New Holland W190D Stage IV Wheel Loader Service Repair Manual by Repair manual download

SER VICE MANUAL

W190DEH, NEW CAB T ier

W190D ZBAREH, NEW CAB T ier

14/12/2017

Product / Engine Product Market Product Engine W190D ZBAR - NEW CAB T ier Europe F4HFE613S*B004 W190DEH, NEW CAB T ier Europe F4HFE613S*B004 14/12/2017

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13] Powershift transmission

Powershift transmission internal components

T orque converter

Drive (4WD) system

Front axle system

Powered front axle

Front bevel gear set and dif ferential

Final drive steering and shafts

Rear axle system . . . .

[27.100]

Brakes and controls

Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.310] Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 Engine lubrication system T ransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[10.414]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

[23.314]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1

rear axle

bevel gear set and dif

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

[27.106] Rear

ferential

[27.120]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

service brakes 14/12/2017

Hydraulic

10]

Parking brake parking lock

Hydraulic systems

Hydraulic systems [35.300]

Main

Pilot system

Remote control valves

Hydraulic fan drive cooling system

Front loader arm hydraulic system

Front loader bucket hydraulic system

Frames

Steering control

Hydraulic control components

Cylinders

Auxiliary steering

Front wheels

[44.520]

Reservoir , cooler , and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

V ariable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.106]

control valve

ool quick coupler hydraulic system

and ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheels

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

Rear

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

wheels

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air conditioning Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [55.100] Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 14/12/2017

Cab climate control

Battery Selective Catalytic Reduction (SCR) electrical system [55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.512] Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.530] Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.DTC] F AUL T CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 Front loader and bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm Bucket cab, and decals [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 operator seat operator seat Machine shields and guards 14/12/2017

14/12/2017

INTRODUCTION 14/12/2017 1

Contents INTRODUCTION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . Basic instructions - How use the maintenance standard and precautions . . . . . . . . . . . . . . . . . Basic instructions - Precaution for disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic instructions - Electrical equipment precautions Consumables Consumables - Biodiesel Fuel Hydraulic contamination Product identification Product identification 14/12/2017 2

Safety rules

Personal safety

This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury

Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with

Read and understand all the safety messages this manual before you operate service the

DANGER indicates a hazardous situation not will result death serious injury

W ARNING indicates a hazardous situation not could result death serious injury

CAUTION indicates a hazardous situation not could result minor moderate injury

F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .

Machine safety

NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.

Throughout this manual you will find the signal word Notice followed special instructions prevent machine property damage. The word Notice used address practices not related personal safety .

Information

NOTE: Note indicates additional information that clarifies other information this

Throughout this manual you will find the word Note followed additional information about a step, other information the The word Note not intended address personal safety property

INTRODUCTION

14/12/2017 3

Personal safety

Carefully read this Manual before proceeding with refuelling other machine

Repairs have carried out only authorized and structed staf specific precautions have taken when welding when using mallets heavy mers.

Non - authorized persons are not allowed repair carry out maintenance this machine. not carry out any work the equipment without prior

Ask your employer about the safety instructions force and safety

TULI12WEX2004AA

Nobody should allowed the cab during machine maintenance unless a qualified operator helping with the maintenance

necessary move the equipment carry out pairs not lift lower the equipment from any other position than the operator ’ s seat.

Never carry out any operation the machine when the engine running, except when specifically indicated.

Stop the engine and ensure that all pressure relieved from hydraulic circuits before removing caps, covers,

All repair and maintenance operations should carried out with the greatest care and

Service stairs and platforms used a workshop the field should built compliance with the safety rules

Any functional especially those fecting the safety the should therefore rectified immediately .

DANGER

Unexpected movement!

Make sure parking brake applied. Secure machine with wheel chocks.

Failure comply will result death serious injury .

D0013A

Before performing any work the attach a maintenance progress This tag can applied the left - hand control lever , safety lever cab door

TULI12WEX2005AA

INTRODUCTION

14/12/2017 4

Emergency prepared for emergencies. Always keep a fire guisher and first aid kit readily Ensure that the fire extinguisher serviced accordance with the ufacturer ’ s

INTRODUCTION

SMIL12WEX0174AA 3

Equipment

W ear close fitting clothing and safety equipment appropriate for the job:

• Safety helmet

• Safety shoes

• Heavy gloves

• Reflective clothing

• W weather clothing

working conditions the following personal safety equipment should hand:

• Respirators (or dust proof masks)

• Ear plugs acoustic ears protections

TULI12WEX2008AA 4

• Goggles with lateral shield masks for eye protection not wear jewelry , unbuttoned flapping clothing such torn open jackets shirts with open zips which could get caught into moving

Engine - Radiator

Never leave the engine running enclosed spaces without proper ventilation which able evacuate toxic haust gases - Keep the exhaust manifold and tube free from combustible

not refuel with the engine especially this increases fire hazard case fuel

Never attempt check adjust the belts when the gine

Never lubricate the machine with the engine

TULI12WEX2009AA 5

14/12/2017 5

Pay attention rotating components and not allow anyone approach these areas avoid becoming

Hands, clothing tools getting caught the fan blades engine can cause violent hemorrages and generate conditions grave danger For this reason avoid touching approaching all rotating moving

A surging spray the coolant from the radiator can cause serious burns and

Before checking the coolant shut - f the engine and allow machine cool down the radiator and Slowly unscrew the cap release any residual

necessary remove the cap while engine hot, wear safety clothes and then loosen the cap slowly relieve the pressure gradually

When checking the oil and coolant use lights and lamps explicitly designated explosion these types lamps are not used, fires explosions may occur

TULI12WEX2010AA

Hydraulic systems

Jets fluids under pressure can penetrate the skin ing serious injuries.

A void this hazard relieving pressure before ing hydraulic other lines.

Relieve the residual pressure moving the hydraulic control levers several times.

T ighten all connections before applying

T o protect the eyes wear a facial shield safety goggles.

Protect your hands and body from possible jets fluids under pressure.

Swallowing hydraulic oil a severe health

TULI12WEX2012AA 8

INTRODUCTION

TULI12WEX201 1AA 7

14/12/2017 6

When hydraulic oil has been avoid but consult a doctor a

accident see a doctor familiar with this type injury immediately .

Any fluid penetrating the skin must removed within a few hours avoid serious infections.

Flammable splashes may originate because heating near lines with fluids under pressure, resulting serious not weld use torches near lines containing fluids other flammable

Lines under pressure can accidentally pierced when the heat expands beyond the area immediately

Arrange for temporary fire resistant shields protect hoses other components during welding torch

Have any visible leakage repaired immediately

Discharged oil pollutes the Soak any oil that has spilled with a proper binding Sweep binding agent and dispose separately from other

Never search for leakages with fingers; use a piece cardboard and always wear

Never repair a damaged line; always replace Replace hydraulic hoses immediately detecting any damaged moist

Always store hydraulic oil the original

INTRODUCTION

9 14/12/2017 7

TULI12WEX2013AA

Hoses and tubes

Always replace hoses and tubes the cone end the end connections the hose are

When installing a new loosely connect each end and make sure the hose takes the correct position fore tightening the Clamps should ened suf ficiently hold the hose without crushing and prevent

After replacing a hose a moving component, check that the hose does not fall moving the component through the complete range sure any hose which has been installed not kinked

Hose connections which are crushed restrict oil flow and the productivity the ponents being Connectors which show signs movement from the original position have failed and will ultimately separate completely

A hose with a frayed outer sheath will allow water

TULI12WEX2014AA

Concealed corrosion the wire reinforcement could subsequently occur along the hose length with resultant hose failure.

Ballooning the hose indicates internal leakage due structural failure. This condition rapidly deteriorates and total hose failure soon

stretched deformed hoses generally suf fer internal structural damage which can result oil a reduction the speed operation and mate hose failure.

Free - unsupported hoses must never allowed touch each other related working surfaces. This causes chafing which reduces hose

O - rings

Replace O - seal rings and gaskets whenever they are

Never mix new and old seals O - regardless Always lubricate new seal rings and O - rings with hydraulic oil before installation relevant seats.

This will prevent the O - rings from rolling over and twisting during mounting which will jeopardize sealing.

INTRODUCTION

14/12/2017 8

Battery

Batteries give f explosive gases.

Never handle open flames and unshielded light sources near (No smoking addressed the next

T o prevent any risk observe the following instructions:

• When disconnecting the battery always nect the negative ( cable

• T o reconnect the battery always connect the negative ( cable last.

• Never short - circuit the battery terminals with metal ob-

• not grind smoke near a battery

Battery electrolyte causes severe burns. The battery tains sulphuric A void any contact with the eyes

T reatment:

• EXTERNAL: Rinse well with water , removing any soiled

• INTERNAL: A void Drink water rinse your mouth. Consult a doctor .

• EYES: Rinse abundantly with water for min and consult a doctor .

• When the electrolyte a battery can plode you attempt charge the battery you try start the engine using a booster battery Always keep the battery charged prevent the electrolyte

Provide good ventilation when changing a battery using a battery enclosed Always protect your eyes when working near a battery

Never set tools down the battery They may induce a short causing irreparable damage the battery and injuring

Never wear metal bracelets watch straps when working the battery The metal parts may induce a short circuit resulting

Dispose used batteries separately from other waste the interests environmental

INTRODUCTION

TULI12WEX2015AA

TULI12WEX2016AA

TULI12WEX2017AA

1 1

14/12/2017 9

Flammable liquids

When handling flammable liquids:

• not

• Keep away from unshielded light sources and open

Fuels often have a low flash point and are readily ignited.

Never attempt extinguish burning liquids with water Use:

• Dry powder

• Carbon dioxide

• Foam

TULI12WEX2016AA

W ater used for extinguishing purposes would vaporize stantaneously contact with burning substances and spread burning for over a wide W ater generates short circuits the electrical system, possibly producing new

Stay away from open flames during refilling hydraulic oil

Fuel oil spills can cause slipping hazards; thoroughly contain and clean fected

Always tighten the safety plugs fuel tank and hydraulic oil tank firmly

Never use fuel clean machine parts that will exposed dirt

Use a non - flammable product for cleaning

Always perform fuel oil refilling well aired and lated

During refuelling hold the pistol firmly and always keep contact with the filler neck until the end the avoid arcing due static electricity

not overfill the tank but leave a space for fuel

Never refuel when the engine

T ake all the necessary safety measures when grinding when working near exposed

TULI12WEX2018AA

TULI12WEX2019AA

INTRODUCTION

14/12/2017

T ires

Before inflating the tires, always check the condition rims and the outer condition tires for the presence tears reinforcement plies other Before inflating a make sure that there are nearby then position yourself tread

When inflating tires, ensure tire pressure does not exceed that prescribed the tire manufacturer Ensure that the pressure the right tire corresponds the pressure the left

NOTE: The front and rear tire pressures may

Never use reconditioned rims because possible heat treatments brazings not performed correctly can weaken the wheels and cause damage Deflate the tires before their disassembly .

TULI12WEX2020AA

Before taking out possible jammed objects from the necessary deflate the tires. Inflate tires means inflation pistol complete with extension and pressure control Use inflation

Cleaning

Clean the exterior all components before carrying out any form repair Dirt and dust can reduce the ficient working life a component and lead costly

Solvents should checked that they are suitable for the cleaning components and also that they not risk the personal safety the user

grease and scattered tools are dangerous for because they can create slipping tripping

For machine cleaning, use a jet warm water steam under pressure and commercial Never use petroleum because they can leave oily residue that attracts and solvents (even weak) damage the paint and can lead the formation

TULI12WEX2021AA

Never use water jets steam connectors other electric

A void direct spray seals and seams prevent water penetration inside the

INTRODUCTION

14/12/2017 1 1

W aste disposal

Improperly disposing waste can threaten the

Each country has its own Regulations this therefore advisable prepare suitable containers collect and store momentarily all solid and fluid materials that must not scattered the environment avoid

These products will delivered preset intervals ing the forward environmental

Below are listed some products from the machine ing disposal:

• Lubricating oil

• Brake system oil

• Coolant condensation rests and pure tifreeze

• Fuel

• Filter oil and fuel filters

• Filter air filters

• Battery

Also polluted paper , sawdust and gloves must disposed compliance with the same procedures.

not use food beverage containers that may mislead someone into drinking from them. not pour waste onto the down a into any water Air conditioning refrigerants escaping into the air can damage the s Government regulations may quire a certified air conditioning service centre recover and recycle used air conditioning refrigerants. Obtain formation the proper way recycle dispose waste from your local environmental recycling from your Dealer

INTRODUCTION

TULI12WEX2022AA 14/12/2017

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