heavymaterials witha
liftingdevice with appropriate capacity. Make sure
that all items are properly secured by appropriate
slings and hooks. Use the lifting eyes provided
for this purpose. Beware of persons standing near
the load to be lifted.
Using a host and lifting chains, hook and assemble
the front frame to the rear frame.

W190-5R007

Fig. 5-39
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5 - 18

W190

BUCKET BOOMS AND FRAME

Insert frame central pivot upper pin (1) using a mallet.

ATTENTION
1

Handle all parts with great care. Do not place hands


or fingers between pieces.Wear authorised
protective clothing/devices such as glasses,
gloves and safety shoes.

W190-5R027

Fig. 5-40
Insert lower pin (2).

W190-5R028

Fig. 5-41
Lock upper pivot pin (1) using screw (3) complete with
washer (4).

W190-5R029

Fig. 5-42
Use a wrench drive to install two screws, lower pivot
pin locking plate (5) and measure the gap present
between plate (5) and the face of lower frame (6).

5
W190-5R030

Fig. 5-43
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W190

5 - 19

BUCKET BOOMS AND FRAME

Insert shims (1) corresponding to the value identified.

W190-5R031

Fig. 5-44
Reinstall plate (2) complete with shims using six
screws (3) tightened by a torque wrench to a torque of
88 Nm. Tighten the three screws (4) to a torque of
215 Nm.

4
3

W190-5R032

Fig. 5-45

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5 - 20

BUCKET BOOMS AND FRAME

W190

5.3 BUCKET STOPS

580

30

MAX LENGHTH -5 mm

Fig. 5-46

Set lower bucket hinging pin axis at 580 mm (22.82 in) from ground.
Extend bucket cylinder to its max. position and then retract it by 5 mm.
Weld the two upper abutting end plugs "A" to the bucket. Plug thickness shall be equal to the span between boom
and bucket.

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W190

5 - 21

BUCKET BOOMS AND FRAME

20

C
B

Fig. 5-47

Set booms to max. height.


Weld the two lower abutting end plugs "B" to the bucket so that with completely tilted bucket, "C" span is equal
to 2 mm (0.07 in) max.

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Copyright New Holland

5 - 22

BUCKET BOOMS AND FRAME

5.4 LIST OF OVERHAUL SPECIAL TOOLS


TOOL NUMBER

DESIGNATION

380002594

Punch dust seal

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

SECTION 6

EQUIPMENT HYDRAULIC SYSTEM


INDEX

PARAGRAPH

SUBJECT

PAGE

6.1
6.1.1

GENERAL DESCRIPTION ...................................................................................... 6-2


Hydraulic system diagram ....................................................................................... 6-3

6.2
6.2.1

HYDRAULIC SYSTEM PUMP ................................................................................ 6-5


Inspection and repair of equipment pump ................................................................ 6-7

6.3
6.3.1
6.3.2
6.3.3

EQUIPMENT CONTROL VALVE ............................................................................


General description .................................................................................................
Main pressure relief valve .......................................................................................
Safety and anti-cavitation valves ............................................................................

6.4
6.4.1
6.4.2

CONTROL VALVE CONTROLS .............................................................................. 6-13


Control valve hydraulic control ................................................................................ 6-15
Supplementary hydraulic function (variant) .............................................................. 6-18

6.5

HYDRAULIC OIL RESERVOIR ............................................................................... 6-20

6.6
6.6.1
6.6.2

CYLINDERS ........................................................................................................... 6-21


Booms cylinders ..................................................................................................... 6-21
Bucket tilt cylinder .................................................................................................. 6-22

6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6

L.T.S. ANTI-PITCHING SYSTEM (Variant) .............................................................


Description ..............................................................................................................
Discharge of the accumulators ................................................................................
L.T.S. hydraulic diagram ..........................................................................................
Functional tests of L.T.S. system ............................................................................
Test of L.T.S. accumulator precharge .....................................................................
Instruction for the resetting of accumulator precharge .............................................

6.8
6.8.1

TROUBLESHOOTING ............................................................................................ 6-30


Troubleshooting using the "ELECTRONIC SERVICE TOOL" device. ...................... 6-30

6.9

TOOLING ................................................................................................................ 6-31

6-9
6-9
6-11
6-12

6-23
6-23
6-23
6-25
6-26
6-27
6-28

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Copyright New Holland

W190

EQUIPMENT HYDRAULIC SYSTEM

6-1

Equipment pump

Hydraulic oil
tank

Main hydraulic
circuit
Bucket dumping
cylinder

Equipment
control valve

Right boom
cylinder

Left boom cylinder

Fig. 6-1 Equipment hydraulic system

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Copyright New Holland

6-2

EQUIPMENT HYDRAULIC SYSTEM

W190

6.1 GENERAL DESCRIPTION


The configuration of the hydraulic system is as follows: A hydraulic oil tank with a 97 lt (25.62 US gal)
capacity (capacity of system 135 lt (35.6 US gal))
mounted centrally on the right of the loader, complete
with filter and by-pass valve set at 1 bar (14.50 psi),
located on the return circuit from the actuators.
A hydraulic pump with discharge valve mounted on
the transmission housing driven by the gear mounted
on the torque converter pump wheel.
An equipment monobloc control valve with two sections receiving the oil from the pump, with a main
pressure relief valve set at 210 bar (3045 psi).
The control valve has two sections in series, controlling two circuits respectively: bucket rollback/dumping and boom raising/lowering.
Each one of the two circuits is equipped with safety
and anti-cavitation valves preventing dangerous pressure peaks that could overload pipes and cylinders.
Each section has a spool hydraulically piloted by a
power assisted pilot valve. The control valve piloting
system operates at a pressure of about 30 bar
(435 psi) and it is connected to the brakes system.
The pilot valve can by hydraulically cut-off by a threeway stop valve so that accidental movements of the
levers are not causing undesired movements of the
equipment.

The equipment control valve is connected the steering circuit. The oil in excess coming from the steering
pump is directed, when the steering is inoperative, to
the equipment circuit by the main priority valve. Also,
the circuit includes, upon request, a system reducing
the stress caused by the travelling of the machine on
rough terrain with a loaded bucket, designated as
L.T.S. (Load Travel Stabiliser).
I fact it is known that when travelling on rough ground,
the bucket load causes a disturbing pitching of the
machine, influencing the stability of the load and of
the loader besides the discomfort of the operator.
In this instance, a large hydraulic accumulator
preloaded with nitrogen, is capable of absorbing the
dynamic loads, is connected to the boom cylinders
through a valve block.
Once the speed of 7 kph (4.35 mph) is exceeded, a
solenoid valve automatically actuates the circuit, connecting the cylinder chambers with the accumulator,
providing the damping action.
A sequence valve set at 120 bar (1740 psi) protects
the accumulator from pressure peaks.

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W190
ATTACHMENT

EQUIPMENT HYDRAULIC SYSTEM


BUCKET CYLINDER

BOOM CYLINDERS

6-3

6.1.1 HYDRAULIC SYSTEM DIAGRAM

7
4
B

A
T

6
Y

A1

X2

B2
A

A2

274 bar

Pb3

MX MA

Pa3

B3
A3

X1

B1

230 bar

B2

186 bar

A2
Pb2

Pa2
A3

P1

T1

210 bar

B1

B3

175 bar

V = 0,71
Po = 19 bar

175 bar

A1
Pa1

Pb1

30 bar

PV

P2

T2

10

Implement

Q = 162 1/ min

Brake / Manipulator / Orbitrol


Q = 32l / min.

Q = 162 1/ min
Steering / implement

VPP

12

Engine rated speed : 2175 rpm


Engine / Pump ratio : 0,894
Pump rated speed : 2300 rpm

63cc/rev. 13cc/rev.

172
bar
63cc/rev.

1 bar

11

Fig. 6-2

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
B.
F.
M.
S.
VP.

Auxiliary application
Bucket cylinder
Boom cylinder
Load Travel Stabiliser (LTS) valve
Three-spool equipment control valve
Pilot valve
Pilot valve cut-off valve
Pilot valve - brakes filter
Pilot system pressure relief valve
Heat exchanger
Hydraulic oil tank
Equipment pump
From Fan Drive system valve block
To brake pedal
From brake pedal
From steering main priority valve
To steering main priority valve inlet

Copyright New Holland

6-4

EQUIPMENT HYDRAULIC SYSTEM

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

W190

EQUIPMENT HYDRAULIC SYSTEM

6-5

6.2 HYDRAULIC SYSTEM PUMP


The hydraulic cylinder control is powered by a hydraulic pump sucking oil from the hydraulic tank and
forwarding it to the equipment control valve.
The pressure to be established in the delivery system is proportional to the performance required and it
is in any case, limited by the pressure relief valve.

This valve set at 210 bar (3045 psi) regulates the maximum pressure in the system, discharging the pressure in excess through a quick discharge valve installed at the output of the equipment pump.

Specifications of equipment pump


Designation: ................................................................................................... KayabaKFP5163AY-APNH
Type: ................................................................................................................ gear with discharge valve
Drive: ................................................................................................................................................ gear
Delivery at 2300 rpm: .................................................... 162 lt/min (35.62 USG/min) at 170 bar (2465 psi)
Maximum pressure at nominal speed: .......................................................................... 210 bar (3045 psi)
Engine/pump speed ratio: ...........................................................................................................0.894 : 1
Pump rotation ranges: ...................................................................................................... 600 2500 rpm
Weight ........................................................................................................................ 28.7 kg (63.27 lbs)

5
4
A

1
2

3
B

Fig. 6-3 Installation of pump on transmission-torque converter group

A. From hydraulic oil tank (suction) - B. To equipment control valve (delivery) - 1. Equipment pump - 2. Quick discharge
pump - 3. Transmission - 4. Steering - brakes pump - 5. O-Ring.

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6-6

EQUIPMENT HYDRAULIC SYSTEM

36

35 37

38

14

W190

9 5 1

13

11

B A
D

B A
6

Detail C

10

Detail D

10

12

26 30 29 28 27 24 30 25 30
32
23

20
22

22

31
17 19 21

34

33 15 16 18
Section B - B

Longitudinal section of
discharge valve

Section A - A

172 Bar

Fig. 6-4 Equipment pump

1. Gear plate - 2. Drive gear - 3. Driven gear - 4. Mounting flange - 5. Plate - 6. Seal - 7. Retainer - 8. Plate - 9. Dowel 10. O-Ring (high temperature) - 11. Seal (high temperature) - 12. Circlip - 13. Washer - 14. Pump cover - 15. Plunger 16. Check valve - 17. Plug - 18. Circlip - 19. Spring - 20. Plug - 21. O-Ring - 22. O-Ring - 23. Nut - 24. Setting screw 25. Nut - 26. Plug - 27. Spring guide - 28. Spring - 29. Push rod - 30. O-Ring - 31. Plug - 32. O-Ring - 33. Plug - 34. O-Ring 35. Screw (L=85.8 mm (3.37 in)) - 36. Screw (L=132 mm (5.19)) - 37. Screw (L=188.5 mm (7.42 in)) - 38. Washer.

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W190

EQUIPMENT HYDRAULIC SYSTEM

6.2.1 INSPECTION AND REPAIR OF EQUIPMENT PUMP

Suction
chamber

When disassembling, mark all components so that


they can be re-installed in the correct position.
After cleaning each individual item, inspect all the parts
of the pump.
1) Gear plate
One of the methods to obtain a better volumetric
efficiency of a gear pump is the design allowing
the end of the teeth to stay in contact with the
inner wall of the chamber containing the gear itself.
Consequently, once the pump starts running, marks
left by the gear teeth are shown around the suction port (fig. 6-5).
The contact mark is normal as long as it is less
than 1/2 the inner circumference of the gear cavity.
Dimension a of the mark depth (fig. 6-6) is normal
if it as about 0.05 mm (0.00196 in). When dimension a exceeds 0.15 mm (0.00589 in) also the shaft
and bearings can wear out. Thus, these items as
well, must be thoroughly checked.
If a is 0.15 mm (0.00589 in), replace the pump
with a new one.

Contact
mark

Fig. 6-6 Dimension of mark depth

2) Driving and driven gear


In case the shaft or the gear surface shows roughness felt by running a finger nail, or in case the
surface of the teeth shows excessive wear zones,
it is necessary to replace the item.

Suction
chamber

6-7

Contact
mark

Fig. 6-5 Gear intermediate plate

Fig. 6-7

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Copyright New Holland

6-8

EQUIPMENT HYDRAULIC SYSTEM

3) Pressure plate
As shown in fig. 6-8, the pressure plate, under
normal conditions, shows smoothed irregularities
on the copper alloy side of the surface touching
the gear.
If during the disassembly operation, the following
situation is found, replace the part with a new one:

W190

Sliding
bearing

In case the level of roughness found shows


several scratches that can be felt by a finger
nail.
Suction side

Irregularities

Discharge
side

Fig. 6-9 Irregularities on the bearings


Suction side

Irregularities

Fig. 6-8 Irregularities on the plate

4) Mounting flange (1) and covering plate (8)


(fig. 6-7)
Regarding the mounting flange and the cover plate,
check to find out it there is an eventual wear in the
bearing zone (fig. 6-9).
If the teflon film is worn-out and the red surface of
the copper base metal is showing for an arc larger
than 150 along the inner circumference of the
bearings, change the part.

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W190

EQUIPMENT HYDRAULIC SYSTEM

6-9

6.3 EQUIPMENT CONTROL VALVE


6.3.1 GENERAL DESCRIPTION
The oil ducts inside it are of a series type, so that the
bucket function has priority over the booms function.
Thus, pressurised oil reaches the booms port only
when the bucket spool is in neutral.
The control valve is hydraulically actuated by the pilot valve located in the cab; it is equipped with a main
pressure relief valve and three safety and anti-cavitation valves.

When the pressure in the system exceeds the value


of 210 bar (3045 psi), the main pressure relief valve
discharges oil to protect cylinders and pipes.
The safety and anti-cavitation valves protect the relevant circuits from sudden preassure peaks due to
mechanical loads on the equipment capable of causing a pressure increase beyond the pre-set value, and
they are mounted on the single spools of the control
valve.

SPECIFICATIONS OF EQUIPMENT 2-SPOOL CONTROL VALVE


Model
Type
Spool sequence
Setting of main valve
Setting of secondary valve (A1)
Setting of secondary valve (B1)
Setting of secondary valve (A2)
Delivery
Weight

Kayaba KVML-270-2
series, hydraulically piloted
P BUCKET BOOMS T
210 bar 5 (3045 psi 72)
230 bar 5 (3336 psi 72)
186 bar 5 (2698 psi 72)
274 bar 5 (3974 psi 72)
270 l/min (59.39 USG/min)
54 kg (119 lbs)

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Copyright New Holland

6 - 10

EQUIPMENT HYDRAULIC SYSTEM

1
2

View from C

Fig. 6-10
1.
2.
3.
4.

Equipment 2 spool control valve

SAFETY AND ANTI-CAVITATION VALVE


(186 bar 5) (2698 psi 72)
MAIN PRESSURE RELIEF VALVE
(210 bar 5) (3045 psi 72)
SAFETY AND ANTI-CAVITATION VALVE
(274 bar 5) (3974 psi 72)
SAFETY AND ANTI-CAVITATION VALVE
(230 bar 5) (3336 psi 72)

A1 - B1 BUCKET SPOOL SECTION


A2 - B2 BOOMS SPOOL SECTION
P1.
OIL INLET (FROM PUMP)
OIL INLET (FROM STEERING VALVE)
P2.
T1.
DISCHARGE
DISCHARGE (FROM STEERING VALVE)
T2.

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W190

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W190

EQUIPMENT HYDRAULIC SYSTEM

6 - 11

6.3.2 MAIN PRESSURE RELIEF VALVE


The main pressure relief valve is located in the inlet
section, between the neutral duct and the low pressure duct (discharge duct).

Operation

b) Operation (A)
When the pressure in neutral duct (HP) increases
and exceeds the pressure setting of the main relief valve piloted valve (5) opens. Pressurised oil,
discharged by the pilot valve, enters low pressure
duct (LP), flowing through sleeve (4) and valve
seat (6).

a) At rest
Oil at the delivery pressure in neutral duct (HP)
flows through orifice (2) of main valve (1) filling
inner cavity (3). Because of the surface difference
on which the pressure actuates, main valve (1)
stays closed in its seat in sleeve (4).

4
6
LP

HP
4
LP
5

LP

HP
Fig. 6-12

Operation (A)

LP

Fig. 6-11

At rest

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6 - 12

EQUIPMENT HYDRAULIC SYSTEM

c) Operation (B)

W190

Operation

When pilot valve (5) opens, the pressure in inner


cavity (3) decreases, moving main valve (1), so
that pressurized oil in neutral duct (HP) can discharge directly into low pressure duct (LP).

a) At rest
Pressurized oil, in the port connected to cylinder
(HP), flows through the orifice in piston valve (1)
and acts on the opposite surfaces of make-up valve
(2) and safety valve (3). Due to the surface difference on which the pressure works, the two valves
are kept closed, one against the other.

LP

LP
HP
HP
LP
1

Fig. 6-14

Fig. 6-13

LP

At rest

Operation (B)

b) Operation (A)

6.3.3 SAFETY AND ANTI-CAVITATION


VALVES
The safety and anti-cavitation valves are mounted in
the bucket and booms sections.
In the bucket section, a valve is located between port
(A1) connected with the cylinder (bottom side) and the
discharge duct, and a valve between port (B1) connected with the cylinder (rod side) and the discharge
duct.
The booms section is equipped with a single safety
valve, located between port (A2) connected with the
cylinders (bottom side) and the discharge duct.
The eventual auxiliary section is also equipped with
two valves configurated, respectively, between the
ports connected with the cylinder chambers and the
discharge.

When the pressure in the port connected to cylinder (HP) increases and exceeds the setting of the
safety pressure, pilot valve (4) opens.
Pressurized oil, discharged by the pilot valve, enters low pressure duct (LP) flowing through makeup valve (2) and valve seat (5).

5
LP

HP

LP
Fig. 6-15

Operation (A)

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EQUIPMENT HYDRAULIC SYSTEM

c) Operation (B)

6 - 13

e) Operation in make-up

When pilot valve (4) opens, the pressure on the


raer side of piston valve (1) decreases, moving
piston valve (1). Consequently, the orifice of piston valve (1) closes so that the pressure on the
rear side of safety valve (3) decreases further.

If the pressure at port (HP) connected to the cylinder is lower than the value in low pressure duct
(LP), being a condition for potential cavitation,
make-up valve (2) moves proportionally to the
surface difference on which a negative pressure
intervenes. Consequently, to avoid cavitations, oil
can flow from low pressure duct (LP) to port (HP)
connected to the cylinder.

LP
LP

HP
HP
1

Fig. 6-16

LP

4
LP

Operation (B)
Fig. 6-18

Operation in make-up

6.4 CONTROL VALVE CONTROLS


d) Operation (C)
The pressure acting on the opposite surfaces of
safety valve (3) are unbalanced. Due to this pressure difference, the safety valve opens so that
pressurized oil can be discharged directly from port
(HP) connected to the cylinder, to low pressure
duct (LP).

LP

The control system of the control valve is of a power


assited type with different levers for the functions:
booms lowering/raising and bucket roll-back/dumping.
The control valve spools are actuated by hydraulic
connections. The circuit pressure (30 bar) (435 psi) is
ensured by a pressure relief valve equipped with an
hydraulic accumulator.
It is possible to install, upon request, a third lever
controlling a third spool of the control valve, in case it
becomes necessary to mount a special type of equipment requiring a third hydraulic function. For this purpose, the support in the cab is arranged for receiving
a third control spool.

HP
WARNING

LP

Fig. 6-17

Operation (C)

The piloting system of the control valve is


equipped with a safety device allowing its cuttingoff. Actuate the cut-off device to lock the control
levers in neutral position when the equipment is
not in use.

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6 - 14

EQUIPMENT HYDRAULIC SYSTEM

W190

3 functions hydraulic
pilot valve
Three way valve
pilot valve cut-off

From brake
valve

Radiator

Piloting/brakes
pump

To brake
valve

Steering pump

Pilot system
pressure
regulating valve
accumulator

Brakes/pilot valve
high pressure filter

Heat
exchanger

Implement
Control valve
Third hydraulic
function lever

To reservoir
To control valve

Fig. 6-19

To control valve

Feeding
(port PV)

Equipment control valve assembly

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EQUIPMENT HYDRAULIC SYSTEM

6.4.1 CONTROL
CONTROL

VALVE

6 - 15

HYDRAULIC

Pilot valve
The pilot valve is of a modular type and is composed
of two valve assemblies connected by two screws. If
the booms or the bucket lever is actuated, the plunger
of the pilot valve moves to direct pressurised oil to
the port of the equipment control valve selected, moving the corresponding spool.

The plungers of the booms valve body and the bucket


roll-in plunger are equipped with solenoid type detents
that hold them respectively in booms max. raise, float
and bucket roll-in positions. The detent occurs when
the relevant control levers are forced full stroke. The
levers can be, in any case, disengaged at any moment.

20.5

20.5

Valve body
assembly
(for booms)

Valve body
assembly
(for bucket)

Connecting
screw

(Code)
1: Port A1 - coil side (boom raise)
2: Port A2 - coil side (bucket rollin)
3: Port B1 - coil side (float)
[3]
A2

A1

B2

B1

P
[1]

[3]
Booms

[1]

A1
B1

[2]

[2]
A2
B2

Bucket

Booms

Fig. 6-20 Pilot valve

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Bucket

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6 - 16

EQUIPMENT HYDRAULIC SYSTEM

16

W190

17

2
3
4
12

13
5

14
15

6
7
8
9

19

10
18

11

T
B2

A2

View from A

Fig. 6-21

Bucket control valve body

1. Nut - 2. Rocker arm - 3. Adjusting screw - 4. Support flange - 5. Piston - 6. Spring - 7. Cup - 8. Split pin - 9. Spring 10. Plunger - 11. Valve body - 12. Solenoid - 13. Plate - 14. Piston - 15. Guide - 16. Screw connecting upper and lower
bodies - 17. Dust boot - 18. O-Ring - 19. Electrical connection.

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EQUIPMENT HYDRAULIC SYSTEM

6 - 17

18
19

2
3

14

15
16

6
7
8
9
10

17

20

11

21

12
13
A

B1

A1
P

View from A

Fig. 6-22

Booms control valve body

1. Nut - 2. Rocker arm - 3. Adjusting screw - 4. Support flange - 5. Piston - 6. Spring guide - 7. Spring - 8. Cup - 9. Spring
support ring - 10. Split pin - 11. Spring - 12. Plunger - 13. Valve body - 14. Solenoid - 15. Plate - 16. Piston - 17. Guide 18. Screw connec. Upper and lower bodies - 19. Dust boot - 20. O-ring - 21. Electrical connections

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6 - 18

EQUIPMENT HYDRAULIC SYSTEM

W190

6.4.2 SUPPLEMENTARY
HYDRAULIC
FUNCTION (VARIANT)
The variant allows the use of a multi-purpose bucket
(4 in 1) or other attachements requiring a third hydraulic function.

A three spool equipment control valve is arranged, a


third control lever in the cab besides the hydraulic
piping.

Supplementary hydraulic
function lever

Fig. 6-23

Configuration of supplementary hydraulic function

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EQUIPMENT HYDRAULIC SYSTEM

B1
B3

Safety and pressure relief valve set


at 230 10 bar (3336 145 psi)

B2

Auxiliary section

A3

6 - 19

A2
A1

Safety and pressure relief valve set


at 230 10 bar (3336 145 psi)

Fig. 6-24

Arrangement of three section control valve for third hydraulic function

A3

A2

(3)

A1

B3

B2

(1)

B1

T
(2)

Aux. valve section


BUCKET

Fig. 6-25

BOOMS

AUX.

Three levers pilot valve

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6 - 20

EQUIPMENT HYDRAULIC SYSTEM

W190

6.5 HYDRAULIC OIL RESERVOIR


Type ................................................................................................................................................. Pressurised
Capacity of reservoir ................................................................................................................. 130 l (34.34 gal)
Setting of by-pass valve on oil filter .......................................................................................... 1 bar (14.50 psi)
Filters on return .................................................................................................................. filtering capacity 15
The reservoir contains the hydraulic oil for the main
hydraulic system, the steering system and the brakes
system.

Inside the reservoir a filter is mounted, on the oil return line, equipped with a by-pass valve that, in case
of clogging of the filtering element, discharges the oil
directly into the reservoir.

1
2
3
4
5

6
7

8
9
A
G
B

C
D

13
12
11
Fig. 6-26

Hydraulic oil reservoir

1. Oil filter cover - 2. O-ring - 3. Spring - 4. Filter holder - 5. Oil return filter - 6. Plug - 7. Introduction filter- 8. Breather pipe 9. Reservoir - 10. Oil level indicator - 11. Cover - 12. O-ring - 13. Inspection passage - A. From heat exchanger - B. From
equipment control valve - C. To steering pump - D. To equipment pump - E. To diverter valve (em.st.) - F. To emer. St. Pump

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EQUIPMENT HYDRAULIC SYSTEM

6 - 21

6.6 CYLINDERS
6.6.1 BOOMS CYLINDERS

Boom cylinder:

The two boom cylinders are double stroke type. The


cylinders are extended and retracted, respectively to
raise or lower the booms. The boom cylinder is composed of: cylinder sleeve, bottom, rod, piston and seal
pack.

Kayaba
double stroke
2
140 mm (5.5 in)
75 mm (2.9 in)
960 mm (37.79 in)
130 kg (286 lbs)

Type
Q.ty
Inner diameter of cylinder
Diameter of rod
Stroke of cylinder rod
Weight (single)

12
1

7
2

11

9-10

Fig. 6-27

Note

Boom cylinders

451 Nm

3450 Nm

57 Nm

1. Rod - 2. Sleeve - 3. Rod seal - 4. Front sleeve - 5. O-Ring - 6. Screw M20x2.5x55 - 7. Piston seals - 8. Piston - 9. Nut 10. Washer - 11. Threaded dowel - 12. Ball

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6 - 22

EQUIPMENT HYDRAULIC SYSTEM

6.6.2 BUCKET TILT CYLINDER

W190

Boom cylinder:

The bucket tilt cylinder is double stroke. Depending


upon the extension or retraction of the cylinder, the
bucket rolls-back or is dumped by the linkage made
of a strut and rod. The bucket cylinder is composed
of: cylinder sleeve, bottom, rod, piston and seal pack.

Type
Q.ty
Inner diameter of cylinder
Diameter of rod
Stroke of cylinder rod
Weight (single)

Kayaba
double stroke
1
190 mm (7.48 in)
95 mm (3.74 in)
505 mm (19.98 in)
190 kg (419 lbs)

1
2
1

7
2

11

12

9-10

Fig. 6-28

Note

Bucket cylinder

1140 Nm

13900 Nm

57 Nm

1. Rod - 2. Sleeve - 3. Rod seal - 4. Front sleeve - 5. O-Ring - 6. Screw M27x3x70 - 7. Piston seals - 8. Piston - 9. Nut 10. Washer - 11. Threaded dowel - 12. Ball

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W190

EQUIPMENT HYDRAULIC SYSTEM

6 - 23

6.7 L.T.S. ANTI-PITCHING SYSTEM (VARIANT)


6.7.1 DESCRIPTION

Positon 0 (L.T.S. OFF)

The L.T.S. (Load Travel Stabilizer) system, supplied


as an optional, ensures a better driving comfort and a
reduction of dynamic loads on the components of the
machine (frame, axles etc.) when the unit travels with
or without load.
Without the L.T.S. system, the machine is subject,
as a result of irregular terrains, to unwanted pitching,
increasing with the travel speed.
With the L.T.S. system ON, the terrain irregularities
are absorbed by the equipment. In this manner, it is
possible to exploit completely the potential of the
machine, especially on uneven terrains, without
stressing mechanical components and providing max.
comfort for the operator.

Position 1 (L.T.S. ON)


Automatic gearbox
The transmission control unit automatically engages
the L.T.S. system whenever the speed of the machine
exceeds 7 km/h (4.34 mph) and disengages it when
the speed drops, thus allowing the loading and dumping of the bucket without unwanted movements of the
boom. The indicator comes on when the system is
ON and stays out when the system is OFF.
This position is recommended for normal use of the
system.

The system includes, essentially:


- A switch (incorporating the indicator) located on the
dashboard, to activate or disactivate the system;
- A piston type accumulator (oil capacity = 5.5 Liters
(1.45 gal); gas capacity = 6 Liters (1.58 gal)
preloaded with nitrogen and connected to the boom
raise/lowering cylinders;
- A valve block controlled by a solenoid valve.

Manual gearshifting
The L.T.S. is OFF when the gearshift lever is in first
speed.
Position 2 (L.T.S. constantly ON)
This position is useful only to allow the discharge of
the accumulator in view of maintenance or repair interventions (for this purpose, it is necessary to place
the equipment control valve in float position).
This position can be used for occasional operation
only, to obtain the cushion effect at speeds below
7 km/h (4.34 mph).

WARNING

L.T.S. system ON
The system is activated by a switch (with built-indicator) located on the switch panel.

For an efficient performance of the L.T.S. system,


the boom must be free to move.
Do not use the L.T.S. system when travelling on
open roads requires the locking of the boom.

WARNING - DANGER
Prior to any maintenance intervention on the
equipment and the L.T.S. system it is required that
the accumulator is discharged to avoid the exit of
pressurised fluid.

The L.T.S. switch has three positions:

6.7.2 DISCHARGE OF THE ACCUMULATORS

Fig. 6-29

L.T.S. three position switch.

To discharge the accumulator, proceed as follows:


- start the engine at idle speed;
- place the L.T.S. switch on position 2 (the indicator
must come ON);
- position the bucket flat on the ground;
- lock the equipment control lever in "Float" position;
- waiting a few seconds in this position the accumulator is discharged.

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6 - 24

EQUIPMENT HYDRAULIC SYSTEM

W190

To L.T.S. powering relay (cab)

"Brown box"
controller

Transmission pilot valve

Transmission "Est-37"
controller

L.T.S. control switch

To transmission
"Est-37" controller

Steering valve

L.T.S. valve

Hydraulic accumulator

Fig. 6-30

Components of L.T.S. system

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EQUIPMENT HYDRAULIC SYSTEM

6 - 25

6.7.3 L.T.S. HYDRAULIC DIAGRAM

1
2

X2

B
7

X1

MX MA A

EQUIPMENT
CONTROL VALVE
T

X2

LTS VALVE
TYPE MHRSM 25 B2X/EG26C 4 M

X1
MA
MX

Fig. 6-31

L.T.S. hydraulic system diagram

1. Accumulator - 2. Solenoid valve "1" - 3. Discharge - 4. Cylinder bottom side valve - 5. Cylinder rod side valve 6. Sequence valve - 7. Pressure relief valve

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6 - 26

EQUIPMENT HYDRAULIC SYSTEM

W190

6.7.4 FUNCTIONAL TESTS OF L.T.S. SYSTEM


Testing of electrical system
Start the engine.

Raise the boom to max. height and insist in this position (valve activation) for about five seconds.

Place the L.T.S. switch on position 2; the indicator


must come ON.

Lower the bucket to the ground.

Bring the engine to medium/high speed and raise the


boom to max. height.

Engage the L.T.S. system placing the L.T.S. switch


into position 2 (the indicator must come ON).

Lower quickly the boom and stop it suddenly at


midlevel.

The bucket should raise about 200 mm (7.87 in).

The boom must oscillate before stopping and no waving movements must be felt in the cab.
Bring the engine speed back to idle and move the
L.T.S. switch to position 1.

Test of hydraulic circuit between boom cylinders,


bottom side, and accumulator
Start the engine and run it at idle speed.

The indicator must remain OFF.


Engage second speed and start the machine.
When the speed of the machine reaches 5 km/h
(3.1 mph), the indicator in the switch must come ON.
Slow down the machine and stop it; the indicator must
go OFF.

With flat bucket, raise it about 30 cm (11.81 in) from


the ground.
Lift the machine from the ground by tilting the bucket.
Move the equipment pilot valve to "Float" position so
that the machine drops to the ground.
Engage the system positioning the L.T.S. switch on
position 2 (the indicator comes ON) so as to discharge
the accumulator.
Move the pilot valve back to neutral.

Valve opening test


The scope of the test is to check the opening of valves
(4 and 5, fig. 6-48).

Roll-back the bucket: the boom should drop until touching the ground.

Start the engine and run it at idle speed.


Move the L.T.S. switch to position 2; the indicator
must come ON.
With bucket flat on the ground, move the equipment
pilot valve to "Float" position to discharge accumulator (1).
Move the pilot valve to neutral.
Switch OFF the L.T.S. system moving the switch to
position 0.

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W190

EQUIPMENT HYDRAULIC SYSTEM

6.7.5 TEST OF L.T.S. ACCUMULATOR


PRECHARGE

6 - 27

The accumulator installed on the L.T.S. anti-pitching


system is of a piston type preloaded with nitrogen.
The nominal precharge pressure is 18 bar (261 psi) at
15 C (59 F) with a 6 Ltr (1.6 gal) capacity.

Accumulator

Important A precharge of the accumulator lower


than the nominal value, can cause a defective operation of the L.T.S. anti-pitching system.
If could be useful to check yearly and when required
the nitrogen precharge. The checking operation must
be performed with the accumulator emptied of hydraulic oil.

2
Fig. 6-32
1. Protection cap - 2. Threaded plug.

WARNING
Prior to any maintenance intervention on the
equipment and the L.T.S. systems it is required
that the accumulator is discharged to avoid
pressurised fluid from escaping.

For the accumulator discharge procedure, please refer to point 6.7.2.

Check the pre-load, proceeding as follows:


1. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake
circuit.
2. Close valves (B) and (C) on the nitrogen charging
kit, refer to the illustration 6-33.

3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumulator.

Fig. 6-33 Nitrogen charging kit 380001737

5. Remove the cap from the accumulator valve stem.


6. Connect valve (F) to the accumulator valve stem.
7. Make sure that valve (D) is open.
8. Turn the stem into valve (F) and read the pressure
gauge (E).
9. The pressure must result 18 bar (261 psi). If the
pressure is too low, charge the accumulator with
dry nitrogen.

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94L95

Copyright New Holland

6 - 28

EQUIPMENT HYDRAULIC SYSTEM

W190

6.7.6 INSTRUCTIONS FOR THE RESETTING


OF ACCUMULATOR PRE-CHARGE
With tool applied to the accumulator connection proceed as explained below:

GS98N801

Fig. 6-34 Nitrogen charging kit 380001737


1. To nitrogen tank - 2. Valve A - 3. Valve B - 4. Valve D - 5. To accumulator - 6. Valve C.

WARNING
Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
WARNING
Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 18 bar
(261 psi). If the charging valve breaks away from
the accumulator, the escaping nitrogen will propel the accumulator at a dangerous rate of speed.

WARNING
Do not expose the accumulator to temperatures
above 49 C (120 F). A charged accumulator contains nitrogen compressed to 18 bar (261 psi). High
heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
Important The four valves must be in the positions
noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer
to the above illustration.
Important To help prevent equipment damage, the low
pressure gauge valve C MUST BE SHUT OFF during high
pressure (10 bar/145 psi and above) applications.

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W190

EQUIPMENT HYDRAULIC SYSTEM

6 - 29

1. Close the shutoff valve A by turning it all the way


to the left (counterclockwise), refer to the illustration on page 6-28.

10. Install the charging hose fitting onto the accumulator pressure valve (2), refer to the illustration on
page 6-27.

2. Open valve B by turning it out all the way to the left


(counterclockwise).

11. Tighten the needle valve by turning it clockwise.


Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the nitrogen
pressure level inside the accumulator, refer to illustration on page 6-28.

3. Close valve C by turning it all the way to the right


(clockwise).
4. Close the gauge valve D by turning it all the way to
the right (clockwise).
5. Connect the charging hose to the nitrogen supply
tank.
6. SLOWLY turn valve A clockwise while watching
the high pressure gauge. Stop turning valve A when
the needle on the gauge reaches 18 bar (261 psi).
Note If the needle goes over the needed pressure, quickly
open and close valve D and check the pressure setting
again.
The charging kit is now ready to be installed on the
accumulator.
7. Remove the two screws and the protection bracket
from the accumulator body.
8. Remove the valve cap from the pressure valve (1)
on the accumulator; refer to the illustration on page
6-28.
9. Back off the needle valve on the accumulator end
of the charging hose by turning it counterclockwise
to the maximum amount. This prevents nitrogen
from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve, refer to the illustration on page 6-28.

12. Open the shutoff valve A on the nitrogen supply


tank. While observing the pressure on the gauge,
slightly open the needle valve on the accumulator charge hose. By regulating the needle valve,
fill the accumulator to 18 bar (261 psi). Close the
needle valve. Close the shutoff valve A on the
nitrogen supply tank.
13. Close valve B by turning to the right (clockwise).
After a few minutes, check the accumulator for
leakage.
14. Back off the needle valve on the accumulator end
of the charging hose by turning it counterclockwise
the maximum amount. This will prevent nitrogen
from escaping from the accumulator as the hose
is removed. Remove the charging hose from the
accumulator pressure valve (2), refer to the illustration on page 6-27.
15. Install the valve cap onto the pressure valve (1)
on the accumulator.
16. Install the protection bracket on the pressure relief
valve using the two screws.
17. Remove the charging hose from the nitrogen supply tank, refer to the illustration on page 6-28.

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6 - 30

EQUIPMENT HYDRAULIC SYSTEM

W190

6.8 TROUBLESHOOTING
A series of pressure pick-ups with J.I.C. 37 7/16-20
joint is located under the panel indicated in the figure
on the side.
The pressure measurement is done on the following
circuits:
- front and rear service brakes
- boom cylinders circuit
- brakes piloting-pilot valve circuit
- oil outlet from torque converter
- forward (FWD) clutch transmission circuit
- reverse (REV) clutch transmission circuit
- 1st speed clutch transmission circuit
- 2nd speed clutch transmission circuit
- 3rd speed clutch transmission circuit
- 4th speed clutch transmission circuit
FRONT

Note For the pressure values, please refer to the


single sections of this Manual

BRAKES

HYDR.

REAR

6.8.1 USE OF THE ELECTRONIC


SERVICE TOOL
EST is a specific and indispensable instrument to
perform diagnoses on the product.
The new instrument designated as Electronic Service
Tool, is essentially made of a portable PC with peculiar
design features (STHPX) and a technologically
advanced flow meter measuring flows, pressures and
temperatures.
The components equipping the EST system are instruments
designed and developed for specific filed usage.
In fact, the PC is able to withstand shocks, contact with
liquids and substances dangerous for normal PCs on the
market.
The EST system provides the diagnosis of the main
groups of the machine through the measuring of
operational parameters of the electronic control
components (controllers, sensors etc.) and the
measure of flows, pressures and temperature.

MAIN

MAIN

TRANSM.

PILOT

FWD

TRANSM.

T. CONV.

-1-

TRANSM.

REV

-3-

TRANSM.

-2-

-4-

The EST system provides the diagnosis on


Excavators, wheeled Loaders Dumpers, Graders
and Dozers.
The EST system is a data bank.
It makes possible saving and forwarding the diagnoses
performed, directly from the operation site, loading all
the technical information required for service activities
(CDs, Manuals, parts Catalogues etc.).
The software starts automatically once the STHPX is
switched ON. It can provide a report of the tests
performed, indicating , besides the i.d. data of the
vehicle being tested, the references to the Customer
and the Dealer's representative performing the
intervention as well.
The technical report, in an electronic format, can be
forwarded by E-mail or recorded for future inspections
and comparison, useful in the implementation of the
PTF-8. The software is protected by an access key
(SMS key) assuring a protected usage.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

EQUIPMENT HYDRAULIC SYSTEM

6 - 31

6.9 TOOLING
380060208 CE - EST DIAGNOSTIC KIT KEYBOARD version
380060157 CE - EST DIAGNOSTIC KIT TABLET version

A.
A.
A.
A.
B.
C.
D.
E.
F.
F.
G.
H.
K.
I.
L.

STHP HDD 80 GB
DVD 8x
Battery for PC
STHPX Computer English
Vehicle interface module DPA-3
DPA-3 to multibrand interface cable
PC to DPA-3 interface cable
STHP Computer Docking Station
"SMS key" application software
12V Vehicle Power Supply
Bag
PC to vehicle interface
Cable PC to vehicle
Cable PC to vehicle interface
Cable PC to vehicle

M.
N.
O.
P.
Q.
R.
S.
T.
T.
U.
V.

Engine diagnosis cable


Cable from multibrand interface
to ZF AEB starter.
Grader diagnosis cable
Cable motor
BB3 diagnosis cable
Special keyboard
I/O Stick
Excavator connecting cable
3,5 FDD
24V Vehicle Power Supply
Printer
Printer cable
1850-2R520

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

6 - 32

EQUIPMENT HYDRAULIC SYSTEM

380001594 PFT-8 HYDRAUIC TEST KIT

1850-2R521

A.
B.
C.
D.
D.
E.
F.

750L/M Flow block


700 bar pressure sensors
Temperature sensors 150 C
Sensor cables
Cable temperature sensors
Suitcase
Module PFT-8

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

W190

EQUIPMENT HYDRAULIC SYSTEM

6 - 33

380060209 CE - EST KIT COMPLETE KEYBOARD version


380060165 CE - EST KIT COMPLETE TABLET version

KIT Hydraulic PFT-8


380001594

CE - EST KIT DIAGNOSTIC


380060209

KIT Hydraulic PFT-8


380001594

CE - EST KIT DIAGNOSTIC


380060165
W190-2R003

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

6 - 34

EQUIPMENT HYDRAULIC SYSTEM

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

SECTION 7

ELECTRICAL SYSTEM
INDEX

PARAGRAPH

SUBJECT

PAGE

SAFETY RULES ...................................................................................................

7-1

7.1

GENERAL LAYOUT OF THE ELECTRICAL SYSTEM ..........................................

7-2

7.2

MAIN CONNECTORS ............................................................................................

7-3

7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5

MAIN COMPONENT CONNECTIONS (CAB) ........................................................


Fuses ....................................................................................................................
Cab instrument board .............................................................................................
Indicators on instrument board ...............................................................................
Switch board ..........................................................................................................
Automatic transmission .........................................................................................

7-8
7-9
7-13
7-16
7-16
7-17

7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5

LOCATION OF MAIN COMPONENTS ON ENGINE ..............................................


Main switch ...........................................................................................................
Starter switch ........................................................................................................
Solenoid switches and diodes ................................................................................
Pressure switches - sensors - switches .................................................................
Alternator ...............................................................................................................

7-21
7-23
7-23
7-24
7-35
7-58

7.5

ACOUSTIC TRANSDUCERS .................................................................................

7-60

7.6

CLIMATISATION SYSTEM ...................................................................................

7-61

Copyright New Holland

Copyright New Holland

W190

ELECTRICAL SYSTEM

7-1

SAFETY RULES

WARNING
When working on the electrical system always
wear protective gloves and remove rings, wrist
watches and any other metallic jewel.

DISCONNECT
WARNING
Prior to proceeding with inspection or repair
interventions of electrical components DISCONNECT GROUND CABLE "A" from negative
terminal "B" of the battery. DISCONNECT THE
CABLE from positive terminal "D".

A
B

BATTERY 12Volt x 2
GROUND

WARNING
NEVER REST METALLIC ITEMS on the battery
to prevent the danger of short circuits.

WARNING
BATTERY GASES ARE FLAMMABLE.
Never place open flames or generate sparks near batteries. During the recharging, the emission of
gases is higher.
WARNING
BATTERY GASES ARE DANGEROUS if in contact with the skin or materials.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7-2

ELECTRICAL SYSTEM

W190

7.1 GENERAL LAYOUT OF THE ELECTRICAL SYSTEM


The electric wires are divided into five main groups:
1. Cab wires
2. Front frame wires
3. Rear frame wires
4. Engine wires
5. Transmission wires.

WARNING
Always disconnect the battery cable prior to cleaning, repairing, connecting or disconnecting any
cable of the electrical system to prevent the possibility of personal injuries.
Always keep all the lights equipping the machine
efficient. Replace at once any burnt-out bulb.

The above mentioned groups are connected among them by five multiple connectors located under the cab, near
the front frame fixtures.

1
B

Fig. 7-1
A. Left side connectors - B. Right side connectors - 1. Cab wires - 2. Front frame cable - 3. Rear frame cable 4. Transmission cable - 5. Engine cables.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7-3

7.2 MAIN CONNECTORS


CABLE CONNECTION ENGINE - CAB
24-31
31

20

30

18
29

2
7
1
8

22
11

16

LEFT SIDE VIEW


OF CAB

10
3

17
28

21
9

19

6
15

23
12

13

27

14
26

24
25

X18

GROUND CABLE (PLAIT)

W190-7R003

Fig. 7-2
MACHINE - CAB INTERFACE
CONTACT
NUMBER

WIRE NUMBER
(MACHINE)

(X18) 24-31 WAY CONNECTOR


WIRE SECTION
(MACHINE)

LAYOUT

EMPTY

EMPTY

WIRE NUMBER
(CAB)

WIRE SECTION
(CAB)

EMPTY

72

0.5

60

0.5

SWITCH

60

0.5

19

0.5

ACCELERAROR PEDAL SWITCH

19

0.5

81

0.5

ACCEL. PEDAL POTENTIOMETER -

81

0.5

83

0.5

ACCEL. PEDAL POTENTIOMETER OUT

83

0.5

10

55

0.5

ACCEL. PEDAL POTENTIOMETER +

55

0.5

11

28

0.5

EDC FAILURE INDICATOR (ENGINE CONTROLLER)

28

0.5

12

43

0.5

AXLE ARRANGEMENT

43

0.5

13

64

0.5

EDC FAILURE INDICATOR (ENGINE CONTROLLER)

64

0.5

14

0.5

EMPTY

15

EMPTY

16

EMPTY

17

EMPTY

18

EMPTY

19

27

0.5

27

0.5

20

21

49

0.5

EMPTY
ACCELERAROR PEDAL SWITCH.

TROUBLESHOOTING BUTTON
EMPTY

72

0.5

TROUBLESHOOTING CONNECTOR

49

0.5

22

22

0.5

ENGINE COOLANT TEMP. INDICATOR CONTROL RELAY (87)

22

0.5

23

23

0.5

ENGINE OIL PRESSURE INDICATOR CONTROL RELAY (87)

23

0.5

24

25

46

0.5

26

59

27

28

0.5

29

836

WATER IN FUEL SENSOR

30

19

GROUND

19

31

31

0.5

LINC K31

31

0.5

EMPTY

COLD STARTING ENGAGED INDIC. CONTROL

46

0.5

0.5

NEUTRAL RELAY CONTACT ARRANGEMENT

59

0.5

0.5

EMPTY

EMPTY

836

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7-4

ELECTRICAL SYSTEM

W190

TRANSMISSION - CAB CABLE CONNECTION

24-23
W
V

X
K
L

J
H

M
A

N
F

LEFT SIDE VIEW


OF CAB

D
E

S
R

O
P

X21

GROUND CABLE (PLAIT)

W190-7R004

Fig. 7-3
MACHINE - CAB INTERFACE

(X21) 24 - 23 WAY COONECTOR

CONTACT
NUMBER

WIRE NUMBER
MACHINE

WIRE SECTION
MACHINE

WIRE NUMBER
CAB

WIRE SECTION
CAB

430

434

SOLENOID Y1

56

SOLENOID Y2

10

438

SOLENOID Y3

32

442

SOLENOID Y4

55

446

SOLENOID Y5

LAYOUT

450

SOLENOID Y6

51

454

VPSI (+) (TRANSM. HYDRAULIC CONTROLLER)

12

458

K
L

EMPTY

TEMP.

39

574

TEMPERATURE SENSOR

49

462

TEMP.

46

GE 2

SPEED SENSOR B1

19

BL2

SPEED SENSOR B1

GN3

SPEED SENSOR B2

41

SW3

SPEED SENSOR B2

RT4

SPEED SENSOR B3

42

BL4

SPEED SENSOR B3

500

SPEED SENSOR B4

504

SPEED SENSOR B4

62

508

SPEED SENSOR B4

45

EMPTY

EMPTY

570

TEMPERATURE SENSOR

46

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7-5

FRONT CABLE - CAB CONNECTION

24-31

20

31
19

15

13
24

14

27

RIGHT VIEW OF CAB

23
12

16

22
11

17
28

10

18
29

21

30

26

25

X20

W190-7R005

Fig. 7-4
MACHINE - CAB INTERFACE

(X20) 24 - 31 WAY CONNECTOR

CONTACT
NUMBER

WIRE NUMBER
MACHINE

WIRE SECTION
MACHINE

169

LTS SOL. VALVE

EMPTY

613

LAYOUT

WIRE NUMBER
CAB

WIRE SECTION
CAB

169

BRAKES ACCUMULATOR PRESS. SW

613

116

HORN PEDAL BUTTON

116

138

HORN

138

103

RIGHT FRONT TURNING LIGHT

103

109

LEFT FRONT TURNING LIGHT

109

EMPTY

EMPTY

10

330

RIGHT FRONT HEAD LIGHT

330

11

339

LEFT FRONT HEAD LIGHT

339

12

EMPTY

13

EMPTY

14

231

LEFT LOW BEAM LIGHT

231

15

223

RIGHT LOW BEAM LIGHT

223

16

219

LEFT HIGH BEAM LIGHT

219

17

221

RIGHT HIGH BEAM LIGHT

221

18

EMPTY

945

19

975

TRANS. CUT-OFF PRESSURE SW (+)

975

20

974

21

995 (M)

0.3

BOOM PROXIMITY SENSOR (+)

TRANS. CUT-OFF PRESSURE SW (OUT)

974

995 (980)

0.3

22

980 (N)

0.3

BOOM PROXIMITY SENSOR (OUT)

980

0.3

23

994 (M)

0.3

BUCKET PROXIMITY SENSOR (+)

994 (981)

0.3

24

981 (N)

0.3

BUCKET PROXIMITY SENSOR (OUT)

981

0.3

25

EMPTY

26

859

27

956

28

954

29

LTS BLOCK SOL. VALVE

859

LTS (+)SOL. VALVE (+)

956

LTS SOL. VALVE (-)

954

EMPTY

30

EMPTY

31

EMPTY

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7-6

ELECTRICAL SYSTEM

W190

REAR CABLE - CAB CONNECTION

24-21
H

K
G

L
F

RIGHT VIEW OF CAB

M
D

E
T

N
S
R

X22

W190-7R006

Fig. 7-5
MACHINE - CAB INTERFACE

(X22) 24 - 21 WAY CONNECTOR

CONTACT
NUMBER

WIRE NUMBER
MACHINE

WIRE SECTION
MACHINE

978

PARKING BRAKE PRESS. SWITCH (+)

EMPTY

996

PARKING BRAKE PRESS. SW. (OUT)

331

RIGHT TAIL LIGHT + PLATE

LAYOUT

WIRE NUMBER
CAB

WIRE SECTION
CAB

978

996

EMPTY

EMPTY

331

EMPTY

332

LEFT TAIL LIGHT

332

1
1

120

LEFT REAR TURNING LIGHT

120

125

RIGHT REAR TURNING LIGHT

125

802

START. SAFETY (REAR RELAY BOX 87)

802

556

ALARM RELAY B (REAR RELAY BOX 85)

556

558

ALARM RELAY B (REAR RELAY BOX 85)

558

876

FDS FAN INVERSION (REAR RELAY BOX 86)

876

895

LINE "M" FROM 15 Amp FUSE (REAR RELAY)

895

1.5

801

LINE "ACC" FROM 15 Amp FUSE (REAR RELAY)

804

1.5

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7-7

REAR CABLE - CAB CONNECTION

24-18
6

7
8

18
9
1
17
10
5

RIGHT VIEW OF CAB

16
4

11

15
12
14

13

X23

W190-7R007

Fig. 7-6
MACHINE - CAB INTERFACE

(X23) 24 - 18 WAY CONNECTOR

CONTACT
NUMBER

WIRE NUMBER
MACHINE

WIRE SECTION
MACHINE

772

10

DIVERTER BOX (30)

809

AIR CONDITIONER PRESSURE SWITCH

LAYOUT

WIRE NUMBER
CAB

WIRE SECTION
CAB

10

809

EMPTY

EMPTY

844

EMERG. STEERING PUMP PRESS. SW.

844

000

2.5

GROUND

2.5

000

2.5

GROUND

2.5

225

2.5

RIGHT REAR WORK LIGHT

225

2.5

835

DIVIDER VALVE (STEERING OIL LOW PRESSURE)

835

10

637

ALTYERNATOR "L" (BATTERY CHARGE INDICATOR)

637

11

EMPTY

12

663

AIR CLEANER CLOGGING (SENSOR)

13

557

FUEL LEVEL SENSOR

14

555

INDICATOR

15

824

16

886

17

885

FRONT WASHER PUMP

18

EMPTY

663

557

555

AIR CONDITIONER PRESSURE SWITCH

824

REAR WASHER PUMP

886

885

"

"

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7-8

ELECTRICAL SYSTEM

W190

7.3 MAIN COMPONENT CONNECTIONS (CAB)

23
14
15

22

24

20

12

19

2
3

34

18

9
10

5
1

28
30

21
29
23

16

32

11

31

24
27

33
17

26
7

25

13

W190-7R009

1. Cable electric - 2. Electronic unit control - 3. Collar - 4. Electronic unit control - 5. Cable - 6. Printed circuit board 7. Printed circuit board - 8. Switch remote control - 9. Washer - 10. Screw - 11. Cable electric-plate - 12. Gasket - 13. Relay
-14. Cable electric - 15. Cable electric - 16. Electronic unit control - 17. Cable electric-switch - 18. Plate - 19. Gasket 20. Spacer - 21. Plaque data - 22. Grommet - 23. Screw - 24. Washer - 25. Flasher unit - 26. Fuse - 27. Plate 28. Electronic unit control - 29. Gasket - 30. Printed circuit board - 31. Printed circuit board - 32. Cable electric 33. Flasher unit - 34. Cable.

The main connections in the cab can be reached after removing the rear and right side plastic material panels.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7-9

7.3.1 FUSES

WARNING

Always disconnect the battery cable prior to


cleaning, repairing, connecting or disconnecting
any cable of the electrical system to prevent the
possibility of personal injuries.
Always keep all the lights equipping the machine
efficient. Replace at once any burnt-out bulb.

2
1

Note In the event a fuse is burnt out, it is necessary


to replace it at once. Search for the cause of the failure.
If the trouble persists, have the system inspected by
competent personnel.
The fuses in the cab can be reached by removing the
panel located behind the operator's seat on the left
side. The burning of a fuse is signalled by the activation
of the relevant indicator light.

Fig. 7-8

TABLE OF CAB FUSES


FUSE

DESCRIPTION

VALUE

F1A
F1B
F1C

CEIL. LIGHT/CLIMATE CONTR.


+ 30 EMERGENCY LIGHTS
+ 15 LIGHTS/FLASHING SW

7.5Amp
7.5Amp
7.5Amp

F2A
F2B
F2C

ROTARY BEACON
CUMMINS ENG. INDIC. LIGHTS CONTROLLER ACTIVATION
FRONT WIPER7PUMP/TIMER

7.5Amp
5Amp
7.5Amp

F3A
F3B
F3C

HEATER (FAN)
LIGHTING SW
BUCKET/FAN INVERT. S.V. BOOM AND RAISE SINGLE LEV.

15Amp
5Amp
5Amp

F4A
F4B
F4C

TURNING LIGHTS
VOLT. REDUCT./RADIO/12V JACK/CB (OPT)
SEAT HEATER

5Amp
7.5Amp
5Amp

F5A
F5B
F5C

ACC REAR RELAY BOX


REAR WORK LIGHT
FRONT WORK LIGHTS

15Amp
10Amp
10Amp

F6A
F6B
F6C

COND. COMP./AUT.LOAD. (OPT)


REAR WIPER/PUMP
LTS/BLOCK S. V.

7.5Amp
5Amp
5Amp

F7A
F7B

"M" REAR RELAY BOX


RH TAILIGHT/LH HEADLIGHT /TUV + CSI/INSTR/CIGAR
LIGHTER LIGHT
RH TAILLIGHT/LH HEAD/TUV + CSI/LHTAIL/LOW
BEAM/LICENCE LIGHT

15Amp

SEAT COMPRESSOR
EMPTY
AUX. INV./ATC FILTERS/ ACC. PEDAL SENS./REVERSE
RELAY/TRANSM. SOL./BUZZER/MULTIPLE INSTR.

5Amp
5Amp
7.5Amp

F9A
F9B
F9C

EMPTY
EMPTY
CENTRALISED LUBE (OPT)

3Amp
3Amp
7.5Amp

F10A
F10B
F10C

CIGARETTE LIGHTER
B CUMMINS CONTROLLER
HIGH BEAM

7.5Amp
10Amp
10Amp

F11A
F11B
F11C

HORN/HORN RELAY
STARTER BOARD
TROUBLESHOOTING SOCKET

7.5Amp
30Amp
3Amp

F12A
F12B
F12C

"B" CUMMINS CONTROLLER


HEAD/TAIL LIGHT POWERING
LOW BEAMS

10Amp
7.5Amp
10Amp

F7C

F8A
F8B
F8C

Fig. 7-9 Fuse group 1


Indicator light

F1A

F1B

F1C

F2A

F2B

F2C

F3A

F3B

F3C

F4A

F4B

F4C

F5A

F5B

F5C

F6A

F6B

F6C

F7A

F7B

F7C

F8A

F8B

F8C

F9A

F9B

F9C

F10A

F10B

F10C

F11A

F11B

F11C

F12A

F12B

F12C

3Amp
3Amp

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7 - 10

ELECTRICAL SYSTEM

W190

A couple of "link" fuses respectively for the machine


services (50 Amp) and alternator (80 Amp) are located
in the left side of the engine compartment.

50A

80A

Fig. 7-10

Fuse group "2"

Fig. 7-11

Fuse group "3"

The following fuses are located inside the relay box


accessible from the right side of the engine
compartment:
F1 E Stop lights (4A)
F2 E Moisture in fuel sensor (4A)
F3 E Back-up alarm (7.5A)
F4 E Alternator "S" (4A)
F5 E Alternator "15" (4A)
F6 E EDC controller (4A)
F1 D EDC engine controller (20A)
F2 D Fuel pre-heater resistor (20A)
F3 D Amplifier + FDS solenoid valve (4A)
M

"MEGA" fuse 150 Amp engine cold starting

D
E

Fig. 7-12

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland


W190

ELECTRICAL SYSTEM

7 - 11

PROTECTION TREE ELECTRIC DIAGRAM


+

FUSE 150A

FUSE 80A
LINK

FUSE 50A
"ACC"
ACCRALAY

ALTERNATOR

MEGA

STARTER

GRID HEATER
F1A - 7.5A

CAB. LIGHTS

LINK

F1D - 20A

EDC CONTROL UNIT

CLIMATE CONTROL UNIT


F1B - 7.5A

F11 B - 20A

EMERGENCY LIGHTS

F2D - 20A
START
ON
ACC
OFF
H

KEY IGNITION

M REAR RELAY BOX


F6E - 4A
F5E - 4A
F8B - 5A

BACK-UP ALARM

F10B - 7.5A

BACK-UP LAMPS

F9B - 3A

15 ALTERNATOR

F8A - 5A

PARKING BRAKE SWITCH

F6C - 5A

ZF CONTROL UNIT

F10C - 10A

HEAD LIGHTS
F11A - 7.5A

F4E - 4A

EDC CONTROL UNIT

S ALTERNATOR

HORN
HORN RELAY SOLENOID

EMPTY

F11C - 3A

SEAT COMPRESSOR - OPTIONAL

F12A - 3A

LTS SOLENOID VALVES

F8C - 7.5A

CONTROL UNIT ZF

F6B - 5A

EDC DIAGNOSTIC CONNECTOR


B. BOX CONTROL UNIT

F12B - 7.5A

SIDE AND TAIL LIGHTS 24 V


F7B-3A

CUT-OFF SAFETY VALVE

BACK-UP ALARM RELAY SOLENOID


SPEED SENSOR

F10A - 7.5A

LIGHTER

F3E - 7.5A

ST M ACC G2 G1 B

F7A - 15A

FUEL PREHEATER RESISTANCE

LTS RELAY SOLENOID

LEFT SIDE LIGHT

REAR WINDSCREEN WIPER MOTOR

LEFT SIDE LIGHT T.U.V. - OPTIONAL

REAR WINDSHIELD MOTOR PUMP

LEFT SIDE LIGHT I.R.T.C. - OPTIONAL

AUXILIARY SELECTOR SW.


RANGE SELECTOR

INSTRUMENT LIGHT

F6A - 7.5A

ELECTROMAGNETIC CLUTCH - OPTIONAL

F9A - 3A

EMPTY

LIGHTER LAMP
F7C-3A

AUTOMATIC LOADING CONTROL - OPTIONAL

F9C - 7.5A

RIGHT SIDE LIGHT

CLUSTER METER
F5C - 10A
F5B - 10A

RIGHT SIDE LIGHT T.U.V. - OPTIONAL

REAR FLOOD LIGHTS

RIGHT SIDE LIGHT I.R.T.C. - OPTIONAL

F5A - 15A

ACC REAR RELAY BOX

ACC RELAY SOLENOID


F1C - 7.5A

PLATE LIGHT

F1E-4A

LIGHTS EXCHANGE SWITCH

STOP LIGHTS

F2A - 7.5A

F12C - 10A

LOWER BEAMS

F2E-4A

BEACONS
F2B - 7.5A

LEFT TAIL LIGHT

FRONT FLOOD LIGHTS

BUZZER + DIGITAL DISPLAY


B. BOX

RIGHT TAIL LIGHT

W.I.F.

CENTRAL GRASE LUBRIFICAT. -

F2C - 7.5A

OPTIONAL
FRONT WINDSCREEN WIPER MOTOR

F4C - 5A

SEAT HEATER

FRONT WINDSCHIELD MOTOR PUMP


F4B - 7.5A

F3A - 15A

TIMER K4 FRONT WINDSCREEN

POT. DIVIDER

CAB ELECTROFAN - OPTIONAL

RADIO - OPTIONAL

F3B - 5A
F3C - 5A

JACK 12 V

LAMPS SWITCH

CB - OPTIONAL

BOOM, BUCKET PROXIMITY SW.


BOOM FLOAT/MAX LIFT DETENT SOLEN.

F4A - 5A

TURN LIGHTS

Fig. 7-13

SINGLE LEVER RELAY SOLENOID - OPT.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
X5
895
804
711
949
724

MPC 2.8 6 VIE 90

1
2
3
4
5
6

5mm

D5

5mm

D4

5mm

D12

5mm

D13

5mm

D11

5mm

D8

5mm

D7

5mm

D17

5mm

D16

5mm

D3

5mm

D6

5mm

D10

5mm

5mm

5mm

5mm

110

922

188

921

921

889

809

809

149
112

889

879

171
995
994

168

168

167

M6

SEAT HEATER

REDUCTION

N.C.

LAMP SW
LIGHT SW

+ WIPER + PUMP

CONDITIONER

N.C.
N.C.

X1-20
X1-21

X1-19 + ROT.BEACON SW

X1-18

X1-17

X1-16

X1-14
X1-15

X1-13

X1-12

CLIMATE PRESSURE SW

+15 FLASHING

X1-11

+15 LIGHTS SW

X1-10

+ FRONT WIPER + PUMP

+15 EMERGENCY LIGHTS

X1-9

X1-8

X1-7

BOOM SV

+ PROXIMITY

X1-6

BUCKET LEVEL SV

X1-5

+ LTS SV SW

REAR WORK

FRONT WORK

ON HARNESS

X1-4

X1-3

X1-2

X1-1

X27

X 4 = M A R K I I 1 1 WAY 9 0 N E U T R A L

X 3 = M A R K I I 2 1 WAY 9 0 N E U T R A L

X 2 = M A R K I I 1 3 WAY 9 0 N E U T R A L

X 1 = M A R K I I 2 1 WAY 9 0 G R E E N

N.C.

ACC. REAR CENTR.


+ HEATING
M FROM KEY
B+ FROM KEY

M REAR CENTR

2.2K L/4W

R5

F2B 7.5A

2.2K L/4W

R4

F2A 7.5A

2.2K L/4W

R12

F4C 5A

2.2K L/4W

R13

F5A 15A

2.2K L/4W

R11

F4B 7.5A

2.2K L/4W

R8

F3B 15A

2.2K L/4W

R7

F3A 15A

2.2K L/4W

R17

F6B 5A

D9

D18

D14

D15

R6

2.2K L/4W

R20

F7B 3A

2.2K L/4W

R21

F7C 3A

2.2K L/4W

R26

F9B 3A

2.2K L/4W

R27

F9C 7.5A

2.2K L/4W

R26

F9A 3A

2.2K L/4W

R24

F8C 7.5A

2.2K L/4W

R22

F8C 5A

2.2K L/4W

R23

F8B 5A

2.2K L/4W

R19

F7A 15A

5mm

D20

5mm

D21

5mm

D26

5mm

D27

5mm

D26

5mm

D24

5mm

D22

5mm

D23

5mm

D19

166

450
450

333

330

331

339
334

332

858
852

858

B.BOX+15

ZF 45

ZF 45

ZF 45
ZF 45
ZF 45
ZF 45

ZF 45

983

587

+ 15 B. BOX

N.C.

+ F2

+ GEARSHIFT

+ REAR. START.
+ SPEED SENSOR
+ ZF + 2 CO. SW
+ ACC.

+ 15

+ HEATED SEAT

N.C.
X3-10

N.C.

N.C.
N.C.

N.C.
X3-20
X3-21

X3-19

+LIGHT FUSE FROM SW

CIG.LIGHTER LIGHT
X3-17

X3-18

INSTR. BACK LIGHT

N.C.
X3-16

X3-15

LH HEADLIGHT
X3-14

RH HEADLIGHT
X3-13

X3-12

RH TAIL LIGHT

N.C.
N.C.
X3-8
X3-9

X3-11

N.C.

LH TAILLIGHT
RH TAIL LIGHT

RH TAIL LIGHT

N.C.

N.C.

X3-7

X3-5
X3-6

X3-4

X3-3

X2-3

+ BUZZER
X2-8
FRONT INSTR. POWER
X2-9
X2-10 + LCD

X3-2

X3-1

X2-13

X2-12

X2-4
X2-5
X2-6
X2-7

X2-11

X2-2

X2-1 + PARK. BRAKE SW

R1

F1A 7.5A

2.2K L/4W

R30

F10C 10A

2.2K L/4W

R36

F12C 3A

2.2K L/4W

R32

F11B 20A

2.2K L/4W

R33

F11C 3A

2.2K L/4W

R34

F12A 3A

2.2K L/4W

R29

F10B 7.5A

2.2K L/4W

R28

F10A 7.5A

2.2K L/4W

R35

F12B 7.5A

2.2K L/4W

R31

F11A 7.5A

2.2K L/4W

R2

F1B 7.5A

2.2K L/4W

+B

R6

EDC +30

5mm

D30

5mm

D36

5mm

D32

5mm

D33

5mm

D34

708

441

721

153

925

X27

923

924

ZF23-ZF68

B.BOX+30

5mm

D29

5mm

D28

5mm

D35

5mm

D31

5mm

D2

5mm

D1

M5

X8

N.C.

DIAGNOSTIC SOCKET

+30 B. BOX

F1 EST37 +30
EST37 +30

+ CIG. LIGHTER

B+ LIGHTS SW

HORN RELAY

B+ EMERG. LIGHTS

+ CEILING LIGHT

X4-10 + HIGH BEAM RELAY

X4-10 + LOW BEAM RELAY

X4-9

X4-8

X4-7

X4-6

X4-5

X4-4

X4-3

X4-2

X4-1

ON HARNESS

7 - 12

2.2K L/4W

R16

F6A 7.5A

2.2K L/4W

R3

F1C 7,5A

2.2K L/4W

R6

F2C 7.5A

2.2K L/4W

R10

F4A 5A

2.2K L/4W

R9

F3C 5A

2.2K L/4W

R18

F6C 5A

2.2K L/4W

R14

F5B 10A

2.2K L/4W

R15

F5C 10A

+ACC

X7

Copyright New Holland

ELECTRICAL SYSTEM
W190

FUSE BOX DIAGRAM

Fig. 7-14

Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 13

7.3.2 CAB INSTRUMENT BOARD


The monitoring system monitors the operating conditions of the loader through sensors and switches installed on the machine and provides information to
the instrument board located in the operator's compartment indicating the current operational conditions
of the loader.

13

22

12 25

10

4-68-15

The instrument board is composed of instruments including the tachometer, control indicator lights signalling that all systems are operating correctly or not
(alarm indicators) and signalling indicators.

5 7 16

21

26

17

27-28

CN1

CN3

23

11 18-19

CN2

Fig. 7-15

CONNECTION
CN1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Acc. oil low press. Indic. light


Eng. coolant high temp. indic. light
Eng. coolant temp. indicator
Instrument board light
Left turning light
Instrument board light
High beam lights
Instrument board light
Ground
Fuel level
Parking brake indic. light
Battery failure indic. light
Fuel reserve indic. light
Not connected
Instrument board light
Right turning light
Tachometer

CONNECTION
CN2

CONNECTION
CN3

18
19
20
21
22
23
24
25
26
27
28

Buzzer
General signal
Instrument board light
Transm. oil temperat. Indicator
Air cleaner clogging indic. light
Emergency steering indic. light
Batteries
Engine oil low press. indic. light
Transm. oil high temp. ind. light
Hourmeter (ground)
Hourmeter (battery)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7 - 14

ELECTRICAL SYSTEM

Connection CN1
1

9 10 11 12 13 14 15 16 17

Connection CN2
18 19

20 21

22 23 24 25 26

Connection CN3
28
27

Fig. 7-16

Instrument board electric diagram

FM
WTM
OTM
EHM
SM
L1-L13
L14 - L21

:
:
:
:
:
:
:

FUEL LEVEL INDICATOR


ENGINE COOLANT TEMPERATURE GAUGE
TRANSMISSION/TORQUE CONVERTER OIL TMPERATURE GAUGE
HOURMETER
TACHOMETER
INDICATOR LIGHTS
INTRUMENT LIGHTS

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 15

BUTTON - 0

BUTTON - 1

BUTTON - 2

BUTTON - 3

Fig. 7-17

Electric diagram of digital display

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7 - 16

ELECTRICAL SYSTEM

W190

7.3.3 INDICATORS ON INSTRUMENT BOARD


Engine coolant
temperature indicator

Engine coolant
temperat. indicator
150 C

50 C

67 C00

102 C00

50 C00

120 C00

Nominal value
of resistance

1st point of measurement

Scale

50 C

120 C

102 C

135 C

67 C

Fuel level
indicator

Instrument

E00

F00

49.8

16.8

91.7

10.4

80

10

Fig. 7-18

7.3.4 SWITCH BOARD

e
n
m
f

l
W190-7R010

Fig. 7-19
a. Seat heater (opt.) - b. Transmission cut-off when braking - c. Transmission auto engagement - d. Boom raising detent
(3 pos.) - e. Pre-heater indicator light + fuel filter with moisture - f. Radiator fan inverter - g. LTS (opt.) - h. Block valve cutoff (opt.) - i. Auxiliary direction reverser safety - l, m, n. Free.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 17

7.3.5 AUTOMATIC TRANSMISSION

T\M OIL TEMP

20
F

COOLANT TEMP

55

30

10
40
50

FUEL

1\10h

44

66

HOURMETER

km\h

88
A

11

99

12
12

77

10
10

11
11

Fig. 7-20

Configuration of automatic transmission

1. Automatic transmission controller ATC - 2. Forward-Reverse control unit - 3. Monitoring board - 4. Gearshift pilot valve 5. Kick-down/shift-down functions button - 6. Forward-reverse diverter - 7. Forward-Reverse diverter safety switch 8. Automatic transmission engagement switch - 9. LTS device switch (opt.) - 10. Transmission - 11. Transmission sensors 12. LTS accumulator control group (opt.).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7 - 18

ELECTRICAL SYSTEM

W190

GEARSHIFT SELECTOR

2
3
4

ND

X2
X2

X1
X1

A
B
C
D

A
B
C
D

Fig. 7-21

SPEED SELECTION
1 = 1st speed
2 = 2nd speed
3 = 3rd speed
4 = 4th speed

SPEED SELECTION
F = FORWARD
R = REVERSE
N = NEUTRAL

Fig. 7-22 Gearshift selector electric diagram

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 19

ZF ELECTRONIC CONTROLLER

Fig. 7-23

WARNING
IT IS ESSENTILA THAT DURING THE CONNECTING AND SICONNECTING PHASES OF THE ZF CONTROLLER THE ELECTRICAL SYSTEM IS DISCONNECTED (BATTERY MAIN SWITCH AND STARTER SWITCH IN
POSITION "OFF") TO PREVENT POSSIBLE DAMAGES TO THE UNIT.
Connection

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Connections

Ground
Ground
Speed sensor B1
Speed sensor B4
LTS solenoid
Back-up alarm relay
Hydraulic transmission
Hydraulic transmission
Hydraulic transmission
Hydraulic transmission
Display connector
Display connector
Diagnostic connector
Speed sensor B1
Transmission control
Parking brake relay
Transmission control
Fuse 10B (7.5 Amp)
Line CAN H
Line CAN L
Line CAN l
Man./Auto SW
Transmission control
Transmission control
Hydraulic transmission
-

Wire

Connection

ZF1
ZF2
ZF3
ZF4
ZF5
ZF7
ZF9
ZF10
ZF12
ZF13
ZF14
ZF15
ZF18
ZF19
ZF20
ZF21
ZF22
ZF23
B
V
V
ZF29
ZF30
ZF31
ZF32
-

35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68

Connections

Hydraulic transmission
Speed sensor B2
Speed sensor B3
Transmission control
Transmission control
Fuse 6C (7.5 Amp)
Hydraulic transmission
Temperature sensor B15
Hydraulic transmission
Hydraulic transmission
Hydraulic transmission
Speed sensor B4
Gearshift selector
Gearshift selector
Gearshift selector
Clutch cut-off sw
Gearshift selector
Fuse 10B (7.5 Amp)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Wire

ZF39
ZF41
ZF42
ZF43
ZF44
ZF45
ZF46
ZF49
ZF51
ZF54
ZF56
ZF62
ZF63
ZF64
ZF65
ZF66
ZF67
ZF68

Copyright New Holland

ELECTRICAL SYSTEM

W190

CAN L

TRANSM. CONTROL
AUXILIARY CONNECTION
WITH SINGLE LEVER

X19-26

ZF20

ZF45

ZF31

ZF22

ZF44

X19-27

ZF22

ZF45

CAN H

7 - 20

ZF5

X19-25

X19-30

ZF1
X19-1

ZF22

X19-22
X19-2

FUSE 7.5A (BOX 8C)

LTS

X19-5

ZF30

ZF2

KICK-DOWN SW.
ZF45

ZF45
GND

ZF45

ZF45
TRANSM. CONTROL
AUXILIARY CONNECTION
F-N-R

ZF31

ZF31

ZF44

ZF44

ZF20

ZF20

ZF45

ZF45

ZF45

X19-31
X19-44

X19-23

X19-20
X19-68

ZF23
FUSE 7.5A (BOX 10B)

ZF68
K2

X19-45

BATT

B3

772

CU 2.5

(A)

ZF65

B2

X6

(B)
B

Z
HORN

ZF63

ZF7

X19-65

197
30

87

85

86

556

FUSE 7.5A (BOX 8C)


558

X19-7
(21/M)

163

CU 2.5

ZF45
(21/N)

X19-63

(C)

(D)

ZF67

BACK-UP
ALARM RELAY

X19-67

(D)

ZF43

ZF56

X19-43

ZF45

ZF64

ZF

X19-32

ZF67

EST 37

ZF15

ZF15

ZF18

ZF18

X19
X19-15

X19-18

B4
500
ZF45

508
504

(23/U)

GND

438
Y3

(23/C)

442
Y4

ZF4
(23/S)

ZF62

Y5

ZF51

450
Y6

(23/F)

TRANSMISSION
CONTROL

TRANSMISSION
HYDRAULIC
BLOCK

446

(23/E)

X19-51

454

ZF12
(23/G)

X19-13

X19-39

ZF13
ZF39

458
TEMP.
(23/J)

X19-4
X19-62

(23/D)

ZF9
X19-9

X19-46

ZF46

462
TEMP.
(23/L)

(23/T)

SPEED SENSORS
OUTPUT

ZF45

DISPLAY
CONNECTOR

ZF32

X19-55

595

X19-12

A5

Y2
(23/B)

ZF55

ZF45

434

X19-10

ZF45

TRANSMISSION
SELECTOR

Y
(23/A)

ZF10
X19-64

(C)

DIAGNOSTIC-INTERFACE
(CONNECTOR)

430

X19-56

(B)

X7

570
X19-49

A6
ZF14

ZF14

(23/X)

ZF49

B15

574

ZF19

X19-19

GE2
(23/M)

ZF3

X19-3

ZF21

BL2
(23/N)

X19-21

GN3

ZF41

X19-41

(23/O)

ZF3

B2

SW3

SPEED SENSORS
PICK-UP

(23/P)

ZF45
ZF29

ZF29

ZF3

X19-29

BL4

(5/4)

(23/R)

ZF42

X19-42

921

921

P.B.

CONVERTER OUTPUT
TEMP. SENSOR

(23/K)
X19-14

B3

RT4

(23/Q)
1

S12

ZF21

MAN./AUT. SW.

S2
X19-66

DIODE

ZF30

30

ZF30

975
ZF45

(31/19)

CLUTCH CUT OFF


PRESSURE SW.

ZF45
87

975

974

ZF66
(31/20)

87

ZF45

943

CN1-25
B.B.

X19-30

86

921

85

921

ZF45

AUXILIARY SELECTOR
ENABLE SW.

PARKING BRAKE
RELAY

S13

ZF45
567

996

ZF45
996

21/C

Fig. 7-24

CLUTCH CUT OFF SW.

S17

PARKING BRAKE SW.

978

ZF45

996

ZF45

978
21/A

ZF transmission electric diagram

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ZF45

Copyright New Holland


W190

ELECTRICAL SYSTEM

7 - 21

7.4 LOCATION OF MAIN COMPONENTS ON ENGINE


VIEW FROM B

RIGHT SIDE SECTION VIEW

Engine coolant temperature


sensor
Common rail pressure sensor
Fuel heater

Camshaft sensor

Crankshaft sensor
BOSCH

EDC7 controller

BOSCH
BOSCH

Alternator
Temperature sensor
Fuse 80 Amp

Fuse 50 Amp
79102142

Engine rpm sensor

Depression switch

Central gear rpm sensor

Converter turbine rpm sensor


Detail Y

Connector x 21
Level indicator sender

A.C. electric compressor

Alternator

Pressure switch
82 bar (1189 psi)

A
Starter motor
Temperature sensor

7-22

TRANSMISSION
VIEW FROM A

SIDE VIEW
LEFT SIDE

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Fig. 7-25

Copyright New Holland


7 - 22

ELECTRICAL SYSTEM

W190

LOCATION OF MAIN COMPONENTS ON THE MACHINE


Batteries (2)
Switch 1 bar (14.50 psi)
L

Proximity sensors

Accelerator pedal

Battery cable

Battery starter
motor cable

Potentiometer
Switch 1 bar (14.50 psi)

DETAIL L

Brake
solenoid valve
cable

Ground cable

DETAIL Z

Z
Battery cable

General switch key

DETAIL K

Switch

Electric
timer

Switch 15 bar
(26.10 psi)

Main switch

ELASIS

DETAIL R
SECT. A-A

VIEW FROM A

Switch 1.8 bar

Proportional amplifier

SECT. B-B

Ground cable

VIEW FROM B
DETAIL W
Washer tank

Relay
Diode
Plaid assembly

Pressure switch 73 bar


(1059 psi)
Washer pump

Solenoid switch

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Diverter box fuse 150 Amp

Fuse holder

Fig. 7-26

Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 23

7.4.1 MAIN SWITCH


LOCATION - Inside the battery left panel.

To ground

Battery

Fig. 7-27

7.4.2 STARTER SWITCH


LOCATION - Cab right console
OFF

AC

BG

ON

STAR
T
B
H
OFF
ACC
ON

G1

G2 ACC

ST

POSITION
B

ST

G2

G1

ACC

START

Fig. 7-28

WIRES
R724
804
949
907

POSITION
"B"
"ACC"
"M"
"ST"

TECHNICAL DATA
DC:
24 V
B-G1, G2: 8 A
B-ACC:
10 A
B-M:
5A
B-ST:
3A

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7 - 24

ELECTRICAL SYSTEM

W190

7.4.3 SOLENOID SWITCHES AND DIODES


COLD STARTING SOLENOID SWITCH
780
782
IV-4
IV-16

782

To fuse 150 Amp


To resistor
To EDC7 controller PIN 4
To EDC7 controller PIN 16

TECHNICAL DATA
Nominal voltage: 24 V
Solenoid nominal current: 2 A

IV-4

IV-16

780
Fig. 7-29

LOCATION - Inside the connection box, right


side of engine compartment
W190-7R002

Fig. 7-30
1. Cold starting relay - 2. Engine oil low pressure indicator light relay - 3. Fuel filters heater relay - 4. Back-up alarm relay.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 25

HOLDING RELAY 90 Amp

804

85

30

G
86

WIRES
804 to starter switch ("ACC")
N
to ground
R
to relay board (+B)
M
to fuse F5A (15 Amp)

TECHNICAL DATA
Nominal voltage: 24 V
Nominal current: 90A
Resistance: 140
Contact closing voltage: 5 18V
Contact reopening voltage: 8 20V

Fig. 7-32

30 85

86 G

Electric diagram

Fig. 7-31

Location of solenoid switch: relay board,


inside the cab behind the operator's
seat

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

7 - 26

ELECTRICAL SYSTEM

W190

BACK-UP ALARM RELAY

556

WIRES
772 to battery
197 to fuse 3E (7.5 Amp)
558 to connection 21N
556 to connection 21M

87

87a

85

197

30

772

86

558

TECHNICAL DATA
Nominal voltage: 24 V
Nominal current: 14 V
Releasing voltage: 4.8 V
Resistance at 20: 240
Maximum current 20 A (contacts N.O.)
Maximum current 10 A (contacts N.C.)

85 87 87a

Diode 1N4004

86

30

Electric diagram

Fig. 7-33

6 5 4

3 2 1

D
6 5 4

3 2 1

Fig. 7-34

Location of relay: inside connection box, right


side of engine compartment

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Copyright New Holland

W190

ELECTRICAL SYSTEM
RELAY 10/20 Amp

87

87a

85
30

86

WIRES
85 To diode (954)
30 To Brown Box controller CN1-23 8956)
86 To fuse 6C (5 Amp) (167)
87 To timer Pin + (B)

RELAY 10/20 Amp

87

87a

85

86

30

WIRES
85 To timer Pin C (H)
30 To solenoid valve 3 (2)
86 To timer Pin b+ (B)
87 To timer Pin +(B)
87a To solenoid valves 1-2 (4)

85 87 87a

Diode 1N4004

86

30

Fig. 7-35

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7 - 27

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7 - 28

ELECTRICAL SYSTEM
LIGHTS RELAY

87

87a

85
30

86

WIRES
85 To ground (N)
30 To fuse 10C (10 Amp) (R923)
86 To dimmer and flash SW PIN 56a (593)
87 To head light (R-H) (221)

LIGHTS RELAY

87

87a

85

86

30

WIRES
85 To ground (N)
30 To fuse 12C (10 Amp) (R294)
86 To dimmer and flash SW PIN 56b (594)
87 To head light (R-H/L-H) (223)

85 87 87a

Diode 1N4004

86

30

Fig. 7-36

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W190

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W190

ELECTRICAL SYSTEM
SOLENOID SWITCH
UNDER STARTER SWITCH

87

87a

85
30

WIRES
85 To ground (N)
30 Connector box (R)
86 To key switch ACC (804)
87 To fuse 5 A (15 Amp)

86

REL PARKING BRAKE

87

87a

85

86

30

WIRES
85 To diode (996)
30 Auxiliary detector enable SW (ZF45)
86 To fuse 8C (7.5 Amp) (ZF45)
87a To ZF EST 37 PIN X19/21 (ZF21)

85 87 87a

Diode 1N4004

86

30

Fig. 7-37

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7 - 29

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7 - 30

ELECTRICAL SYSTEM
NEUTRAL RELAY

87

87a

85
30

86

WIRES
85 To diode
30 To EDC7 controller PIN 20 (802)
86 To ZF EST 37 PIN X19/67 (595)
87 To key switch ST (907)

REL DEVICE ENGINE OIL PRESS.


INDICATOR LIGHT

87

87a

85

86

30

WIRES
85 To EDC7 controller PIN 63 (63)
30 To ground (000)
86 To EDC7 controller PIN B+ (8)
87 Brown-Box controller CN7-21 (23)

85 87 87a

Diode 1N4004

86

30

Fig. 7-38

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W190

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W190

ELECTRICAL SYSTEM
HORN REL 10/120A

87

87a

85
30

86

WIRES
85 To horn pedal SW (116)
30 To fuse 11A (7.5 Amp) (R925)
86 To fuse 11A (7.5 Amp) (R925)
87 To horn (138)

HORN REL 10/120A

87

87a

85

86

30

WIRES
85 To Ground (N)
30 To fuse 11A (7.5 Amp) (R925)
86 To ZF (Z)
87 To horn (138)

85 87 87a

Diode 1N4004

86

30

Fig. 7-39

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7 - 31

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7 - 32

ELECTRICAL SYSTEM
COLD START REL

87

87a

85
30

86

WIRES
85 EDC7 controller (IV6)
30 Fuse 150A (CU16)
86 Controller EDC 7 (IV4)
87 Grid heater

FUEL PREHEATER REL

87

87a

85

86

30

WIRES
85 EDC7 controller (IV6)
30 Fuse 150A (CU16)
86 Controller EDC 7 (IV4)
87 Resistor

85 87 87a

Diode 1N4004

86

30

Fig. 7-40

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W190

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W190

ELECTRICAL SYSTEM

7 - 33

LTS TIMER
WIRES
3
To connection sol. valve EV2-EV3
B
To pos. 87 relay "1"
B
To pos. 86 relay "2"
H
To pos. 85 relay "2"

3
B

Fig. 7-42
Fig. 7-41

K1
K2
K3
K4
K5
K6
K7
K8

High beam relay


Reserve
Flasher unit
Low beam relay
Safety starting relay in neutral
Horn relay (control on gearshift selector)
Horn relay (control on pedal button)
Parking brake relay

Location of LTS relay and timer: inside


box APV12 on front frame

K1

K2

K3

Note For the specific connections of the relays,


please refer to the relevant diagram.

K4

Fig. 7-43

K5

K6

K7 K8

Location: relay board, inside the cab


behind the operator's seat

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7 - 34

ELECTRICAL SYSTEM

W190

RELAY BOARD ELECTRIC DIAGRAM (CAB)

D11 IN4007

P. BRAKE INDIC. X3 - 21

567

D9 IN4007

P. BRAKE PRESS. X3 - 19

K8
V23074

996PB

D10 IN4007

ZF 21

X3 - 13 + F2
X3 - 16 I. P. BRAKE SW

30

996

P. BRAKE X3 - 20

ZF 45

87A

87

X3 - 14 N.C.

86

N.C. X3 - 12

85

X3 - 17 N.C.

D7
IN4007

X3 - 18 N.C.
F2 X3 - 11

ZF45

K7
V23074

R925

X3 - 1 + HORN RELAY

87A
30
87

138

X3 - 4 HORN

86
85
D6
IN4007
11

N.C. X3 - 5

X3 - 6 HORN PEDAL. BUTT.

K6
V23074

87A
30
87

DIVERT. BUTT. X3 - 2

86

595

85

X3 - 15 N.C.

D5
IN4007

GND X34 X3 - 3

K1
V23074

R923

87A

87

X2 - 2

594

11
219

30

86 LOW BEAM
RELAY

J1 + 30
J2 B + FUSES
J3 30 RELAY 90A

N1

221

+B
X2 - 6 + HIGH BEAM RELAY
X2 - 9 HIGH BEAM IND.
X2 - 8 LH HIGH BEAM
X2 - 7 RH HIGH BEAM

86
85
D1
IN4007

K4
V23074

R924

X2 - 3 + LOW BEAM RELAY

87A
223

30
87

86 HIGH BEAM
X2 - 1
RELAY

593

231

X2 - 4 RH LOW BEAM
X2 - 4 LH LOW BEAM

86
85
D3
IN4007

GND
K3
FLASHER UNIT

K5
V23074

802

X2 - 11 STAT. SAF.
X3 - 10
+ FLASHER

87A

102

86

190

85

30

87

30
87

86 START.
SAF.

X2 - 15

ZF67

907

X2 - 10 30 START

86

X3 - 7
49 FLASHER

85

87A

D4
IN4007

P.B. PRESS

X2 - 12

996PB
K2
V23074

X2 - 14 N.C.
87A

M FROM KEY

ACC FROM KEY X3 - 9

804

87

X3 - 13 N.C.

85

X1

86

D2
IN4007

1
A

30

N.C. X2 - 16

86 RELAY 90A

GND X34 X3 - 8

N1

85 RELAY 90 A

N.C. X2 - 17

Fig. 7-44

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ELECTRICAL SYSTEM

7 - 35

7.4.4 PRESSURE SWITCHES - SENSORS - SWITCHES

2
1

Fig. 7-45

1 - STOP LIGHTS PRESSURE SWITCH


WIRES
117
To fuse 1E (4E)
175
To stop lights
TECHNICAL DATA
Thread:
M10 x 1
Setting:
1.8 0.5 bar (26.10 7.25 psi)

3 - BRAKE ACCUMULATOR LOW PRESSURE


PRESSURE SWITCH
WIRES
613
To Brown Box CNI-3 controller
000
To ground on front frame
TECHNICAL DATA
Thread:
R 1/8 taper
Setting:
73 5 bar (1058 72.51 psi)

2 - TRANSMISSION CUT-OFF PRESSURE SWITCH


WIRES
974
To controller ZF at PIN X/9-66
975
To pos. 1 transmission cut-off switch
TECHNICAL DATA
Thread:
Setting:
Tightening torque:

M10 x 1
15 1 bar (217 14.50 psi)
20 Nm

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ELECTRICAL SYSTEM

W190

MAIN ELECTRICAL AND ELECTRONIC COMPONENTS OF EDC 7 SYSTEM

13
6

12

11

10

Fig. 7-46
Ref.

Description

Coolant temperature sensor

Electric injector

Rail pressure sensor

Air temperature/pressure

Starter motor

Timing sensor

Pressure regulation solenoid valve

Fuel temperature sensor

EDC 7 electronic controller

10

Crankshaft sensor

11

Engine oil level sender (*)

12

Engine oil pressure/temperature sensor

13

Pre-post-heater resistor

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ELECTRICAL SYSTEM

7 - 37

ELECTRONIC CONTROLLER EDC 7

Fig. 7-47

A. Injector connector - B. connector for powering and for functions scheduled in the application - C. Sensors connector.

It is installed directly on the engine by a heat exchanger providing its cooling, using elastic pads reducing the
vibrations transmitted by the engine.
It is powered through a 20 Amp fuse. The main relay normally used to power the system is located inside the
controller itself.

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7 - 38

ELECTRICAL SYSTEM

W190

INJECTOR CONNECTION (A)

12

16

11

Fig. 7-48

View form wire input side


ECU PIN

WIRE
COLOUR

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

RU
WP
WV
RW
RG
UN
UG
WR
RY
W
UO
UY

FUNCTION
Injector cylinder 2
Injector cylinder 3
Injector cylinder 4
Injector cylinder 2
Ground
Ground
Injector cylinder 1
Injector cylinder 6
Injector cylinder 5
Injector cylinder 3
Injector cylinder 1
Injector cylinder 4
Injector cylinder 6
Injector cylinder 5

Legenda of colours
B
black
R
red
U
blue
W
white
P
ciano
G
green
N
brown
Y
yellow
O
orange

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W190

ELECTRICAL SYSTEM

7 - 39

SENSORS CONNECTORS (C)

1 3

23

16 9

15 22

4
5

30 36

29

Fig. 7-49

View form wire input side


ECU PIN

WIRE
COLOUR

2
4
5
7
9
10
12
17
18
19
20
21
23
24
25
27
28
29
30
31
32
33
34
35
36

NW
NP
PY
NY
GY
YR
YN
PN
GN
N
U
U
R
GO
NG
UO
R
PO
YU
PG
YO

FUNCTION
Negative for pressure regulator
Positive for pressure regulator
Positive for engine oil temperature pressure sensor
Positive for air pressure temperature sensor
Positive for rail pressure sensor
Negative for fuel temperature sensor
Negative for coolant temperature sensor
Negative for engine oil pressure temperature sensor
Negative for rail pressure sensor
Positive for air pressure/temperature sensor
Camshaft sensor
Crankshaft sensor
Crankshaft sensor
Signal from rail pressure sensor
Signal from air pressure sensor
Signal from air temperature
Signal from camshaft
Signal from engine oil temperature sensor
Positive from fuel temperature sensor
Signal from engine oil pressure sensor
Positive from coolant temperature sensor

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7 - 40

ELECTRICAL SYSTEM

CONTROL UNIT

CONNECTOR A to C (COMMOIN FOR ALL APPLICATIONS)

Fig. 7-50

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W190

ELECTRICAL SYSTEM

7 - 41

CONNECTOR (B) POWERING THE COMPONENTS AND


ALL THE FUNCTIONS PROVIDED BY THE APPLICATION

71

89

72

54

11

1
7
12

53

35

18

36

17

Fig. 7-51

View form wire input side


ECU
PIN
1
2
3
4
7
8
9
12
13
14
15
16
19
20
27
28

WIRE
774
2
000
4
774
8
000
774
774
000
000
16
19
802
270156
28

FUNCTION
Positive direct from fuse 1E (20 Amp)
Fuel pre-heater relay 10/120A
Ground
Colt start relay
Positive direct from fuse 1E (20 Amp)
Engine oil pressure device relay indic. Light/switch/ pre-heater indicator/
pus-button/switch/pre-heater indicator light
Ground
Positive direct from fuse 1E (20 Amp)
Positive direct from fuse 1E (20 Amp)
Ground
Ground
Colt start relay
Neutral relay
Accelerator pedal pressed
Push button switch
Positive for diagnostic indicator EDC

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7 - 42
ECU
PIN
31
36
37
39
43
45
46
52
53
55
60
63
64
72
81
83

ELECTRICAL SYSTEM

WIRE
31
36
888
39
43
45
46
V
B
55
60
63
64
72
81
83

FUNCTION
Line K for 30 pole diagnostic connector
Positive for fuel filter heater solenoid switch
Positive for starter motor
Fuse 6E (4 Amp)
Accelerator pedal pressed
Positive from stop button inside engine compartment
Negative for pre-heater actuated indicator light
Line CAN L
Line CAN H
Positive for accelerator pedal position sensor
Switch
Engine oil press. Device relay indicator light
Negative for EDC diagnostic indicator
Negative from accelerator pedal pressed switch
Negative for accelerator pedal position sensor
Signal from accelerator pedal position sensor

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W190

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W190

ELECTRICAL SYSTEM

STARTING
ENGINE

REL
GOLD START

REL
PREHEARTER

Fig. 7-52

EDC 7 electronic controller electric circuit diagram

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7 - 43

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7 - 44

ELECTRICAL SYSTEM

W190

ELECTRIC INJECTORS
It is a N.O type solenoid valve.
Individually connected to the EDC controller on connector A.
The resistance of the solenoid of each individual injector is 0.56 to 0.57 .

Ref.
CONNECTOR 1

CONNECTOR 2

CONNECTOR 3

Description
Injector cylinder 2
Injector cylinder 2
Injector cylinder 1
Injector cylinder 1
Injector cylinder 4
Injector cylinder 4
Injector cylinder 3
Injector cylinder 3
Injector cylinder 6
Injector cylinder 6
Injector cylinder 5
Injector cylinder 5

1
2
3
4
1
2
3
4
1
2
3
4

Controller pin
3A
6A
13 A
9A
5A
14 A
12 A
4A
10 A
15 A
16 A
11 A

Fig. 7-53

Fig. 7-54

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ELECTRICAL SYSTEM

7 - 45

RESISTOR AND SOPLENOID SWITCH FOR PRE-POST-HEATING


It is a resistor located in the intake manifold.
It is used to warm-up the air in the pre/post heating operations. It is powered by a solenoid switch located on the
left side of the frame.
The resistance is about 0.5 .

RESISTOR
Fig. 7-55

Fig. 7-56
A. Control solenoid switch.

The control solenoid switch is connected to the controller at pins 4B 16B.


The control occurs with water and/or fuel temperature below 5 C (41 F).
The resistance of the solenoid switch is about 15 .

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7 - 46

ELECTRICAL SYSTEM

W190

COOLANT TEMPERATURE SENSOR


It is a variable resistance type sensor capable of measuring the coolant temperature to provide the controller with
an indication of the thermal condition of the engine.
The same signal is used by the controller to pilot a temperature gauge installed on the dashboard (if any).
It is connected to controller pins 18C 36C.
The resistance at 20 C (68 F) is about 2.50 k

Fig. 7-57
A. Coolant temperature sensor.

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W190

ELECTRICAL SYSTEM

7 - 47

FUEL TEMPERATURE SENSOR


It is a sensor equal to the previous one.
It monitors the fuel temperature to provide to the controller an indication of the thermal condition of the fuel.
It is connected to controller at pins 17C 34C.
Its resistance at 20 C (68 F) is about 2.5 kW

1
2

Fig. 7-58
1. Fuel temperature sensor - 2. Resistor for filter heating.

The ECU pilots the control solenoid valve for the filter heating to a fuel temperature of 36 C (97 F).

CONNECTOR
Fig. 7-59

Fig. 7-60

Ref.
1
2

DESCRIPTION
Ground
Temperature signal

CONTROLLER PIN
WATER
FUEL
18C
36C

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17C
34C

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7 - 48

ELECTRICAL SYSTEM

W190

AIR TEMPERATURE-PRESSURE SENSOR


It is a component integrating a temperature and a pressure sensor.
Installed on the intake manifold, it measures the maximum flow of air taken in and it calculates in an accurate
manner the quantity of fuel to be injected at each cycle.
It is connected to the controller at pins 21C 29C 10C 28C.
It is powered at 5 Volt.
The voltage present on the output is proportional to the pressure or temperature measured by the sensor.
Pin 21C 29C Temperature
Pin 10C 28C Pressure
ENGINE OIL TEMPERATURE PRESSURE SENSOR
It is a sensor equal to the previous one.
It is installed vertically on the engine oil filter support.
It measures the temperature and pressure of the engine oil.
It is connected to the controller at pins 19C - 33C - 9C - 35C.
It is powered at 5 Volt. The signal monitored is forwarded to the EDC controller that in turn controls the indicator
instrument on the dashboard (indicator + low-pressure indicator light).
The oil temperature is not visualised by any instrument; it is only used by the controller.

Pin 19C 33C Temperature


Pin 9C 35C Pressure

ELECTRIC DIAGRAM
Fig. 7-61

Fig. 7-62

Ref.

DESCRIPTION

CONTROLLER PIN
OIL
AIR

Ground

19C

21C

Signal NTC (temperature)

33C

29C

Power + 5 Volt

9C

10C

Signal (pressure)

35C

28C

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ELECTRICAL SYSTEM

7 - 49

HIGH-PRESSURE PUMP - PRESSURE REGULATOR

Fig. 7-63
A. Pressure regulator

The quantity of fuel supplying the high-pressure pump is dosed by the pressure regulator located on the lowpressure system; the pressure regulator is controlled by the EDC 7 controller.
The delivery pressure to the rail is modulated between 250 and 1450 bar (3626 and 21030 psi) by the electronic
controller actuating the pressure regulator solenoid valve.
It is a N. O. solenoid valve.
It is connected to the controller at pins C5 - C7.
Its resistance is about 3.2 .

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7 - 50

ELECTRICAL SYSTEM

W190

FUEL PRESSURE SENSOR


Installed at one end of the rail, it measures the existing pressure of the fuel and informs the controller (feedback).
The value of the injection pressure is used to control the pressure itself and to determine the duration of the
electric control of the injection.
It is connected to the controller at pins 20C 27C 12C.
It is powered at 5 Volt.

FUEL PRESSURE SENSOR CONNECTOR


Fig. 7-64

Ref.
1
2
3

Description
Ground
Signal
Power

Controller pin
20 C / 68 F
27 C / 80.6 F
12 C / 53.6 F

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W190

ELECTRICAL SYSTEM

7 - 51

ENGINE CRANKSHAFT SENSOR


It is a sensor of induction type and it is located on the front left side of the engine. It generates signals obtained
by the lines of magnetic flow that are closed through the openings of the phonic wheel mounted on the crankshaft.
It is connected to the controller at pins 25C-24C. The value of the resistance of the sensor is ~ 900 .

CRANKSHAFT SENSOR

Fig. 7-65

TIMING SENSOR
It is a sensor of induction type and it is located on the rear left side of the engine. It generates signals obtained by
the lines of magnetic flow that are closed through the openings on the gear installed on the camshaft. The signal
generated by this sensor is used by the electronic controller as a timing signal of the injection.
Although it is similar to the flywheel sensor it is NOT interchangeable since it has a different external shape.
It is connected to the controller at pins 23C-30C. The value of the resistance of the sensor is ~ 900 .

TIMING SENSOR
Fig. 7-66
1

3
1
3
2

CONNECTOR

ELECTRIC DIAGRAM
Fig. 7-68

Fig. 7-67

Controller Pin
Ref.

Description

Cranfshaft sensor

1
2
3

Signal
Signal
Shielding

24C
25C

Timing
sensor
30C
23C

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7 - 52

ELECTRICAL SYSTEM

W190

ENGINE CLUTCH SENSORS F4AE0684H E


It is a proximity electronic switch powered at 24 Volt.
It is installed on the clutch pedal and monitors that the clutch engagement occurred.
It is equipped with a yellow signalling led lighting when the pedal is released.
It is connected to the electronic controller at pins 62B-8B.

1 (GROUND)
2 (+24)
3 (SIGNAL)
1

Fig. 7-69
1. Sensor sensing part - 2. Securing screws (torque 10 Nm) - 3. Brass body - 4. Yellow led - 5. Connector.

Ref.
1
2
3

Description
Ground
Power + 24 V
Signal

Controller Pin
8B
62B

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W190

ELECTRICAL SYSTEM

PRESSURE SWITCH FOR STEERING MAIN CIRCUIT LOW PRESSURE


WIRES
835 To Brown Box CN1-17
000 To ground
TECHNICAL DATA
Thread:
M14 x 1.5
Setting:
(Push-OFF)

Fig. 7-70
PRESSURE SWITCH FOR EMERGENCY STEERING CIRCUIT LOW PRESSURE
WIRES
844 To Brown Box CN1-19
000 To ground
TECHNICAL DATA
Thread: M10 x 1 taper
Setting: 1 0.2 bar (14.5 2.9 psi)

Fig. 7-71

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7 - 53

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7 - 54

ELECTRICAL SYSTEM

PARKING BRAKE PRESSURE SWITCH

W190
996
996

978
978

WIRES
978 To ground
996 Parking brake relay
TECHNICAL DATA
N.C.
Thread: M10 x 1
Setting: 82 1 bar (1189 14.5 psi)

LOCATION - Rear side of transmission


Fig. 7-72

TRANSMISSION OIL TEMPERAURE SENSOR


570
570

574
574

WIRES
570 To controller ZF PIN X19-46
574 To controller ZF PIN X19-49
TECHNICAL DATA
Thread: M16 x 1.5

LOCATION: Left side of torque converter cover


Fig. 7-73

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W190

ELECTRICAL SYSTEM

7 - 55

BUCKET POSITIONER PROXIMITY SENSOR

WIRES
BLUE
BROWN
BLACK

BLACK

To ground
To connection 31 way (994)
To connection 31 way (981)

BLUE
BROWN

TECHNICAL DATA
Thread:
M18 x 1
Tightening torque:
25 Nm
Setting of sensor intervention gap: 5 mm max.

981

LOCATION: On bucket cylinder


Fig. 7-74

BOOM KICK-OFF PROXIMITY SENSOR

WIRES
BLUE
BROWN
BLACK

BLACK

To ground
To connection 31 way (995)
To connection 31 way (980)

BLUE
BROWN

TECHNICAL DATA
Thread:
M18 x 1
Tightening torque:
25 Nm
Setting of sensor intervention gap: 5 mm max.

980

A
LOCATION: on front frame, in correspondence with
left boom pivot.
Fig. 7-75

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7 - 56

ELECTRICAL SYSTEM

W190

TRANSMISSION SPEED SENSOR


B1

SPEED SNEOR B1 (ENGINE)


WIRES
GE2 To controller ZF PIN X19-19
BL2 To controller ZF PIN X19-3

536
536

SPEED SENSOR B2
WIRES
GN3 To controller ZF PIN X19-41
SW To controller ZF PIN X19-3

537
537

B2

534
534

SPEED SENSOR B3
WIRES
BL4 To controller ZF PIN X19-3
RT4 To controller ZF PIN X19-42

SPEED SENSOR B4
WIRES
500 To controller ZF PIN X19-4
504 To controller ZF PIN X19-62
508 508 To use 8C (7.5 Amp)

535
535

B3

534
534

535
535

Fig. 7-76

INSTALLATION NOTE FOR SENSORS:


Apply LOCTITE 572 to the sensors.
Setting: To obtain a correct installation of the sensors, tighten them until touching the transmission gear,
then loosen the sensor one and a half turn.

B1

B2

B3

B4

Fig. 7-77

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Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 57

FUEL LEVEL SENSOR


WIRES
555 To Brown Box controller CN1-7
557 To Brown Box controller CN1-22
000 Ground
LOCATION: Inside the tank

FULL

3/4
409

262

272

25

(55)
1/2

320

409

227

R500
110

1/4

(55)

557
555

WARNING
POINT
EMPTY
FULL
3/4
1/2
1/4
EMPTY

()
10
19
32
49.5
80

Floater

Fig. 7-78

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7 - 58

ELECTRICAL SYSTEM

W190

7.4.5 ALTERNATOR

BOSCH

B+
BOSCH

BOSCH

BS
L
IS
BS
DFN

80A

B.B.
4A
(4E)

4A
(5E)

B+
707

637

DFN
BS
15
L
S

875

24V

18/10

ENGINE SOLENOID TERMINAL OR POINT


NEAR THE BATTERY CONNECTED TO THE
BATTERY BY LARGE DIAMETER CABLE

Fig. 7-79
WIRES
773 To LINK fuse (80A)
637 To connector "18/10" (cab connections)
000 Ground

TECHNICAL DATA
Nominal voltage of electrical system: 24 Volt
Nominal current output: 70 Amp

LOCATION: left side of engine compartment

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Copyright New Holland

W190

ELECTRICAL SYSTEM

7 - 59

AIR CLEANER CLOGGING PRESSURE SWITCH


WIRES
663 To Brown Box controller CN1-11
000 The ground
TECHNICAL DATA
Setting (closing of contacts): 57 to 67 mbar
Tightening: tighten manually, without tools.

LOCATION: On air cleaner inside engine hood.

663

000
Fig. 7-80

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7 - 60

ELECTRICAL SYSTEM

W190

7.5 ACOUSTIC TRANSDUCERS


HORN
LOCATION: Inside front frame
WIRES
138 To connector 31/5
000 To ground
TECHNICAL DATA
Nominal voltage: 24 Volt
Current absorption: 5A (0.2 )
Sound level: 117 db at 1.2 m
000

138

Fig. 7-81

BACK-UP ALARM
LOCATION: Radiator compartment.

000

163

WIRES
163 To back-up alarm relay through fuse 3E
(7.5 Amp)
000 Ground

TECHNICAL DATA
Nominal voltage: 24 Volt
Sound level: adjustable (97 - 107 - 112 db)

VIEW OF BRIDGE FOR SETTING


OF ACOUSTIC POWER

MIN.

MED.

MAX

Fig. 7-82
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W190

ELECTRICAL SYSTEM

7 - 61

7.6 CLIMATISATION SYSTEM


When this button is pressed all the climate
system functions are fully automatically controlled.
The system provides to reach and maintain constant
the temperature selected for the compartment.

This button intervenes on the panel switching


from outer air to re-circulation and viceversa.
The air re-circulation is automatically activated when
outside temperature exceeds 26 C (79 F).

Fig. 7-83

Selection of desired temperature inside the


compartment.
Each push corresponds to a variation of 1 C (86 F)
of the value indicated by the display.
For values below 8 C (46.4 F) or exceeding 30 C
(86 F). the display shows LO and HI respectively.
Under these extreme conditions, the system is
configured in a stable setting so that it always provides
maximum cold LO or maximum heat HI.

Activation/deactivation of air conditioner


compressor.
The activation of the compressor is signalled by the
activation of the relevant led.
In this case if an inner temperature lower than the outer
one is required, the led flashes for a few seconds to
warn the operator indicating that the system is unable
to cool the air.
When the outer temperature is below 3 C (37.5 F) the
compressor is deactivated.

(rightward). Manual selection of the quantity


of air injected into the compartment.
By actuating these buttons, led AUTO goes OFF. The
system still regulates automatically except for the
manual selection.
By pressing the speed decrement button with zero
speed, the controller goes to condition OFF (everything
inoperative and functions deactivated).

Indication of outside temperature.


When the outside air temperature approaches 0 C
(32 F) the display flashes for a few seconds at regular
intervals, indicating the danger of ice formations on the
ground.

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7 - 62

ELECTRICAL SYSTEM

W190

CLIMATISATION DIAGRAM
16 AZZURRO-GIALLO/LIGHT BLUE-YELLOW

+Batteria/+Battery

15 ROSSO/RED

+Chiave/+Key

6 BIANCO-NERO/WHITE-BLACK

+Luci/+Light

12 NERO/BLACK

Massa/Ground

Sensore temperatura aria miscelata


Mixed air temperature sensor

8 VIOLA-BIANCO/VIOLET-WHITE
18 VIOLA-BIANCO/VIOLET-WHITE

9 ROSA-NERO/PINK-BLACK
Sensore temperatura aria esterna
External air temperature sensor

19 ROSA-NERO/PINK-BLACK
11 1
12 2

10 ROSSO-NERO/RED-BLACK

13 3
14 4

Sensore temperatura aria interna


Internal air temperature sensor

20 ROSSO-NERO/RED-BLACK

15 5
16 6

2 AZZURRO-BIANCO/LIGHT BLUE-WHITE

17 7
18 8

13 BIANCO-WHITE

Connettore (per la centralina) da utilizzare nel cablaggio:


Molex MiniFit 20 vie porta femmina cod. 557-20R

19 9
20 10
Centralina
Control Unit

Pin femmina:cod.5556
Valvola ad acqua motorizzata
Water valve with motor
Energized
= blow-by
Rel.
energized=blow-by
4 MARRONE-BIANCO/BROWN-WHITE

87

Usato per attuatore di ricircolo


Used only for recycling acuator

87
85
30

86

1 VERDE/GREEN

87
87
85
30

86

Tasto A/C
A/C Switch

All'impianto di
condizionamento
To A/C system

11 BLU/BLUE
3 GIALLO/YELLOW
5 MARRONE/BROWN
2

+Key
+Key

2.5 mm

87
86

87
85
30

87
86

87
85
30

87
86

85
30

+key
+Key
a
2 Velocit
nd
2 Speed

a
3 Velocit
th
3 Speed

a
1 Velocit
st
1 Speed

Electric
Electricfan
fan

Brown
Black
Brown

Blue
Blue
Light
blue-yellow
Light
blue- yellow

Fig. 7-84
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W190

ELECTRICAL SYSTEM

7 - 63

CLIMATISATION ELECTRIC CIRCUIT


711

x1-12
x1-12+24V
+24 VALIMENTAZIONE
POWER

UI

R1

470 ohm 1/2 w


+C3
000F
50V

C1
100nF
63V

+C3
10F 63V

190

7812 0
GND
+C3
10F
63V

CLIMA04
191
RL1
24V

85

87 87a

86

30

OUT +12

x1-1

GND X1

C2
100nF
63V
NI

D1

x1-7

RELAY
x1-14 85
85RECIRCULATION
RELE' RICIRCOLO
MOTOR
x1-13 RECIRCULATION
MOTORE RICIRCOLO

IN4007

CLIMA11
01

D2

RL2
24V

85

87 87a

86

30

x1-6
x1-4

st RELE 1a
185
SPEED RELAYVELOCITA
VELOCITA
11sta SPEED

x1-8
x1-9

nd RELE 2a VELOCITA
285
SPEED RELAY
22ndaSPEED
VELOCITA

IN4007

CLIMA03
02

D3

RL3
24V

85

87 87a

86

30

IN4007

CLIMA05
03
RL4
24V

85

87 87a

86

30

a
rd RELE 3
x1-10 386
VELOCITA
SPEED RELAY
x1-13 33rdaSPEED
VELOCITA

D4
IN4007

CLIMA01
824

D5

RL5
24V

85

87 87a

86

30

X1-2 CONDITIONER
86 RELE CONDIZIONATORE
RELAY
X 1-3 CONDITIONER
USCITA CONDIZIONATORE
OUTPUT

IN4007

Fig. 7-85
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7 - 64

ELECTRICAL SYSTEM

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W190

Copyright New Holland

SECTION 8

CAB
TABLE OF CONTENTS

PAGE

PARAGRAPH

SUBJECT

8.1

GENERAL DESCRIPTION ...................................................................................... 8-1

8.2
8.2.1

REPAIR .................................................................................................................. 8-2


Cab (Removal/Installation) ...................................................................................... 8-2

8.3

WINDSCREEN WIPERS AND WASHERS .............................................................. 8-4

8.4
8.4.1
8.4.2

HEATER ................................................................................................................. 8-5


Generalities ............................................................................................................. 8-5
Main components and specifications ...................................................................... 8-5

8.5
8.5.1

CAB GLAZING ........................................................................................................ 8-6


Disassembly and assembly ................................................................................... 8-7

8.6
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.6.8
8.6.9
8.6.10

AIR CONDITIONING UNIT .....................................................................................


Operating instructions ............................................................................................
Technical data .......................................................................................................
Cab climate control and error code .........................................................................
Service precautions ...............................................................................................
Tools connections ..................................................................................................
Discharging ............................................................................................................
Refrigerant charching .............................................................................................
Leak inspection ......................................................................................................
Troubleshooting chart .............................................................................................
Special tools ..........................................................................................................

8-11
8-11
8-12
8-14
8-16
8-18
8-19
8-19
8-20
8-22
8-29

Copyright New Holland

Copyright New Holland

W190

CAB

8-1

8.1 GENERAL DESCRIPTION

Fig. 8-1
The cab is a tested protection structure against rollover hazard (ROPS).
The cab is complete with the drivers seat, steering
column, controls and instruments to drive and operate the machine.
Other standard features are the heating system, demister, front and rear windscreen washer-wipers, ceiling light, clock/thermometer, loud-speakers, safety
glasses, rear-view mirrors, sun visor, and emergency
exit.
Access inside the cab is through the left-hand door.
The right-hand door is used to gain access to the
heater/air conditioning system compartment. Doors
can be locked wide open and are fitted with a key
lock.
The main components such as the hydraulic reservoir, hydraulic pump and control valve, steering control valves and cylinders, and drive shafts can be removed or repaired without disassembling the cab.

Fig. 8-2
The cab serial number is etched on a plate located on
the inner side of the cab left-hand post.

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8-2

CAB

W190

8.2 REPAIR
8.2.1 CAB (REMOVAL/INSTALLATION)
Removal
Park the machine on level ground and block wheels
securely to prevent motion.
Disconnect the battery isolator switch.

Loosen the four safety screws and the four screws


securing the cab to the frame.
Install an appropriate lifting device over the cab hooking the 4 lifting eyes previously tightened (weight of
the cab about 700 kg - 1540 lbs) and set a slight tension on the lifting chain.

WARNING
Always disconnect the battery isolator switch
before cleaning, repairing, overhauling or parking
the machine.

WARNING
Always use hoists or similar devices of suitable
capacity to lift or move heavy components. Ensure that the sling is perfectly made.
Use the lifting eyes.

ON

OFF

Fig. 8-3
Remove the guards around the bottom of the cab from
both sides.
Disconnect the ground plait and the electric connections between cab and frame.

Fig. 8-5 Lifting cab

Slightly raise the cab taking care not to tension any


electrical cables or hoses.
Lifting height should be such to allow detachment of
all lines and cables from machine assemblies.
Fig. 8-4

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Copyright New Holland

W190

CAB

8-3
Close the heater feeding valves.
Disconnect the two heater hoses located in the rear
right side of the cab.
Make sure that all connections on the machine are
disconnected, then lift the cab, moving it sideways.

Disconnect the sensor and potentiometer wires from


the accelerator pedal.
Disconnect, after labelling them, the pipes to orbitrol
(6). Loosen the screws securing the brake pedal valve
and remove the pedal assembly without sisconnecting
the pipes.
Open the panel on the right side of the machine and
label the hoses of equipment control levers (3) and
three-way valve (4). Disconnect the pipes of the
windshield washer from the washer liquid tank.
Close the heater feeding valves.

Reinstallation
The installation is the reversal of the removal.
Tighten the cab screws to the frame to the specified
torque.

12

5
4
3
10

11
6
1

11

Fig. 8-6

Note -

Screw M16 - Tightening torque 230 Nm

1. Safety screw M30 - 2. Safety screw M24 - 3. Equipment control lever pipes - 4. Three-way valve pipes - 5. Potentiometer 6. Orbitrol valve - 7. Cab and frame front securing nut M16 - 8. Cab and frame rear securing nut m16 - 9. Accelerator pedal 10. Steering column - 11. Elastic pads - 12. "HOLD" function sensor.

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Copyright New Holland

8-4

CAB

W190

8.3 WINDSCREEN WIPERS AND WASHERS


The front windscreen wiper motor (1) is located at the
front of the steering column. The front windscreen wiper
has two intermittent working speeds: 35 strokes per
min (slow) and 55 strokes per min (fast).
A dog-leg mechanism transforms the motor shaft rotary motion into 45 strokes of the wiping arm.

The rear windscreen wiper motor (2) is located under


the cab trim behind the drivers seat, on the right-hand
side. The rear windscreen motor has but one speed
(approx. 54 strokes per min).
Internal gears provide an 80 oscillation of the wiping
arm.

Note 1 Before setting the wiper blades in motion,


operate the windscreen washer to minimise the risk
of scratching the glass.

Note 2 Use the cleaning fluid DP1 diluted with water


dependent upon working temperature. A 50% detergent/water solution does not freeze down to -10 C
(50 F). Below this temperature, use cleaning fluid only.

Pump hoses are connected to the nozzles located at


the sides of the wiping arms.

3
4

Fig. 8-7
The windscreen washer fluid bottle (3) is located inside the engine compartment, on the left-hand side.
The bottle is fitted with two pumps (4) and (5) for the
front and rear windscreens, respectively.

Specifications
Bottle capacity .......................... 2.5 lt. (0.87 US/gal)
Rated voltage .................................................... 24V
Absorbed current .............................................. 2A
Max. flow ........................ 3 lt./min (0.6 USG/min)

Fig. 8-8
In case of motor or arm assembly replacement, it will
be necessary to reassemble the arm assembly to the
drive part correctly to centre the wiping action over
the glass width.
To this aim, select the most suitable position for the
arm on the knurled drive part shown by the arrow in
the figure.

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Copyright New Holland

W190

CAB

8-5

8.4 HEATER
8.4.1 GENERALITIES
The cab heater is placed in a special compartment,
on the cab right-hand side.
The associated switches are located on the control
console and are used to:

6
2

- adjust air temperature;


- control air flow intensity;
- admit air from the outside or recirculate the air inside
the cab.
In case of air intake from the outside, air is drawn in
through the filter A. If air is being recirculated, internal
cab air is driven through the filtering panel B.
Both filter A and filtering panel B should be replaced
periodically.

7
5
A

Fig. 8-10

8.4.2 MAIN COMPONENTS AND


SPECIFICATIONS
The heater main components are:

Fig. 8-9

1.
2.
3.
4.
5.
6.
7.
8.
9.

Electrical fan
Outside air filter
Filtering panel
Heat exchanger
Shroud
Housing
Water lines
Air ducting
Feed valve

Specifications
Heat value .......................................... 10 000 Kcal/h
Air flow ........................................... 575 10% m3/h
Absorbed power ........................................... 400 W
Working temperature range
....................................... 15 + 50 C (14 + 122 F)

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Copyright New Holland

8-6

CAB

W190

8.5 CAB GLAZING


All cab glasses are differential hardening type.
Glasses should be ordered from the manufactured.
They should be kept clean at all times to guarantee
good visibility. When cleaning the glasses, pre-wash
them with a water and detergent solution or other proprietary product using a squeegee to reduce abrasion
and make cleaning easier.

4
6
2

Notice - Never use hot water over cold glasses.

All glasses fitted to the cab have been subjected to


differential hardening and have a 5 0.2 mm thickness. They are firmly bonded to their seats by means
of a polyurethane sealant.

1
7

Fig. 8-12

5 0.2 mm
0.19 0.007 in

1. Front windscreen - 2. Rear windscreen - 3. Door glass


- 4. RH side glass (emergency exit) - 5. LH rear glass 6. RH rear glass - 7. Bonding kit.

Fig. 8-11

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W190

CAB

8-7

8.5.1 DISASSEMBLY AND ASSEMBLY


Disassembly

Preparing the replacement glass

1. Push a pointed object through the adhesive from


inside the cab and insert the wire.

1. Place the glass momentarily in position and mark


with adhesive tape to position it correctly during
final bonding.

2. Using the wire, cut the adhesive all around the


glass. Lift out the glass using two suction cups.
3. To leave a smooth bevel of approximately 1 or 2
mm, which should be kept clean as it will be the
bonding base for the polyurethane adhesive. Should
the paint be partially damaged, apply some glass
primer as a protection against corrosion.
Note Work only in well ventilated premises. The
polyurethane adhesive does not contain low molecular weight (monomolecular) volatile isocyanates. Therefore, there is no danger of irritation for the respiratory
tract. However, all precautions required when using
chemicals should be observed. Avoid contact with
the eyes and skin.

Fig. 8-14
2. Thoroughly clean the glass edge using the special
cloth moistened in the degreaser supplied.

Important - After degreasing, wipe the degreased part


using a clean dry cloth.

Fig. 8-13

WARNING
Always wear gloves and use special suction cups
with handles when replacing the glasses.
Do not strike the glasses to remove.

Fig. 8-15

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Copyright New Holland

8-8

CAB

3. Shake well the glass activator bottle before use (at


least 1 minute after ball separation from the sediment). Apply an even continuous bead of activator
along the black stencil using the applicator supplied.

W190
5. Punch the membrane in the threaded connection.

Important - Once applied, allow the activator to dry for


at least 10 minutes keeping the surface clean.

Fig. 8-18

Fig. 8-16

4. Remove the sealant cartridge bottom cover and


salts therein.

6. Cut off the nozzle and apply a smooth continuous


bead of BETASEAL sealant-adhesive along the
edge of the body or windscreen keeping the gun
vertical.

Fig. 8-19
Fig. 8-17

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W190

CAB

8-9

Glass assembly
WARNING
1. Position the glass in its seat slightly pressing it.

Any variation to instructions specified, such as


use of materials after expire date or improper work
procedures, may negatively affect the results of
the operation. The manufacturer does not assume
any responsibility for damages which may derive
to persons and/or things.

Fig. 8-20

Note The glass must be fitted to the machine within


maximum 15 minutes after applying the BETASEAL
sealant-adhesive.

Note Work only in well ventilated premises. The


polyurethane adhesive does not contain low molecular
weight (monomolecular) volatile isocyanates. Therefore, there is no danger of irritation for the respiratory
tract. However, all precautions required when using
chemicals should be observed. Avoid contact with the
eyes and skin.

Note The BETASEAL sealant-adhesive hardens


with air moisture. Hardening depends upon ambient
humidity and relative penetration degree. Therefore,
machine downtime ranges from 2 to 3 hours at a
temperature of 23 C (73 F). During this period the
machine should not be submitted to any stress whatever.

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Copyright New Holland

8 - 10

CAB

Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual

W190

Copyright New Holland


W190

CAB

8 - 11

8.6 AIR CONDITIONING UNIT


8.6.1 OPERATING INSTRUCTIONS
The principle of operation can be summarised as follows: the refrigerant, R134a, in its gaseous state, is sucked
by the compressor at low pressure and taken to a final pressure. The gas, heated by the compression, flows, still
in a gaseous state, into the condenser where, under the effect of the cooling provided by the air flowing through
it by the action created by the fan, reaches the condensation point, passing into a liquid state at high pressure.
Subsequently, the refrigerant, at liquid state, reaches a dehydration filter, which has the function of capturing
impurities, absorb moisture trapped into the system and operate as a reserve reservoir for the refrigerant itself.
Then, the Freon reaches the expansion thermostatic valve, which has the purpose of regulating the refrigerant
flow into the evaporator at low pressure, causing its passage from liquid to gaseous state. At the same time, the
air flowing through the evaporator, under the action of the fan, having a temperature which is higher than the
refrigerator contained by the evaporator itself, causing its boiling and full evaporation, releasing heat.
The air, being cooled, deposits on the fins of the evaporator parts of its moisture content, under the form of little
drops, which drop into the tanks and are discharged outside the cab.
Air cooled and dehumidified, is sent into the cab. The refrigerant, at the outlet of evaporator, is sucked again by
the compressor, beginning a new cycle.

Fan unit

Evaporator
Compressor

Expansion valve
Condenser

Intake

High
pressure

Low
pressure

Filter
Pressure switch
W190-8R001

Fig. 8-21
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8 - 12

CAB

W190

8.6.2 TECHNICAL DATA


Cab Air Fan
Voltage
Electrical input
Air flow
Speed

24 V
17 A
1190 m3/h
3

Heater
Power
Rate of flow
Air flow
Input air temperature

11,7 KW
500 l/h
575 m3/h
-15 C (5 F)

Evaporator
Power
Rate of flow
Air flow
Input air temperature
Relative humidity
Vaporisation temperature
Condensation temperature

8,17 KW
500 l/h
575 m3/h
43 C (109 F)
30%
5 C (41 F)
60 C (140 F)

Condenser
Mass dimension
Input air temperature
Relative humidity
Vaporisation temperature
Condensation temperature

375 x 480 x 37,5 mm


35 C (109 F)
50%
5 C (41 F)
60 C (140 F)

Expansion valve
Type
Gas
Superheat

TGK TEV 216 PO-2


Freon R134A
4 C (39 F)

Compressor
Type
Displacement
Pulley
Lubricant oil q.ty

SANDEN SD7H15 md 7948 for 134A


154.9 cc
135.6 mm
200 cc

Dehydrator filter
Type
Dimension
Capacity
Dehydrating
Pipe fitting

SKG CC164
141 x 76 mm
415 cc
140 gr
5/8'' - 18 UNF

Pressure switch
Type
Interruption:

3L-F LMH-971-641
Low pressure
High pressure
(Fan)

Thermostat
Type
Setting

RANKO K50-L9421
Cold

OFF
ON
OFF
ON
OFF
ON

2.45
2.6
28
25
12
17

bar (36 psi)


bar (38 psi)
bar (406 psi)
bar (363 psi)
bar (174 psi)
bar (247 psi)

OUT 0 C (32 F)
IN
5 C (41 F)

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W190

CAB

CONTROL
BOARD

8 - 13

ELECTRONIC CONTROLLER

CONDENSER
AIR COMPRESSOR

HOSE

DRIVE FAN
HOSE

SENDER

FILTER

Sensor

PRIMARY AIR
FILTER
EVAPORATOR
SECONDARY AIR
FILTER

Sensor

HYDRAULIC
ONNECTION

VALVE

FAN

RADIATOR

ENGINE
HOSE

THERMOSTAT

W190-8R002

Conditioner components
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Copyright New Holland

8 - 14

CAB

W190

8.6.3 CAB CLIMATE CONTROL AND ERROR


CODES
3

6
1.
2.
3.
4.
5.
6.
7.
8.
9.

Inner temperature increment.


Inner temperature decrement.
Indication of inner temperature.
Fan speed increment.
Fan speed decrement.
Automatic operation.
Compressor act./deact. button.
Re-circulation.
Outer temperature.

ERROR CODES TABLE


In the event of troubles, the following error codes are
indicated:
ERROR

ERROR DESCRIPTION

E1

The outer air temperature sensor is cut-off.

E2

The outer air temperature sensor is short circuited.

E3

The operators compartment air temperature sensor is cut-off.

E4

The operators compartment air temperature sensor is short circuited.

E5

The mixed air temperature sensor is cut-off.

E6

The mixed air temperature sensor is short circuited.

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W190

CAB

Electronic temperature control (E.C.S.)


The E.C.S. controls the temperature and the quantity
of air flowing into the compartment.
This control is ensured within a temperature range
between - 20 C (- 4 F) and + 50 C (122 F).

Buttons selecting the desired temperature


inside the compartment.
A variation of 1 C of the value displayed corresponds
to each pressing.
For values lower than 18 C (64 F) or exceeding
30 C (86 F) the symbols LO and HI respectively,
appear on the display.
Under these extreme conditions, the system is
configurated in a stable manner so that it always
provides maximum cold in LO and maximum heat in
HI.

8 - 15
the outside temperature exceeds 26 C (79 F)

When actuating this button, the outer


temperature is displayed for about 6 seconds.
When the temperature of outer air is near 0 C (32 F)
the display flashes for a few seconds at regular
intervals, to warn of danger of formation of ice on the
road.

(at the right). Buttons changing manually the


quantity of air flowing into the compartment.
When actuating these buttons, the AUTO led goes
OFF. The system still regulates in automatic mode,
with the exception of the manual selection.
When pressing the speed decrement button with zero
speed, the controller goes into OFF condition (all
switched-off and functions deactivated).

When pressing this button, all climatisation


functions are automatically controlled.

Button to switch ON/OFF the operation of


the air conditioner.
The switching ON of the compressor is signalled by
the glowing of the relevant led.
When the compressor is inoperative (led OFF) the
system is not cooling.
When the outside temperature drops below 3 C
(37 F) the compressor is cut-off.
This button actuates the panel switching
from outside air to re-circulation and viceversa.
The air re-circulation is automatically activated when

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8 - 16

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W190

Conditioning Performance

Piping precautions

IN ACCORDING WITH ISO 10263

- Position the O-Ring against the bulge in the pipe


when connecting hoses and pipes.

8.6.4 SERVICE PRECAUTIONS

- Coat the piping connections and the O-Rings with


PAG oil.

WARNING
Direct contact with refrigerant can cause frostbite
or blindness.
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face.

- Fit the nuts and unions tightly against the base of


the companion pieces then hand tighten the nut as
much as possible. Then, tighten to the specific
torque.
Note Always use oil specified for R134a system to
coat the O-Rings.

CAUTION
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere.

O-Ring
Union

Handle the air conditioner components carefully. Do


not knock or drop them.
Nut

1850-2R392

Fig. 8-23

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W190

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Do not release refrigerant into the air


Although R134a is not subject to CFC regulations, it
can have an effect on global warming, and so should
not be released into the air.

8 - 17

WARNING
Cap the oil container after use and the air conditioner system parts, when servicing.
Never mix compressor oil with other types of oil.

WARNING
When removing refrigerant from the air conditioner
system, always use a refrigerant recovery unit
made especially for R134a (Attrezzatura specifica
380001326).

OIL

Do not release the


refrigerants
into the atmosphere
Cap all container and components

Fig. 8-25

R134a
The oil must be replaced or replenished in the following cases:
- when refrigerant or oil leaks from the system;
Recovery unit

- when refrigerant is suddenly discharged from the


system;
- when system components are replaced.

Fig. 8-24

Note The oil plug O-ring must be replaced with a


new one.

Compressor oil
Use compressor oil made specifically for use with
R134a.
R134a system compressor oil has an extremely high
moisture absorption capacity.

Refrigerant charge inspection


As shown in the left hand figure seguente, compressor oil will not blend with refrigerant (R134a) at certain
temperatures. At these temperatures, the refrigerant
may appear 'cloudy' when checked using the
sightglass, and the charge may be mistakenly judged
as insufficient.

Fig. 8-26

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8 - 18

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W190

8.6.5 TOOL CONNECTIONS


1. Fully close both manifold gauge valves.
WARNING
Do not connect hoses to the air conditioner system when the manifold gauge valves are open.

2. Connect the three hoses securely to the manifold


gauge.
3. Connect the utility hose to the vacuum pump or
refrigerant source

CAUTION
If there is any refrigerant in the air conditioner system, connect the hoses only after the service hoses
and the manifold gauge have been evacuated.

4. Connect the couplers to the high and low pressure


hoses. Turn the knob on the fitting to depress the
core if so equipped.
Before disconnecting hoses, close both manifold
gauge valves.
Manifold gauge
Low pressure

High pressure

Charging hose

Charging hose

Coupler

Vacuum pump

Refrigerant container

Fig. 8-27
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8 - 19

8.6.6 DISCHARGING
CAUTION
WARNING
Do not release the refrigerant into the air.
Discharge refrigerant only into the refrigerant recovery unit.

If the pointer moves toward 0 (zero) the system is


not sealed. Inspect the system to identify the leakages and repair them.

The recovered refrigerant must be recycled trough a


refrigerant recovery unit to ensure that it is clean and
free of moisture.
Refer to the user's instruction manual for refrigerant
recovery unit handling and operations.

8.6.7 REFRIGERANT CHARGING


There are various methods of charging refrigerant into
the air conditioner system. These include using refrigerant recovery units and direct charging using a
scale.

Fig. 8-28

Evacuation
1. Operate the vacuum pump.
2. Open both manifold gauge valves
3. Evacuate the system for at least 20 minutes.
4. Close both manifold gauge valves.

Initial charge
1. Put the refrigerant container on the scale.

Note Change refrigerant in the system of wheel


loader every 2 years.

Initial evacuation
1. Close both manifold gauge valves.
2. Connect the high and low pressure hoses to the
system.
3. Connect the utility hose to the vacuum pump.
4. Open the manifold gauge's high and low pressure
valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to stabilize the vacuum inside the system.
7. Close both valves and stop the vacuum pump.

Checking air tightness


1. Leave the system as it is for 5 to 10 minutes.
Ensure the low pressure gauge needle does not move
towards the atmospheric pressure side (gauge pressure 0).

Fig. 8-29
2. Disconnect the utility hose from the vacuum pump
and connect it to the refrigerant container.
3. Purge air from the utility hose.
4. Record the refrigerant weight.
5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side
valve to charge refrigerant from the low pressure
side valve to charge refrigerant from the low pressure side.

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8 - 20

CAB

W190

7. Charge with refrigerant until the low pressure manometer exceeds the minimum threshold of pressure switch 0.26 mPa (2.6 bar).
The optimal refrigerant's weight is approximally
1300 gr.
8. Close the instrument manifold low pressure valve.

CAUTION
Do not overcharge the system.
Initial check for leakages
Use an electronic leakage sensor to check the connections of the system for possible leakages.

Fig. 8-31

Inspection procedure

Evacuation

Refrigerant
charging
Electronic leak detector
380001327

A22090

Operate compressor for


at last 5 min

Check for refrigerant


leaks from high
pressure side parts

8.6.8 LEAK INSPECTION


To facilitate refrigerant leak detection, operate the air
conditioner at the full cooling setting with the fan running at maximum speed for at least 5 minutes.
Stop the engine and, using a leak detector, check for
refrigerant leaks on the high pressure side.
This must be done immediately because when the
refrigerant stops circulating, the high pressure decreases gradually, as shown in the graph, while the
low pressure side pressure increases gradually.

Operation test

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Repair

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8 - 21

Inspection sequence
High pressure side
Compressor
discharge port

Condenser
inlet and outlet

Cooling unit
inlet

Receiver drier inlet


and outlet

Low pressure side


Compressor
suction port

Cooling unit
outlet

CAUTION
Clean all inspection points.
Check all connections carefully.
To prevent incorrect diagnoses, ensure there is
no refrigerant or cigarette smoke in the vicinity of
the vehicle.
Inspection points

W190-8R003

Fig. 8-32
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8 - 22

CAB

W190

8.6.9 TROUBLESHOOTING CHART


(a) Fan motor does not operate
Inspection

Possible cause

Remedy

1. Blown fuse

Inspect the air conditioner fuse.

Replace.

2. Broken wiring
or bad connection

Check the fan motor earth and connectors.

Repair the wiring or


connect correctly.

3. Fan motor
malfunction

Check the two lead wires from the motor with a circuit
tester. If there is no conductance, the motor is malfunctioning.

Replace.

4. Broken resistor wiring

Check resistor conductance using a circuit tester. If there is


no conductance, the wiring is broken.

Replace.

5. Fan motor switch


failure

Operate the fan switches in sequence and check whether


the fan operates.

Replace.

(b) Fan motor operates normally, but air flow is insufficient


Inspection

Possible cause

Remedy

1. Evaporator iniet
obstruction

Check the iniet.

Remove the obstruction


and clean.

2. Air leak

Check the cooling unit case fittings.

Repair of adjust.

3. Defective thermo
switch

Check whether the evaporator is frozen. Check the switch


using a circuit tester.

Replace.

(c)

Insufficient cooling although air flow and compressor operation are normal

Inspection

Remedy

1. Insufficient
refrigerant.

There will be little temperature difference between the lowand high-pressure sides. Air bubbles or a "cloudy" flow will
be visible in the sightglass.

Repair any leaks and


recharge the refrigerant
to the correct level.

2. Excessive refrigerant

The high-pressure side pressure will be high and even if


the condenser is cooled using water, air bubbles will not
appear in the sightglass.

Drain small quantity of


refrigerant until air bubbles appear periodically
through the window.

Possible cause

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W190

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8 - 23

(d) The compressor does not operate at all, or operates improperly


Possible cause

Inspection

Remedy

1. Loose V-belt

The belt oscillates considerably.

Adjust the tension.

2. Internal compressor
malfunction

The V-belt slips.

Repair or replace.

Low battery voltage

Clutch slips.

Recharge the battery.

Faulty coil

Same as above.

Replace the magnetic


clutch.

Oil on the clutch


surface

The magnetic clutch face is dirty, causing it to slip.

Replace, or clean the


clutch surface.

3. Magnetic clutch related

Excessive clearance
between the clutch
plate and clutch disk.
The clutch plate clings
when pushed.

Adjust the clearance, or


replace.

Open coil

Clutch does not engage and there is no reading when a


circuit tester is connected between the coil terminals.

Replace.

Broken wiring or poor


earth

Clutch will not engage at all. Inspect the earth and connections.

Repair.

Wiring harness components

Test the conductance of the pressure switch,


thermoswitch, relay, etc.

Check operation, referring to the wiring diagram, and replace defective parts.

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8 - 24

CAB

W190

Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35 C (86 ~ 95 F) and
engine speed of approx. 1500 rpm are:
High pressure side pressure: 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm2, 213 ~ 242 psi)
Low pressure side pressure: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm2, 18 ~ 28 psi)
Remedy

Possible cause

Inspection

Low -pressure side pressure too high.

The pressure in the low-pressure side becomes, normally, too high


when the pressure on the high-pressure side is excessive. As
explained here below, the check that follows is performed only when
the pressure on the low-pressure side is too high.

1. Defective thermoswitch.

The magnetic clutch switch turns off before the outlet air temperature
is sufficiently low.

Adjust or replace.

2. Defective compressor
gasket or valve.

The high- and low-pressure side gauge pressures equalize when the
magnetic clutch is turned off.

Repair or replace the compressor.

3. Poor expansion valve temperature sensor contact.

Frost has adhered to the compressor connector so that the temperature is lower than that of the evaporator outlet side piping.

Install the temperature sensor against the low-pressure


pipe.

4. The expansion valve


opens too far.

Same as above, or there is little pressure fluctuation when the


temperature sensor is places against the pipe and then removed.

Replace.

5. Clogged compressor suction filter.

The compressor connector is cool but the low-pressure hose is not.

Remove and clean the filter.

1. Insufficient refrigerant.

Refer to "Insufficient refrigerant" on previous page.

Same as at left.

2. Clogged receiver drier.

Considerable temperature difference between the inlet and outlet


sides, or the tank is frosted.

Replace the receiver drier.

3. Clogged expansion valve.

The expansion valve's inlet side is frosted.

Clean the filter or replace the


expansion valve.

4. Expansion valve temperature sensor gas leak (damaged capillary tube, etc.)

The expansion valve's outlet side is chilled, and low pressure gauge
indicates a vacuum.

Clean or replace the piping.

5. Clogged or blocked piping.

When the piping is clogged or blocked, the low-pressure gauge reading


will decrease, or a negative reading may be shown.

Clean or replace piping.

6. Defective thermoswitch.

The evaporator is frozen.

Adjust or replace.

1. Poor condenser cooling.

Dirty or clogged condenser. Cooling fan does not operate correctly.


Blown fuse, broken wiring or poor contact. Fan motor malfunction.

Clean, and repair the fan.


Repair the wiring or replace
the fuses.

2. Excessive refrigerant.

Refer to "Excessive refrigerant" on previous page.

Low-pressure side pressure too low.

High-pressure side pressure too high.

3. Air in the system.

Evacuate and recharge with


refrigerant.

High-pressure side pressure too low


1. Insufficient refrigerant.

Refer to "Insufficient refrigerant" on previous page.

Same as at left.

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Gauge pressure diagnosis

Low pressure side

1.47 - 1.67 MPa


{15 - 17 kg/cm2,
213 - 242 psig}

1.5

9
10

10

11
12

2
0

15

1.0

15

2.0
2.5

20

10

25

0.5

3.0

30
0

13

15

Problems in the system can be diagnosed using a


manifold gauge by reading the system's low and high
pressures.

High pressure side

0.13 - 0.2 MPa


{1.3 - 2.0 kg/cm2,
18 - 28 psig}

8 - 25

Normal pressures
Low-pressure side: 0.13 ~ 0.2 MPa {1.3 ~ 2.0 kgf/
cm2, 18 ~ 28 psig}
High-pressure side: 1.47 ~ 1.67 MPa {15 ~ 17 kgf/
cm2, 213 ~ 242 psig}

35

3.5

14

Conditions
Atmospheric temperature:
Engine speed:
Blower speed:
Temperature switch:

30 ~ 35 C
(86 ~ 95 F)
1 500 r/min
HI (high-speed)
Full cooling

Fig. 8-33

Low pressure side

High pressure side

98 MPa
{1.0 kg/cm2,
18 psig}

0.78 - 0.98 MPa


{8 - 10 kg/cm2,
114 - 142 psig}

5
4

10

1.5

9
10
11
12

2
0

1
0

15
15

13
14

1.0

15
10
5

0.5

Indications: Low pressures on both the low pressure and high-pressure sides;
Discharge temperature will not decrease.

2.0
2.5

20
25

3.0

30
0

Insufficient refrigerant

35

Cause:

Refrigerant leakage.

Remedy:

Inspect using a gas leak detector, repair the leak, and replenish the refrigerant.

3.5

Fig. 8-34

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8 - 26

CAB
Low pressure side

High pressure side


2.26 MPa
{23 kg/cm2,
327 psig}

0.25 - 0.29 MPa


{2.5 - 3.0 kg/cm2,
36 - 43 psig}
5
4

10

10

1.5

9
11
12

2
0

15

1.0

2.5
25

0.5

Excessive refrigerant
(poor condenser radiation)
Indication:

Both the low and high pressures are too


high.

Causes:

Pressure increment due to excessive


refrigerant.
Insufficient condenser cooling.

Remedy:

Clean the condenser.


Inspect and adjust the fan belt and condenser motor.
Check the refrigerant level.

2.0
20

10

3.0

30
0

13

15

15

W190

35

3.5

14

Fig. 8-35
Low pressure side

High pressure side

0.25 - 0.34 MPa


{2.5 - 3.5 kg/cm2,
36 - 50 psig}

1.96 - 2.45 MPa


{20 - 25 kg/cm2,
284 - 356 psig}

5
4

1.5

10

10
11
12

2
0

1
0

15
15

13
14

1.0

15
10
5

0.5

2.5
25
3.0

30
0

2.0
20

Air in cooling system


(insufficient suction)
Indications: Both the low and high pressures are too
high.
The low-pressure side piping is not cold.
Cause:

Air entered the cooling system. When


the suction is not applied, the reading of
the instruments are indicated in the illustration on the left.

Remedy:

Evacuate the system, replenish the refrigerant and check the gauge readings.
After prolonged operation with air in the
system, the receiver drier must be replaced.

35
3.5

Fig. 8-36

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Low pressure side High pressure side
2.16 - 2.26 MPa
{22 - 23 kg/cm2,
313 - 327 psig}

0.25 MPa
{2.5 kg/cm2,
36 psig}

5
4

1.5

9
10

10

11
12

2
0

15

1.0

15

2.0

Defective expansion valve


Indication:

Both the low and high pressures are too


high.

Causes:

Improper refrigerant charge.


Defective expansion valve.
Improper temperature sensor installation.

Remedy:

Check temperature sensor installation,


and insulation.
If normal, replace the expansion valve.

2.5

20

10

25

35

0.5

13

15

8 - 27

3.0

30

3.5

14

Fig. 8-37
Insufficient compressor compression
Low pressure side

High pressure side

0.39 - 0.59 MPa


{4 - 6 kg/cm2,
18 psig}

0.69 - 1.08 MPa


{7 - 11 kg/cm2,
99 - 156 psig}

5
4

1.5

10

10
11
12

2
0

1
0

15
15

13
14

1.0

15
10
5

0.5

2.5
25
3.0

30
0

2.0
20

Indications: High pressure on the low-pressure side,


pressure too low on the high pressure
side.
The high and low pressures are already
equal when operation is stopped.

35
3.5

Causes:

Insufficient compression due to a defective compressor gasket or damaged suction valve.

Remedy:

Disassemble and repair the compressor.

Fig. 8-38

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8 - 28

CAB
High pressure side

Low pressure side

0.59 - 1.77 MPa


{6 - 18 kg/cm2,
85 - 256 psig}

Vide - 0.13 MPa


{Vide - 1.3 kg/cm2,
Vide - 18 psig}
7

5
4

1.5

10

1.0

10
11
12

2
0

15

2.5

20
25

Indication:

The low-pressure side pressure alternates between a vacuum and normal


pressure.

Causes:

Moisture has frozen in the air conditioner


system, clogging the expansion valve,
which then blocks the air conditioner system. When the ice melts, normal operation resumes.

Remedy:

Replace the receiver drier.


Evacuate the system.
Recharge with refrigerant to the proper
level

35

3.5

14

15

3.0

30
0

13

Infiltration of moisture

2.0

15
10

0.5

W190

Fig. 8-39
High pressure side

Low pressure side

0.49 - 0.59 MPa


{5 - 6 kg/cm2,
71 - 85 psig}

- 101.3 MPa
{- 760 mm Hg,
- 29.92 in Hg}
5
4

10
11
12

2
0

1
0

Fig. 8-40

1.5

10

15
15

13
14

1.0

15
10
5

0.5

2.5
25

Indications: The low pressure side pressure becomes


a vacuum and the high pressure side
pressure reads 0.49 ~ 0.59 MPa {5 ~ 6
kgf/cm2, 71 ~ 85 psi}.

3.0

30
0

2.0
20

Refrigerant does not circulate

35

Ice or condensation are forming on the


piping connections of the drier receiver
or the expansion valve.

3.5

Causes:

The air conditioner system is blocked


by ice or dirt.
The air conditioner system is shut off
by a defective expansion valve temperature sensor.

Remedy:

Stop operation and check for ice or contamination.


If the problem is moisture, evacuate the
system.
Replace the expansion valve temperature sensor if defective.
Replace the receiver drier.
Recharge with refrigerant to the proper
level.

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W190

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8 - 29

8.6.10 SPECIAL TOOLS

Tool Code

Description

Refrigerant recovery, recycling and changing


station
380001326

Electronic leak detector

380001327

Belt tension test tool


380001325

Sanden compressor overhauling tools


380050012

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8 - 30

CAB

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W190

Copyright New Holland