Beruflich Dokumente
Kultur Dokumente
W190
Workshop Manual
Workshop
Manual
W190
PROVEN PERFORMANCE
W190
WHEEL LOADER
Workshop Manual
Print N 604.13.502.01 English
IX - 2005
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.
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.
SUMMARY
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.
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-2
W190
SAFETY RULES
Start and stop the machine carefully when the bucket is full.
Do not move off without first reducing engine speed.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
0-3
SAFETY RULES
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.
MAINTENANCE
GENERALITIES
STOPPING
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-4
W190
SAFETY RULES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
0-5
SAFETY RULES
STARTING
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)
0-6
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.
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.
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)
W190
0-7
SAFETY RULES
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)
0-8
W190
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)
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)
W190
0-9
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)
0 - 10
W190
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
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
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)
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
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)
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
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
or
Ambra Master Gold
FLUIDS OR LUBRICANT
NH-900A
1 (3)
16 (4.2)
QUANTITY
LITRES (USG)
OIL FILTER
ENGINE
ITEM
0 - 11
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:
Example.
I / a
d e / f
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
WARNING
TORQUE TABLES
- Tolerance on torque: 5%
- Resistance classes R80, R100, R120 must be
understood as follows:
"
R120
replaces R80
for nuts
12
"
R100
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0 - 14
W190
NUTS (ZNT)
SCREWS (ZNT/DEIDR)
normal
Diameter
and pitch
low type
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)
SECTION 1
ENGINE
INDEX
PARAGRAPH
SUBJECT
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1-16
1-17
1-18
1-19
1-21
1.5
1.5.1
1.5.2
1.5.3
1-33
1-34
1-35
1-37
1.6
1.7
1.7.1
1.7.2
1.8
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
W190
ENGINE
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
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.
Engine oil
dipstick
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)
W190
1-3
ENGINE
Flex-disc
mounting holes
Flywheel
Water pump
pulley
Alternator pulley
Belt tensioner
Drive belt
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1-4
W190
ENGINE
Engine coolant
by-pass seat
Tappet cover
Injector
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
GENERAL FEATURES
Type
Cycle
Diesel 4-stroke
Air intake
Turbocharged w/aftercooler
Injection
Direct
Number of cylinders
6 in-line
Bore
mm
102
Stroke
mm
120
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
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)
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
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
Belt driven
81 C (177 F)
96 C (204.8 F)
CAPACITY
Total capacity
of first filling:
litres (USG)
kg (lbs)
23 (6.07)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1-7
ENGINE
TIMING
beginning BTDC
end ATDC
A
B
8.5
8.5
beginning BBDC
end ABDC
D
C
51
12.5
mm
mm
Operational
mm
0.25 0.05
mm
0.50 0.005
FUEL
Injection
Type:
Bosch CP3.3
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)
1-8
W190
ENGINE
mm
Cylinder sleeves
102.009 102.031
2
L
Outer diameter
Cylinder sleeves:
L
outer diameter
length
3
X Cylinder sleeves:
1
X
inner diameter
X
1
2
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
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)
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
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
43.279 43.553
40.019 40.033
1.955 1.968
0.266 0.566
0.037 0.016
Conrod half-bearings
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
87.982 88.008
87.977 88.013
0.041 0.119
0.041 0.103
0.033 0.041
Thrust crankshaft
journal
X1
37.475 37.545
X1
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)
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 guide
Valves:
6.970 6.999
60 0.25
6.970 6.999
45 0.25
0.052 0.092
Outer diameter of
valve seat;
Angle of valve seat
on cylinder head:
X Sinking
60
45
0.59 1.11
0.96 1.48
Valve seats
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 12
W190
ENGINE
(1 mm = 0.03937 in)
CYLINDER HEAD - TIMIMG
mm
H1
free spring
47.75
H1
H2
35.33
25.2
Protrusion of injectors
X
1 2 3 4
59.222 59.248
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
0.038 0.162
Cam lift:
H
H
H
6.045
7.582
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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:
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 14
1.3
ENGINE
W190
Fig. 1-7
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ENGINE
Fig. 1-8
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 15
1 - 16
1.4
W190
ENGINE
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.
5
1
7
2
9
4
B
For engines with valve seats inserted in the
cylinder head
Fig. 1-9
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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;
2
3
Oil filler
Fig. 1-10
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 18
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;
Fig. 1-11
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 19
ENGINE
TO DISCHARGE LINE
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 20
W190
ENGINE
DIMENSIONS OF PORTS
P1 T
A B
G1 MT
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 21
ENGINE
Electrical system
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 22
ENGINE
Key switch
Diagnostic connector
Blink-Code button
Coolant temperature
10
Revolution counter
11
Pre-heater ON indicator
12
Starter motor
13
Crankshaft sensor
14
15
16
17
Timing sensor
18
19
20
Pre-heater resistor
21
Electric injectors
22
23
24
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
1 - 23
ENGINE
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
Fig. 1-15
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 24
ENGINE
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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.
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 27
ENGINE
HIGH PRESSURE PUMP CP3
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
D
E
Fig. 1-19
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).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 28
W190
ENGINE
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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).
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 30
W190
ENGINE
B
A
Fig. 1-21
1. Body - 2. Piston - 3. Stop - 4. Spring - 5. Discharged directed to tank - 6. Seat on rail.
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 31
ENGINE
Electric injector
The injector has a design similar to traditional ones.
The electric injector can be considered composed of
two parts:
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 32
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ENGINE
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 33
1 - 34
W190
ENGINE
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
12. OK button
13. serial port indicator
Controller-instrument
connecting cable
Connection point
P T- 0 1
CAN
Fig. 1-25
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 35
ENGINE
ON
ENGINE
DIAGNOSTIC
1-26
Fig. 1-26
Engine inoperative
Key on second click (ON)
"Diagnostic" switch ON
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 36
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 37
ENGINE
6
7
8
9
10
NO
NO
YES
Batteries efficient.
YES
NO
YES
NO
YES
NO
NO
Replace.
YES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 38
W190
ENGINE
NO
YES
NO
NO
YES
Injector efficient.
YES
NO
NO
NO
YES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 39
ENGINE
NO
YES
Thermostat efficient.
NO
Replace.
NO
NO
NO
NO
Replace.
NO
Replace.
YES
Radiator efficient.
YES
YES
YES
YES
Fan efficient.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 40
W190
ENGINE
NO
YES
NO
YES
Thermostat efficient.
NO
Replace.
YES
NO
NO
NO
NO
NO
YES
YES
YES
as
YES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 41
ENGINE
NO
NO
NO
Check - recondition.
YES
NO
Replace.
YES
Injectors efficient.
NO
NO
YES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 42
W190
ENGINE
Injectors efficient.
NO
YES
NO
YES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 43
ENGINE
Knock in crankshaft.
YES
NO
Knock in conrods.
YES
NO
Knock in pistons.
YES
NO
YES
NO
YES
Knock in timing.
NO
YES
YES
NO
Knock in injectors.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 44
W190
ENGINE
NO
YES
NO
Replace.
YES
NO
INSUFFICIENT OR ESCESSIVE
OIL PRESSURE
NO
YES
NO
YES
NO
NO
YES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
10
1 - 45
ENGINE
NO
YES
NO
Replace.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 46
W190
ENGINE
1
6
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 47
ENGINE
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).
Fig. 1-28
1-31
Fig. 1-29
Fig. 1-31
After disconnecting the piping, return stop (1) into locking position of Fig. A to prevent that it could be deformed.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 48
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
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
6
Fig. 1-34
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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.
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 nuts (7) and remove tappet cover (8) complete with gaskets.
1
7
2
8
3
4
Fig. 1-36
Fig. 1-38
Note The fuel manifolds (4) removed, must not be reused, but replaced by new ones.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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.
2
Fig. 1-41
Sling brackets (1) with steel ropes and a hoist to remove cylinder head (2) from the cylinder block.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 52
W190
ENGINE
1
2
1
3
Fig. 1-42
Fig. 1-44
Fig. 1-45
Fig. 1-43
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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.
1
4
3
5
6
3
Fig. 1-47
Fig. 1-49
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 54
W190
ENGINE
1
2
5
1
2
6
4
Fig. 1-50
Fig. 1-52
1
1
2
4
2
Fig. 1-51
Fig. 1-53
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 55
ENGINE
2
2
3
Fig. 1-54
Fig. 1-56
1
2
1
4
2
Fig. 1-55
Fig. 1-57
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 56
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
Fig. 1-61
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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.
1
3
Fig. 1-63
Fig. 1-65
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 58
ENGINE
W190
Fig. 1-66
1
1
Fig. 1-67
Extract tappets (1) from the cylinder block.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 59
ENGINE
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.
1st
B
2nd
3rd
1
1
2
Fig. 1-69
2
Fig. 1-68
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 60
W190
ENGINE
0,06 F
0,015
1,25 + 0,25
(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).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 61
ENGINE
TIMING
Camshaft
54.005
54.035
Fig. 1-72
1
2
Fig. 1-73
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 63
ENGINE
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 64
W190
ENGINE
1
1
3
2
Fig. 1-80
Fig. 1-82
Fig. 1-81
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 65
ENGINE
CRANKSHAFT
Measuring main and conrod journals
CAUTION
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
*
**
45
INTERMEDIATE
FRAMES
2 x 45
FIRST FRAME
FRONT SIDE
45
Fig. 1-86
TOLERANCES
OF SHAPE
OF ORIENTATION
OF POSITION
OF OSCILLATION
GRAPHIC SYMBOL
/
/
//
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 67
ENGINE
2
3
Fig. 1-87
Fig. 1-89
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 68
W190
ENGINE
1
2
Fig. 1-91
Fig. 1-93
Fig. 1-92
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 69
ENGINE
3
1
2
1
2
7
8
6
Fig. 1-95
Fig. 1-97
1. Circlips - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws 6. Half bearings - 7. Conrod - 8. Bush.
1
2
Fig. 1-96
Removal of piston rings (1) from piston (2) using pliers (3).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 70
W190
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.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 71
ENGINE
Piston pins
Piston rings
1
1
2
Fig. 1-101
Fig. 1-103
1
2
1
3
Fig. 1-104
Fig. 1-102
Check the play between piston rings (3) of the second and third grooves and the relevant seats on piston (2) with feeler gauge (1).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 72
W190
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
72.987
73.013
1.955
1.968
Fig. 1-107
MAIN DATA OF CONROD, PISTON PIN BUSH AND
HALF BEARINGS
*
1
2
Fig. 1-106
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 73
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 74
W190
ENGINE
1
2
2
B
3
5
4
4
Fig. 1-110
Fig. 1-111
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 75
ENGINE
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 76
W190
ENGINE
Fig. 1-116
Fig. 1-118
CONROD - PISTON ASSEMBLY IN THE PASSAGE
1
2
3
2
Fig. 1-117
Fig. 1-119
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 77
ENGINE
2
1
Fig. 1-122
Fig. 1-120
1
1
Fig. 1-123
Fig. 1-121
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 78
W190
ENGINE
1
Fig. 1-124
6
4
10
8
3
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 79
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
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).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 80
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
3
1
4
6
5
Fig. 1-132
3
Fig. 1-134
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 81
ENGINE
Fig. 1-135
Fig. 1-137
1
2
Fig. 1-136
Fig. 1-138
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 82
W190
ENGINE
1
1
2
2
Fig. 1-139
Fig. 1-141
2
1
2
3
4
6
5
Fig. 1-140
Fig. 1-142
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 83
ENGINE
2
1
2
3
Fig. 1-143
Fig. 1-145
5
6
1
1
2
2
3
4
Fig. 1-144
Fig. 1-146
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 84
W190
ENGINE
1
4
2
1
3
2
3
Fig. 1-147
Fig. 1-149
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 85
ENGINE
4
1
2
2
3
6
Fig. 1-151
Fig. 1-153
1
2
1
2
3
3
Fig. 1-152
Fig. 1-154
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 86
W190
ENGINE
CYLINDER HEAD
Disassembly of valves
2
A
1
2
Fig. 1-157
S
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.
S = exhaust side
2
1
1
4
Fig. 1-158
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).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 87
ENGINE
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
D
A
B
C
0 3 TOTAL
0.01/50 x 50
Fig. 1-160
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 88
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 89
ENGINE
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 90
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 92
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
Fig. 1-175
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 93
ENGINE
Fig. 1-179
Fig. 1-181
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 94
W190
ENGINE
1
4
Fig. 1-183
Fig. 1-185
1
22.001
22.027
2
21.965
21.977
3
4
5
Fig. 1-184
Fig. 1-186
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ENGINE
3
1
2
Fig. 1-187
cylinder no.
intake
exhaust
1
-
2
*
3
*
-
4
*
5
*
-
6
*
*
1
*
*
2
*
-
3
*
4
*
-
5
*
6
-
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 95
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 97
ENGINE
1
3
2
Fig. 1-189
Fig. 1-191
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 98
W190
ENGINE
1
2
Fig. 1-193
Fig. 1-195
4
2
1
Harness support
3
1
Fig. 1-196
4
3
Fig. 1-194
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1 - 99
ENGINE
1
7
3
2
1
2
5
6
Fig. 1-197
Fig. 1-199
1
2
Fig. 1-198
Install rocker arm cover (1) install nuts (2) and tighten
them to the prescribed torque.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 100
1
2
W190
ENGINE
10
11
12
13
14
6
7
15
8
Fig. 1-200
Fig. 1-201
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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).
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 102
W190
ENGINE
2
1
2
3
3
1-31
Fig. 1-203
Fig. 1-205
4
1
2
9
6
7
10
2
3
4
5
Fig. 1-204
Fig. 1-206
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ENGINE
Fig. 1-207
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 103
1 - 104
W190
ENGINE
TORQUE
1st phase
2nd phase
3rd phase
1st phase
2nd phase
1st phase
2nd phase
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 106
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
1.8
ENGINE
TOOLING
TOOL NUMBER
DESIGNATION
P T- 0 1
380001218
1
4
7
2
5
8
0
CAN
3
6
9
X
1010
380000665
380000663
380001099
Injector puller
380000666
380000664
380000732
380000667
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 107
1 - 108
ENGINE
W190
TOOLING
TOOL NUMBER
DESIGNATION
380000220
Band for the insertion of pistons into the cylinder sleeve (60 - 120 mm)
380000668
380000158
380000216
380000301
380000661
380000362
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ENGINE
TOOLING
TOOL NUMBER
DESIGNATION
380000304
380000221
380000302
380001223
380000228
380000669
380000670
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
1 - 109
1 - 110
ENGINE
TOOLING
TOOL NUMBER
DESIGNATION
380000144
380000364
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
SECTION 2
TRANSMISSION
INDEX
PARAGRAPH
SUBJECT
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2-3
2-4
2-5
2-6
2-7
2-8
2.4
2.4.1
2.4.2
2.4.3
2-11
2-12
2-13
2-16
2.5
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.4.1
2.6.4.2
2.7
2.7.1
2.7.2
2.8
2.8.1
2.8.2
2.8.3
2.9
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
PAGE
2-19
2-20
2-21
2-22
2-43
2-44
2-45
2-55
2-55
2-55
2-72
W190
TRANSMISSION
2-1
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)
Front
Engine
Torque
Front
Transmission
Rear
Rear
Support
Front shaft
Fig. 2-1
Intermediate shaft
Rear shaft
Rear axle
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
TRANSMISSION
2-3
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2-4
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
TRANSMISSION
2-5
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
AN
K4
108
Z=58
AN
K4
K2
KR
KV
AN
K4
K2
K3
112
Z=36
KV
AN
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
K2
105
Z=44
K3
Transmission output
speed sensor
AB
Idle gears
AN
Clutch diagram
Travel direction
Forward
107
Z=49
AB
Reverse
KV
AN
KV
AN
KR
KR
KR
KV
114
Z=55
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
TRANSMISSION
48
47
W190
21
VIEW X
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Speed
1
2
3
4
1
2
3
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
TRANSMISSION
2-7
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2-8
TRANSMISSION
W190
Connector/harness
Cover
Cover
Cover
SECTION A - A
Main pressure relief valve
16 + 2 bar
Connector/
harness
Intermediate 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
W190
TRANSMISSION
2-9
Clutch 1 beginning of
disengagement
G ra d ie n t
(nEng)
= f
Pressure
Clutch 2 End
of engagement
Clutch 2 Beginning
of engagement
Fast filling
Time
Modulation
2-8
Fig. 2-8
Gearshifting
Clutch filling
Clutch
filling
Modulating time
Pressure
Compensazione
Pressione
Veloce
Fig. 2-9
Time
Clutch filling
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 10
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 11
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
20
F
30
10
40
50
FUEL
1\10 h
HOURMETER
HOUR
km\h
Dashboard
Fig. 2-10
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 12
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 13
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 14
1.
TRANSMISSION
W190
Introduction
2.
List of abbreviations
3.
Step to do
Display message
Remarks
Transmission heating
Disengage starting
none
"PL"
"K1"
(Information about
the AEB conditions)
"OK"
(AEB successful)
10
none
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4.
TRANSMISSION
2 - 15
Display
Symbol
Meaning
PL
ST
K1,..K4,KV,KR
e Kx
Remarks
= e Kx
= e Kx
Determination of compensation
pressure of clutch Kx
OK
STOP
STOP e Kx
Wrench e Kx
Kx cannot be calibrated,
AEB terminated
FT
FB
FO
FN
FP
STOP
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 16
TRANSMISSION
W190
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
OUTPUT CURRENT
(INDUCTIVE LOAD)
AD1 AD7
ILmin = 10 mAmp
ILPR = 0.6 Amox
UA = US - 0.3 Volt
- 30 C .. + 70 C
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
=
=
=
=
Fig. 2-13
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 17
FORWARD
FORW.
KD
REVERSE
REV.
NEUTRAL
NEUTRAL.
1 2 3 4
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7
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
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)
2 - 18
TRANSMISSION
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 19
f ed
a bc
left
digit
right
digit
Fig. 2-16
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
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)
2 - 20
TRANSMISSION
W190
Meaning
1F, 1R
2F, 2R
3F, 3R
4F
5F
6F
LF, LR
F or R no speed
F or R
flashing
NN
**
*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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
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
FP
STOP
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 21
11
12
14
Remarks
2 - 22
Reaction TCU
TCU
EEC
PTP
open circuit
short circuit
mode of operation
Abbreviations:
Trouble
Code
(hex)
o.c.
s.c.
OP-Mode
TRANSMISSION
W190
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Trouble
Code
(hex)
15
21
22
23
Remarks
W190
Reaction TCU
TRANSMISSION
2 - 23
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Reaction TCU
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
Remarks
2 - 24
TRANSMISSION
W190
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Trouble
Code
(hex)
27
28
31
Remarks
W190
Reaction TCU
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
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
33
34
35
32
Reaction TCU
Trouble
Code
(hex)
Remarks
2 - 26
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
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
Trouble
Code
(hex)
36
37
38
39
W190
Remarks
TRANSMISSION
2 - 27
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Remarks
2 - 28
3C
3B
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
Trouble
Code
(hex)
TRANSMISSION
W190
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
No reaction
No reaction
59
61
71
3E
Reaction TCU
Trouble
Code
(hex)
W190
Remarks
TRANSMISSION
2 - 29
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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. 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
2 - 30
Reaction TCU
TRANSMISSION
W190
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
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
Trouble
Code
(hex)
Remarks
W190
TRANSMISSION
2 - 31
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
O. C. ON CLUTCH K3
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective
Trouble
Code
(hex)
79
81
Reaction TCU
Remarks
2 - 32
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
O. C. ON CLUTCH K4
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective
83
84
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
Trouble
Code
(hex)
Remarks
W190
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 33
O. C. ON CLUTCH KV
The value of the resistance is off-limits.
wire/connection defective and connected to battery voltage
regulator defective
86
87
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
Trouble
Code
(hex)
Remarks
2 - 34
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
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
Trouble
Code
(hex)
Remarks
W190
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 35
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
Reaction TCU
Remarks
2 - 36
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
Reaction TCU
Remarks
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.
B7
BB
C3
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Remarks
2 - 38
No reaction
OP: normal
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
Trouble
Code
(hex)
TRANSMISSION
W190
It moves to neutral
OP-Mode: Stops TCU
It moves to neutral
OP-Mode: Stops TCU
It moves to neutral
OP-Mode: Stops TCU
D2
D3
D4
D5
check fuses
check wires between batteries
and TCU
check connections between
batteries and TCU
replace TCU
Remarks
W190
D1
Reaction TCU
Trouble
Code
(hex)
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
E3
E4
E5
Remarks
2 - 40
check fuse
check wires from transmission
to TCU
check connectors from gearbox to TCU
replace TCU
It moves to neutral
OP-Mode: Stops TCU
D6
Reaction TCU
Trouble
Code
(hex)
TRANSMISSION
W190
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Transmission stays in
neutral
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
Reprogram the correct configuration for vehicle (ex. With cluster controller etc.)
Replace TCU
Remarks
W190
Transmission stays in
neutral
OP-Mode: TCU stop
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
Trouble
Code
(hex)
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
CLUTCH FAILURE
AEB was unable to regulate the correct clutch
load parameters
one of the AEB values off limits
F4
F5
F6
Remarks
2 - 42
perform AEB
check clutch
F2
Reaction TCU
Trouble
Code
(hex)
TRANSMISSION
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
TRANSMISSION
2 - 43
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
Ad
602
+
EST - 37
Diagnosis
Software
W190-2R002
Fig. 2-17
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 44
TRANSMISSION
W190
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
Fig. 2-19
For
Fortroubleshooting
Diagnostic always
position
= OFF
always in
positio
= OFF
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)
W190
TRANSMISSION
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
2 - 46
TRANSMISSION
W190
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)
W190
TRANSMISSION
2 - 47
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)
2 - 48
TRANSMISSION
W190
S
S
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 49
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
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
Fig. 2-35
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 50
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 51
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
Fig. 2-40
Fig. 2-41
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 52
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 53
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 54
TRANSMISSION
W190
Install the intermediate plate with the mesh filters oriented upward.
Fig. 2-49
Install gasket (2).
2
Fig. 2-50
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 55
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 56
TRANSMISSION
W190
Fig. 2-55
Fig. 2-57
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 57
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 58
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 59
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 60
TRANSMISSION
W190
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!
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 61
Fig. 2-72
Extract the taper roller bearing.
Remove the opposite taper roller bearing in the same
manner.
Bush 380001293
Fig. 2-73
KR
AN
KV
K4
K2
K1
K3
Fig. 2-74
Fig. 2-75
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 62
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 63
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
Fig. 2-81
Fig. 2-82
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 64
TRANSMISSION
W190
Fig. 2-83
Remove the taper roller bearing from the shaft.
Then remove the opposite taper roller bearing.
Bush 380001289
Fig. 2-84
Fig. 2-85
Fig. 2-86
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 65
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 66
TRANSMISSION
W190
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
Fig. 2-93
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 67
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 68
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 69
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 70
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 71
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 72
TRANSMISSION
W190
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.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 73
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 74
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 75
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 76
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 77
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 78
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 79
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 80
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 81
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 82
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 83
= 2.4+0.2 mm
= 1.8+0.2 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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 84
TRANSMISSION
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
1
2
3
2 - 85
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 86
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 87
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 88
TRANSMISSION
W190
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
WARNING
Install outer disc 3 with the unlined face directed
toward the piston.
Fig. 2-164
Fig. 2-165
Install the end spacer and insert the retaining ring
(ex. s = 3.4 mm).
Fig. 2-166
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 89
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 90
TRANSMISSION
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 91
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 92
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 93
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.
K2
K3
AN
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 94
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 95
AN
KV
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 96
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 97
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 98
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 99
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 100
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 101
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 102
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 103
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 104
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 105
Drawing ref.
1=
2=
3=
4=
5=
Gasket
Oil ducts plate
Gasket
Intermediate plate
Gasket
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 106
TRANSMISSION
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
48
2 - 107
47
21
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 108
TRANSMISSION
W190
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
88 - 102 Nm
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 109
6
1
2
10
1
2
4
2
5
9
Fig. 2-237
10
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 110
TRANSMISSION
W190
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
Differential housing
Integral type
Differential limiter
Torque proportional
differential
Final drive
Type
Epicyclic
Weight
Rear
Front
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 111
Fig. 2-239
Note -
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 112
TRANSMISSION
Fig. 2-240
Note -
10
227 Nm
Install with the groove toward plate (6)
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
4
2 - 113
7
1
10
11
12
13
Fig. 2-241
Note -
14
Front axle
230 Nm
230 Nm
Lip: Grease
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 114
TRANSMISSION
Fig. 2-242
W190
10
11
13
14
12
15
5
2
Rear axle
Note - 1
230 Nm
230 Nm
Lip: Grease
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 115
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 116
TRANSMISSION
W190
12
13
14
10
15
11
Fig. 2-244
20
19
18
17
16
Differential
Note -
90 Nm (66.4 ft-lbs)
___
Lip: Grease
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 117
2
10
11
1
1
Fig. 2-245
270-300 Nm
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 118
TRANSMISSION
W190
6
8
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 120
TRANSMISSION
W190
1)
1.
Fig. 2-248
2.
Fig. 2-249
3.
Fig. 2-250
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 121
4.
5.
6.
Fig. 2-251
Fig. 2-252
7.
Fig. 2-253
2)
1.
Fig. 2-254
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 122
2.
TRANSMISSION
W190
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.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
6.
2 - 123
8.
9.
3)
1.
Fig. 2-259
Fig. 2-260
Thrust bolt
Portal jig
Plate
Ring gear
Fig. 2-261
Fig. 2-262
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 124
2.
TRANSMISSION
W190
Fig. 2-263
3.
Note Use caution not to lose the needle roller because they may come off with the planet gear.
Fig. 2-264
4.
5.
Fig. 2-265
6.
Fig. 2-266
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 125
4)
1.
2.
3.
Fig. 2-267
2 1
Fig. 2-268
2
4.
W190-2R004
Fig. 2-269
5.
6.
Fig. 2-270
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 126
TRANSMISSION
5)
1.
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.
Fig. 2-273
6)
1.
Fig. 2-274
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2.
3.
2 - 127
Fig. 2-275
4.
5.
6.
7.
Break the oil seal on the bearing cage with a screwdriver and remove it.
Fig. 2-276
Fig. 2-277
Fig. 2-278
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 128
8.
TRANSMISSION
W190
Fig. 2-279
9.
Fig. 2-280
7)
1.
2.
Fig. 2-281
3.
Fig. 2-282
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
4.
5.
2 - 129
Fig. 2-283
6.
Remove the ring gear and differential case assembly from the differential body.
8)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 130
3.
TRANSMISSION
W190
Tap the center of the spider with a rod to separate the case into two halves.
Fig. 2-287
4.
Fig. 2-288
5.
Fig. 2-289
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 131
9)
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.
3.
4.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 132
W190
TRANSMISSION
1)
1.
Fig. 2-294
2.
Fig. 2-295
3.
Fig. 2-296
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 133
4.
5.
6.
7.
Fig. 2-297
Fig. 2-298
Fig. 2-299
Fig. 2-300
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 134
8.
TRANSMISSION
W190
Fig. 2-301
9.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 135
3)
1.
Note Clean accurately all the parts before assembling them using non-flammable and non-toxic solvents.
Fig. 2-305
2.
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.
Fig. 2-308
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 136
4.
TRANSMISSION
W190
Fig. 2-309
5.
Fig. 2-310
6.
Fig. 2-311
7.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
9.
0.05-0.15
2 - 137
10. Close the differential and check again the correct operation.
Fig. 2-313
Fig. 2-314
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 138
TRANSMISSION
3)
1.
W190
Fig. 2-315
2.
Fig. 2-316
3.
4.
Fig. 2-317
Fig. 2-318
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 139
5.
Insert the pinion shaft into the support, then install the bearing race on the drive pinion.
6.
7.
Fig. 2-319
Fig. 2-320
8.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 140
9.
TRANSMISSION
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 141
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)
1.
2.
Fig. 2-327
Fig. 2-328
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 142
3.
TRANSMISSION
W190
Fig. 2-329
4.
Fig. 2-330
5)
1.
Fig. 2-331
2.
Fig. 2-332
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 143
3.
4.
6)
1.
Fig. 2-333
Fig. 2-334
2.
Fig. 2-335
3.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 144
W190
TRANSMISSION
7)
1.
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.
Face
Frank
Fig. 2-337
a.
Ring gear
Fig. 2-338
b.
Ring gear
Drive pinion
Fig. 2-339
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
c.
2 - 145
Ring gear
Drive pinion
Fig. 2-340
d.
Ring gear
Drive pinion
Fig. 2-341
e.
Ring gear
Drive pinion
Fig. 2-342
8)
1.
Install O-rings at the 2 grooves at the outer diameter of the brake piston. After that, apply
grease.
Fig. 2-343
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 146
2.
W190
TRANSMISSION
W190-2R005
Fig. 2-344
3.
Fig. 2-345
4.
Install the snap ring, disk hub and snap ring onto
the sun gear and shaft.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 147
7.
8.
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)
1.
Fig. 2-351
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 148
2.
W190
TRANSMISSION
Fig. 2-352
3.
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.
Fig. 2-355
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 149
6.
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.
2.
Fig. 2-358
Fig. 2-359
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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.
Note - The measurement position of the height difference (Y) is shown in Fig. 2-361.
Fig. 2-361
5.
Fig. 2-362
6.
7.
Fig. 2-363
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
8.
2 - 151
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.
Fig. 2-365
Fig. 2-366
3.
Fig. 2-367
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 152
4.
TRANSMISSION
W190
Fig. 2-368
5.
Fig. 2-369
6.
7.
Fig. 2-370
8.
Put the selected shim on the axle shaft and install the reassembled planet carrier on the shaft.
Fig. 2-371
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 153
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.
Fig. 2-373
3.
Fig. 2-374
4.
Fig. 2-375
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 154
5.
TRANSMISSION
W190
Fig. 2-376
6.
Fig. 2-377
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
2 - 155
W190-2R008
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190-2R009
2 - 156
TRANSMISSION
W190
W190-2R010
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
2 - 157
TRANSMISSION
2.11 WHEELS/TYRES
Wheels
Tyres
=
=
=
=
=
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
FRONT
REAR
FRONT
REAR
Good Year
3.75 (54.3)
2.50 (36.2)
2.75 (39.8)
2.75 (39.8)
Michelin
3.00 (43.5)
2.00 (29)
2.00 (29)
2.00 (29)
Michelin
3.25 (47)
2.00 (29)
2.00 (29)
2.00 (29)
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)
Michelin
3.25 (47)
2.00 (29)
2.00 (29)
2.00 (29)
Michelin
3.25 (47)
2.00 (29)
2.00 (29)
2.00 (29)
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)
Galaxy
2.50 (36.2)
2.25 (32.6)
Alliance
2.50 (36.2)
1.50 (21.7)
2 - 158
W190
TRANSMISSION
2.12 TROUBLESHOOTING
Trouble
Problem Cause
Noisy differential.
Remedy
Replace.
Adjust or replace.
Replace bearing.
Replace.
Loose bolts.
Retighten.
Replace.
Replace bearing.
Adjust shims.
Replace O-ring.
Loose bolt.
Retighten.
Repair or replace.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
2 - 159
TRANSMISSION
Trouble
Problem Cause
Remedy
Erratic braking.
Retighten or replace.
Overhaul and replace.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 160
W190
TRANSMISSION
Standard dimension
Allowable
limit
Remarks
1.41
2.24
Set by nut
Set by spacer
89.863
Setting shims
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
2 - 161
TRANSMISSION
Values in mm
Item
Standard Size
Useful limit
5.9 to 6.5 mm
(0.232 to 0.256 inch)
5.58 mm
(0.220 inch)
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)
Setting
height
Remarks
Tightening torque
Nm (lbs.ft)
Remarks
230 (170)
150 (110)
90 (66)
230 (170)
Flange nut
670 (494)
50 (37)
1110 (818)
230 (170)
50 (37)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 162
TRANSMISSION
DESIGNATION
380001274
380001275
380001276
380001277
380001280
380001281
380001288
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
TRANSMISSION
2 - 163
TOOLING
TOOL NUMBER
DESIGNATION
380001291
380001295
380001296
380001292
380001269
380001283
380001271
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 164
TRANSMISSION
TOOLING
TOOL NUMBER
DESIGNATION
380001272
380001273
380001290
380001294
380001289
380001293
380001278
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
TRANSMISSION
2 - 165
TOOLING
TOOL NUMBER
DESIGNATION
380001279
Mounting tool for primary shaft oil seal To be used with 380001278
380001270
380001284
380001285
380001286
380001287
380000818
AEB Starter
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 166
TRANSMISSION
TOOLING
TOOL NUMBER
DESIGNATION
380001217
380001219
380001221
380001222
380001224
DPA 04 interface
380001226
380001225
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
TRANSMISSION
TOOLING
TOOL NUMBER
DESIGNATION
380001227
380001297
Display assembly
380002499
380002600
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 167
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
TRANSMISSION
1850-2R521
A.
B.
C.
D.
D.
E.
F.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
2 - 169
2 - 170
W190
TRANSMISSION
380060209 CE - EST KIT COMPLETE KEYBOARD version
380060165 CE - EST KIT COMPLETE TABLET version
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190 EVOLUTION
BRAKE SYSTEM
3-1
SECTION 3
BRAKE SYSTEM
INDEX
PARAGRAPH
SUBJECT
3.1
3.2
3.2.1
3.2.2
3.3
3.3.1
3.4
3.5
3.6
3.6.1
3.6.2
3.7
3.7.1
3.7.2
3.7.3
3.8
3.8.1
3.9
3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
3.10.6
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
W190
BRAKE SYSTEM
3-1
- 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
M
T1
14
N
11
8
6
S
Fig. 3-1
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3-2
BRAKE SYSTEM
W190
2
16
15
14
5
6
13
12
M
7
8
S
11
17
10
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
3-3
3.2 OPERATION
3.2.1 GENERALITIES
Brake system
Conditions of:
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
21
18
T2
16
T1
20
2
7
23
14
N
Conditions of:
-
10
engine running
service brakes engaged
parking brake disengaged
accumulators charged.
17
V = 0,71
Po = 19 bar
11
TO ENGINE
HYDRAULIC FAN
V = 1,41
Po = 70 bar
T
30 bar
PV
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)
3-4
BRAKE SYSTEM
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
BRAKE SYSTEM
3-5
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3-6
BRAKE SYSTEM
W190
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
Backlash
take-up screw
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
BRAKE SYSTEM
3-7
10
Item "C"
13
12
11
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3-8
BRAKE SYSTEM
W190
W190-3R001
Fig. 3-8
ON
OFF
P
Fig. 3-9
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
BRAKE SYSTEM
3-9
B
T
Fig. 3-10
P
S
M
F
G
Fig. 3-11
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3 - 10
BRAKE SYSTEM
W190
Fig. 3-12
F
G
Fig. 3-13
D C
E
Fig. 3-14
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
BRAKE SYSTEM
3 - 11
5
4
Fig. 3-15
Parking brake
1. Brake piston - 2. Springs - 3. Support plate - 4. Transmission output shaft disc - 5. Brake discs.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3 - 12
BRAKE SYSTEM
W190
Fig. 3-16
Accumulator
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
BRAKE SYSTEM
3 - 13
max 19
N
M
T1
F
R2
R1
T2
R3
TI2
P
T1
R1
R2
B
T2
TI1
X
Fig. 3-17
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3 - 14
BRAKE SYSTEM
W190
Release the lock-nut (E, Fig. 3-18) and turn the screw
in or out if pressure values are not within the rated
range.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
BRAKE SYSTEM
3 - 15
M1
M2
7
8
Fig. 3-19
34
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
3 - 16
BRAKE SYSTEM
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
94L95
W190
BRAKE SYSTEM
3 - 17
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
94L95
3 - 18
BRAKE SYSTEM
W190
Fig. 3-22
Brake oil bleed screw (S) locations on the axle (1 per brake)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
BRAKE SYSTEM
3 - 19
Fig. 3-23
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)
3 - 20
BRAKE SYSTEM
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
SECTION 4
STEERING SYSTEM
INDEX
PAGE
PARAGRAPH
SUBJECT
4.1
4.1.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4-6
4-6
4-8
4-9
4-9
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4-10
4-11
4-12
4-14
4-16
4.4
4.5
4.6
4.6.1
4.6.2
4.6.3
4-21
4-21
4-22
4-22
W190
4-1
STEERING SYSTEM
4
5
4
To equipment control
valve
12
To brakes
circuit
14
Hydraulic tank (S)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4-2
STEERING SYSTEM
W190
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4-3
STEERING SYSTEM
7
8
L
R
T LS
5-6
10
11
4
D
F
12
13
14
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
STEERING SYSTEM
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4-5
4-6
W190
STEERING SYSTEM
S2
EF
123456
123456
123456 Static oil
Oil to discharge
CF
EF
LS
CF
EF
CF
LS
LS
PP
PP
PP
S1
P
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4-7
STEERING SYSTEM
Removal
Disassembly
Drain the hydraulic oil from the tank, tagging and disconnecting the oil hoses. Remove the securing screws
and remove the valve.
1
2
3
5
2
6
4
60 Nm
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4-8
W190
STEERING SYSTEM
EF
CF
EF
CF
PP
PP
LS
LS
P
P
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4-9
STEERING SYSTEM
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 10
W190
STEERING SYSTEM
4
T
LS
DANFOSS
1
2
PT L
R
OVPL 28
OSPL 1000 LS
LS
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4 - 11
STEERING SYSTEM
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 12
STEERING SYSTEM
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 14
W190
STEERING SYSTEM
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.
B
C
A
B
C
7
5
Fig. 4-12
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 16
W190
STEERING SYSTEM
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
Note -
37 - 43 Nm
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4 - 17
STEERING SYSTEM
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 18
W190
STEERING SYSTEM
Delivery side
Suction side
Delivery
IN
Suction
Rotation direction
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 20
STEERING SYSTEM
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
4 - 21
STEERING SYSTEM
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
16 Nm (11.8 ft-lbs)
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
4 - 22
STEERING SYSTEM
W190
4.6.3 INSTALLATION
After starting the engine, check, with repeated movements of the steering, that the cylinder rod does not
show signs of leakages.
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 .
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
SECTION 5
PARAGRAPH
SUBJECT
PAGE
5.1
5.1.1
5.1.2
5.1.3
5-1
5-5
5-6
5-7
5.2
5.2.1
5.2.2
5.3
5.4
W190
5-1
Linkage
Bucket shape
Bucket capacity:
Heaped
Struck
Bucket positioner
Boom kick-out
Weight:
Booms
Strut
Link
DEB bucket (without cutting edge)
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)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5-2
W190
6
5
11
7
7
12
12
11
9
10
10
Detail of typical pin
Bucket pins
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5-3
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
Note -
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5-4
W190
Section D-D
Duter lube
groove
8 mm
Immer lube
groove
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5-6
W190
Fig. 5-5
Fig. 5-6
Fig. 5-7
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5-7
A
C
Fig. 5-8
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5-8
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5-9
Note -
1510 Nm
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.
Fig. 5-11
Safety bar
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 10
W190
(Upper hinging)
6
7
1
2
13
(Lower hinging)
14
15
6
16
10
17
11
18
12
2
Note -
88 Nm
215 Nm
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5 - 11
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
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
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.
3
W190-5R003
Fig. 5-15
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 12
W190
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
W190-5R007
Fig. 5-19
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5 - 13
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 14
W190
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
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.
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.
Fig. 5-27
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5 - 15
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 16
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5 - 17
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
W190-5R007
Fig. 5-39
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 18
W190
ATTENTION
1
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5 - 19
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 20
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
5 - 21
20
C
B
Fig. 5-47
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
5 - 22
DESIGNATION
380002594
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
SECTION 6
PARAGRAPH
SUBJECT
PAGE
6.1
6.1.1
6.2
6.2.1
6.3
6.3.1
6.3.2
6.3.3
6.4
6.4.1
6.4.2
6.5
6.6
6.6.1
6.6.2
6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
6.8
6.8.1
6.9
6-9
6-9
6-11
6-12
6-23
6-23
6-23
6-25
6-26
6-27
6-28
W190
6-1
Equipment pump
Hydraulic oil
tank
Main hydraulic
circuit
Bucket dumping
cylinder
Equipment
control valve
Right boom
cylinder
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6-2
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
BOOM CYLINDERS
6-3
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
Q = 162 1/ min
Steering / implement
VPP
12
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
6-4
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
6-5
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.
5
4
A
1
2
3
B
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6-6
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
Suction
chamber
Contact
mark
Suction
chamber
6-7
Contact
mark
Fig. 6-7
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6-8
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
Irregularities
Discharge
side
Irregularities
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
6-9
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)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 10
1
2
View from C
Fig. 6-10
1.
2.
3.
4.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
6 - 11
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 12
c) Operation (B)
W190
Operation
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)
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)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
c) Operation (B)
6 - 13
e) Operation in make-up
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
LP
HP
WARNING
LP
Fig. 6-17
Operation (C)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 14
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)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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.
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Bucket
6 - 16
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
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 18
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.
Supplementary hydraulic
function lever
Fig. 6-23
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
B1
B3
B2
Auxiliary section
A3
6 - 19
A2
A1
Fig. 6-24
A3
A2
(3)
A1
B3
B2
(1)
B1
T
(2)
Fig. 6-25
BOOMS
AUX.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 20
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
6 - 21
6.6 CYLINDERS
6.6.1 BOOMS CYLINDERS
Boom cylinder:
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 22
W190
Boom cylinder:
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
6 - 23
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.
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.
Fig. 6-29
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 24
W190
"Brown box"
controller
Transmission "Est-37"
controller
To transmission
"Est-37" controller
Steering valve
L.T.S. valve
Hydraulic accumulator
Fig. 6-30
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
6 - 25
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 26
W190
Raise the boom to max. height and insist in this position (valve activation) for about five seconds.
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.
Roll-back the bucket: the boom should drop until touching the ground.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
6 - 27
Accumulator
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.
3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumulator.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
94L95
6 - 28
W190
GS98N801
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
6 - 29
10. Install the charging hose fitting onto the accumulator pressure valve (2), refer to the illustration on
page 6-27.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 30
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
BRAKES
HYDR.
REAR
MAIN
MAIN
TRANSM.
PILOT
FWD
TRANSM.
T. CONV.
-1-
TRANSM.
REV
-3-
TRANSM.
-2-
-4-
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 32
1850-2R521
A.
B.
C.
D.
D.
E.
F.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
6 - 33
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
6 - 34
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
SECTION 7
ELECTRICAL SYSTEM
INDEX
PARAGRAPH
SUBJECT
PAGE
7-1
7.1
7-2
7.2
7-3
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
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
7-21
7-23
7-23
7-24
7-35
7-58
7.5
7-60
7.6
7-61
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)
7-2
ELECTRICAL SYSTEM
W190
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)
W190
ELECTRICAL SYSTEM
7-3
20
30
18
29
2
7
1
8
22
11
16
10
3
17
28
21
9
19
6
15
23
12
13
27
14
26
24
25
X18
W190-7R003
Fig. 7-2
MACHINE - CAB INTERFACE
CONTACT
NUMBER
WIRE NUMBER
(MACHINE)
LAYOUT
EMPTY
EMPTY
WIRE NUMBER
(CAB)
WIRE SECTION
(CAB)
EMPTY
72
0.5
60
0.5
SWITCH
60
0.5
19
0.5
19
0.5
81
0.5
81
0.5
83
0.5
83
0.5
10
55
0.5
55
0.5
11
28
0.5
28
0.5
12
43
0.5
AXLE ARRANGEMENT
43
0.5
13
64
0.5
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
22
0.5
23
23
0.5
23
0.5
24
25
46
0.5
26
59
27
28
0.5
29
836
30
19
GROUND
19
31
31
0.5
LINC K31
31
0.5
EMPTY
46
0.5
0.5
59
0.5
0.5
EMPTY
EMPTY
836
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7-4
ELECTRICAL SYSTEM
W190
24-23
W
V
X
K
L
J
H
M
A
N
F
D
E
S
R
O
P
X21
W190-7R004
Fig. 7-3
MACHINE - CAB INTERFACE
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
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)
W190
ELECTRICAL SYSTEM
7-5
24-31
20
31
19
15
13
24
14
27
23
12
16
22
11
17
28
10
18
29
21
30
26
25
X20
W190-7R005
Fig. 7-4
MACHINE - CAB INTERFACE
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
169
EMPTY
613
LAYOUT
WIRE NUMBER
CAB
WIRE SECTION
CAB
169
613
116
116
138
HORN
138
103
103
109
109
EMPTY
EMPTY
10
330
330
11
339
339
12
EMPTY
13
EMPTY
14
231
231
15
223
223
16
219
219
17
221
221
18
EMPTY
945
19
975
975
20
974
21
995 (M)
0.3
974
995 (980)
0.3
22
980 (N)
0.3
980
0.3
23
994 (M)
0.3
994 (981)
0.3
24
981 (N)
0.3
981
0.3
25
EMPTY
26
859
27
956
28
954
29
859
956
954
EMPTY
30
EMPTY
31
EMPTY
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7-6
ELECTRICAL SYSTEM
W190
24-21
H
K
G
L
F
M
D
E
T
N
S
R
X22
W190-7R006
Fig. 7-5
MACHINE - CAB INTERFACE
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
978
EMPTY
996
331
LAYOUT
WIRE NUMBER
CAB
WIRE SECTION
CAB
978
996
EMPTY
EMPTY
331
EMPTY
332
332
1
1
120
120
125
125
802
802
556
556
558
558
876
876
895
895
1.5
801
804
1.5
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7-7
24-18
6
7
8
18
9
1
17
10
5
16
4
11
15
12
14
13
X23
W190-7R007
Fig. 7-6
MACHINE - CAB INTERFACE
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
772
10
809
LAYOUT
WIRE NUMBER
CAB
WIRE SECTION
CAB
10
809
EMPTY
EMPTY
844
844
000
2.5
GROUND
2.5
000
2.5
GROUND
2.5
225
2.5
225
2.5
835
835
10
637
637
11
EMPTY
12
663
13
557
14
555
INDICATOR
15
824
16
886
17
885
18
EMPTY
663
557
555
824
886
885
"
"
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7-8
ELECTRICAL SYSTEM
W190
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)
W190
ELECTRICAL SYSTEM
7-9
7.3.1 FUSES
WARNING
2
1
Fig. 7-8
DESCRIPTION
VALUE
F1A
F1B
F1C
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
15Amp
10Amp
10Amp
F6A
F6B
F6C
7.5Amp
5Amp
5Amp
F7A
F7B
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
10Amp
7.5Amp
10Amp
F7C
F8A
F8B
F8C
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)
7 - 10
ELECTRICAL SYSTEM
W190
50A
80A
Fig. 7-10
Fig. 7-11
D
E
Fig. 7-12
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
ELECTRICAL SYSTEM
7 - 11
FUSE 150A
FUSE 80A
LINK
FUSE 50A
"ACC"
ACCRALAY
ALTERNATOR
MEGA
STARTER
GRID HEATER
F1A - 7.5A
CAB. LIGHTS
LINK
F1D - 20A
F11 B - 20A
EMERGENCY LIGHTS
F2D - 20A
START
ON
ACC
OFF
H
KEY IGNITION
BACK-UP ALARM
F10B - 7.5A
BACK-UP LAMPS
F9B - 3A
15 ALTERNATOR
F8A - 5A
F6C - 5A
ZF CONTROL UNIT
F10C - 10A
HEAD LIGHTS
F11A - 7.5A
F4E - 4A
S ALTERNATOR
HORN
HORN RELAY SOLENOID
EMPTY
F11C - 3A
F12A - 3A
F8C - 7.5A
CONTROL UNIT ZF
F6B - 5A
F12B - 7.5A
F10A - 7.5A
LIGHTER
F3E - 7.5A
ST M ACC G2 G1 B
F7A - 15A
INSTRUMENT LIGHT
F6A - 7.5A
F9A - 3A
EMPTY
LIGHTER LAMP
F7C-3A
F9C - 7.5A
CLUSTER METER
F5C - 10A
F5B - 10A
F5A - 15A
PLATE LIGHT
F1E-4A
STOP LIGHTS
F2A - 7.5A
F12C - 10A
LOWER BEAMS
F2E-4A
BEACONS
F2B - 7.5A
W.I.F.
F2C - 7.5A
OPTIONAL
FRONT WINDSCREEN WIPER MOTOR
F4C - 5A
SEAT HEATER
F3A - 15A
POT. DIVIDER
RADIO - OPTIONAL
F3B - 5A
F3C - 5A
JACK 12 V
LAMPS SWITCH
CB - OPTIONAL
F4A - 5A
TURN LIGHTS
Fig. 7-13
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
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
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.
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
CIG.LIGHTER LIGHT
X3-17
X3-18
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
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
X4-9
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
ELECTRICAL SYSTEM
W190
Fig. 7-14
W190
ELECTRICAL SYSTEM
7 - 13
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
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)
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
FM
WTM
OTM
EHM
SM
L1-L13
L14 - L21
:
:
:
:
:
:
:
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
ELECTRICAL SYSTEM
7 - 15
BUTTON - 0
BUTTON - 1
BUTTON - 2
BUTTON - 3
Fig. 7-17
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 16
ELECTRICAL SYSTEM
W190
Engine coolant
temperat. indicator
150 C
50 C
67 C00
102 C00
50 C00
120 C00
Nominal value
of resistance
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
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)
W190
ELECTRICAL SYSTEM
7 - 17
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
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)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
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
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
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)
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
S17
978
ZF45
996
ZF45
978
21/A
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
ZF45
ELECTRICAL SYSTEM
7 - 21
Camshaft sensor
Crankshaft sensor
BOSCH
EDC7 controller
BOSCH
BOSCH
Alternator
Temperature sensor
Fuse 80 Amp
Fuse 50 Amp
79102142
Depression switch
Connector x 21
Level indicator sender
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
ELECTRICAL SYSTEM
W190
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
DETAIL K
Switch
Electric
timer
Switch 15 bar
(26.10 psi)
Main switch
ELASIS
DETAIL R
SECT. A-A
VIEW FROM A
Proportional amplifier
SECT. B-B
Ground cable
VIEW FROM B
DETAIL W
Washer tank
Relay
Diode
Plaid assembly
Solenoid switch
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Fuse holder
Fig. 7-26
W190
ELECTRICAL SYSTEM
7 - 23
To ground
Battery
Fig. 7-27
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)
7 - 24
ELECTRICAL SYSTEM
W190
782
TECHNICAL DATA
Nominal voltage: 24 V
Solenoid nominal current: 2 A
IV-4
IV-16
780
Fig. 7-29
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)
W190
ELECTRICAL SYSTEM
7 - 25
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 26
ELECTRICAL SYSTEM
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 27
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 29
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)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 31
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
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
K1
K2
K3
K4
Fig. 7-43
K5
K6
K7 K8
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 34
ELECTRICAL SYSTEM
W190
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
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
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 35
2
1
Fig. 7-45
M10 x 1
15 1 bar (217 14.50 psi)
20 Nm
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 36
ELECTRICAL SYSTEM
W190
13
6
12
11
10
Fig. 7-46
Ref.
Description
Electric injector
Air temperature/pressure
Starter motor
Timing sensor
10
Crankshaft sensor
11
12
13
Pre-post-heater resistor
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 37
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.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 38
ELECTRICAL SYSTEM
W190
12
16
11
Fig. 7-48
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 39
1 3
23
16 9
15 22
4
5
30 36
29
Fig. 7-49
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 40
ELECTRICAL SYSTEM
CONTROL UNIT
Fig. 7-50
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
ELECTRICAL SYSTEM
7 - 41
71
89
72
54
11
1
7
12
53
35
18
36
17
Fig. 7-51
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
W190
ELECTRICAL SYSTEM
STARTING
ENGINE
REL
GOLD START
REL
PREHEARTER
Fig. 7-52
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 43
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 45
RESISTOR
Fig. 7-55
Fig. 7-56
A. Control solenoid switch.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 46
ELECTRICAL SYSTEM
W190
Fig. 7-57
A. Coolant temperature sensor.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 47
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
17C
34C
7 - 48
ELECTRICAL SYSTEM
W190
ELECTRIC DIAGRAM
Fig. 7-61
Fig. 7-62
Ref.
DESCRIPTION
CONTROLLER PIN
OIL
AIR
Ground
19C
21C
33C
29C
Power + 5 Volt
9C
10C
Signal (pressure)
35C
28C
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 49
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 .
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 50
ELECTRICAL SYSTEM
W190
Ref.
1
2
3
Description
Ground
Signal
Power
Controller pin
20 C / 68 F
27 C / 80.6 F
12 C / 53.6 F
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 51
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 52
ELECTRICAL SYSTEM
W190
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 53
7 - 54
ELECTRICAL SYSTEM
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)
574
574
WIRES
570 To controller ZF PIN X19-46
574 To controller ZF PIN X19-49
TECHNICAL DATA
Thread: M16 x 1.5
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 55
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 56
ELECTRICAL SYSTEM
W190
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
B1
B2
B3
B4
Fig. 7-77
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 57
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 59
663
000
Fig. 7-80
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 60
ELECTRICAL SYSTEM
W190
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)
MIN.
MED.
MAX
Fig. 7-82
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 61
Fig. 7-83
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
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
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
20 ROSSO-NERO/RED-BLACK
15 5
16 6
2 AZZURRO-BIANCO/LIGHT BLUE-WHITE
17 7
18 8
13 BIANCO-WHITE
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
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
ELECTRICAL SYSTEM
7 - 63
x1-12
x1-12+24V
+24 VALIMENTAZIONE
POWER
UI
R1
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
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 64
ELECTRICAL SYSTEM
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
W190
SECTION 8
CAB
TABLE OF CONTENTS
PAGE
PARAGRAPH
SUBJECT
8.1
8.2
8.2.1
8.3
8.4
8.4.1
8.4.2
8.5
8.5.1
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
8-11
8-11
8-12
8-14
8-16
8-18
8-19
8-19
8-20
8-22
8-29
W190
CAB
8-1
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.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
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.
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.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
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.
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 -
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.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8-4
CAB
W190
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.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
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
7
5
A
Fig. 8-10
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)
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8-6
CAB
W190
4
6
2
1
7
Fig. 8-12
5 0.2 mm
0.19 0.007 in
Fig. 8-11
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
W190
CAB
8-7
Fig. 8-14
2. Thoroughly clean the glass edge using the special
cloth moistened in the degreaser supplied.
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
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8-8
CAB
W190
5. Punch the membrane in the threaded connection.
Fig. 8-18
Fig. 8-16
Fig. 8-19
Fig. 8-17
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
W190
CAB
8-9
Glass assembly
WARNING
1. Position the glass in its seat slightly pressing it.
Fig. 8-20
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 10
CAB
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
W190
CAB
8 - 11
Fan unit
Evaporator
Compressor
Expansion valve
Condenser
Intake
High
pressure
Low
pressure
Filter
Pressure switch
W190-8R001
Fig. 8-21
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 12
CAB
W190
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
Expansion valve
Type
Gas
Superheat
Compressor
Type
Displacement
Pulley
Lubricant oil q.ty
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
OUT 0 C (32 F)
IN
5 C (41 F)
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
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
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 14
CAB
W190
6
1.
2.
3.
4.
5.
6.
7.
8.
9.
ERROR DESCRIPTION
E1
E2
E3
E4
E5
E6
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
8 - 15
the outside temperature exceeds 26 C (79 F)
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 16
CAB
W190
Conditioning Performance
Piping precautions
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.
CAUTION
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere.
O-Ring
Union
1850-2R392
Fig. 8-23
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
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
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
Fig. 8-24
Compressor oil
Use compressor oil made specifically for use with
R134a.
R134a system compressor oil has an extremely high
moisture absorption capacity.
Fig. 8-26
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 18
CAB
W190
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.
High pressure
Charging hose
Charging hose
Coupler
Vacuum pump
Refrigerant container
Fig. 8-27
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
8 - 19
8.6.6 DISCHARGING
CAUTION
WARNING
Do not release the refrigerant into the air.
Discharge refrigerant only into the refrigerant recovery unit.
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.
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.
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.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
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
Operation test
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
Repair
CAB
8 - 21
Inspection sequence
High pressure side
Compressor
discharge port
Condenser
inlet and outlet
Cooling unit
inlet
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
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 22
CAB
W190
Possible cause
Remedy
1. Blown fuse
Replace.
2. Broken wiring
or bad connection
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.
Replace.
Replace.
Possible cause
Remedy
1. Evaporator iniet
obstruction
2. Air leak
Repair of adjust.
3. Defective thermo
switch
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.
2. Excessive refrigerant
Possible cause
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
8 - 23
Inspection
Remedy
1. Loose V-belt
2. Internal compressor
malfunction
Repair or replace.
Clutch slips.
Faulty coil
Same as above.
Excessive clearance
between the clutch
plate and clutch disk.
The clutch plate clings
when pushed.
Open coil
Replace.
Clutch will not engage at all. Inspect the earth and connections.
Repair.
Check operation, referring to the wiring diagram, and replace defective parts.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
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
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.
Frost has adhered to the compressor connector so that the temperature is lower than that of the evaporator outlet side piping.
Replace.
1. Insufficient refrigerant.
Same as at left.
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.
6. Defective thermoswitch.
Adjust or replace.
2. Excessive refrigerant.
Same as at left.
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
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
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
98 MPa
{1.0 kg/cm2,
18 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
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 26
CAB
Low pressure side
10
10
1.5
9
11
12
2
0
15
1.0
2.5
25
0.5
Excessive refrigerant
(poor condenser radiation)
Indication:
Causes:
Remedy:
2.0
20
10
3.0
30
0
13
15
15
W190
35
3.5
14
Fig. 8-35
Low pressure side
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
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
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
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
Causes:
Remedy:
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
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
35
3.5
Causes:
Remedy:
Fig. 8-38
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 28
CAB
High pressure side
5
4
1.5
10
1.0
10
11
12
2
0
15
2.5
20
25
Indication:
Causes:
Remedy:
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
- 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
3.0
30
0
2.0
20
35
3.5
Causes:
Remedy:
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
CAB
8 - 29
Tool Code
Description
380001327
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
8 - 30
CAB
Carefully read personal and machine SAFETY PRECAUTIONS at the beginning of this Manual
W190