New Holland W190D Service Manual
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New Holland W190D Service Manual

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

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  • Page 1 SERVICE MANUAL W190D Stage IV Wheel Loader Part number 48144035 English June 2017 © 2017 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL W190D XR - EH, NEW CAB Tier 4B W190D ZBAR - EH, NEW CAB Tier 4B 48144035_EN 03/07/2017 Find manuals at https://best-manuals.com...
  • Page 3 Link Product / Engine Product Market Product Engine W190D ZBAR - EH, NEW CAB Europe F4HFE613S*B004 Tier 4B W190D XR - EH, NEW CAB Tier Europe F4HFE613S*B004 48144035_EN 03/07/2017 Find manuals at https://best-manuals.com...
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.202] Air cleaners and lines .
  • Page 5 Hydraulic systems............... 35 [35.000] Hydraulic systems..............35.1 [35.300] Reservoir, cooler, and filters.
  • Page 6 [55.989] Exhaust Gas Recirculation (EGR) electrical system ....... 55.5 [55.512] Cab controls............... . 55.6 [55.530] Camera.
  • Page 7 48144035_EN 03/07/2017 Find manuals at https://best-manuals.com...
  • Page 8 INTRODUCTION 48144035_EN 03/07/2017 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Safety rules ..................3 Personal safety .
  • Page 10 INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.
  • Page 11 INTRODUCTION Personal safety Carefully read this Manual before proceeding with main- tenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and in- structed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy ham- mers.
  • Page 12 INTRODUCTION Emergency Be prepared for emergencies. Always keep a fire extin- guisher and first aid kit readily available. Ensure that the fire extinguisher is serviced in accordance with the man- ufacturer’s instructions. SMIL12WEX0174AA Equipment Wear close fitting clothing and safety equipment appropri- ate for the job: •...
  • Page 13 INTRODUCTION Pay attention to rotating components and do not allow anyone to approach these areas to avoid becoming en- tangled. Hands, clothing or tools getting caught in the fan blades or engine belts, can cause amputations, violent hemorrages and generate conditions of grave danger. For this reason avoid touching or approaching all rotating or moving parts.
  • Page 14 INTRODUCTION When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital. If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid penetrating the skin must be removed within a few hours to avoid serious infections.
  • Page 15 INTRODUCTION Hoses and tubes Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the correct position be- fore tightening the connections.
  • Page 16 INTRODUCTION Battery Batteries give off explosive gases. Never handle open flames and unshielded light sources near batteries. (No smoking is addressed in the next in- struction). To prevent any risk of explosion, observe the following instructions: • When disconnecting the battery cables, always discon- nect the negative (-) cable first.
  • Page 17 INTRODUCTION Flammable liquids When handling flammable liquids: • Do not smoke. • Keep away from unshielded light sources and open flames. Fuels often have a low flash point and are readily ignited. Never attempt to extinguish burning liquids with water. Use: •...

  • Page 18: Personal Safety

    INTRODUCTION Tires Before inflating the tires, always check the condition of rims and the outer condition of tires for the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tire, make sure that there are no nearby persons, then position yourself at tread side.
  • Page 19 INTRODUCTION Waste disposal Improperly disposing of waste can threaten the environ- ment. Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

  • Page 20: Basic Instructions - Important Notice Regarding Equipment Servicing

    Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your NEW HOLLAND CONSTRUCTION Sales and Service Networks. 48144035_EN 03/07/2017...

  • Page 21: Basic Instructions - How To Use The Maintenance Standard And Precautions

    INTRODUCTION Basic instructions - How to use the maintenance standard and precautions Application WHEN THE MACHINE IS NEW Confirm that the performances are in accordance with standard specifications as compared to the performance stan- dards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY) Use the data for the criterion, for the purpose of correction, adjustment and replacement.
  • Page 22 INTRODUCTION PARTS REQUIRING REGULAR REPLACEMENT Critical hoses that are necessary to secure safety, we designate as Very Important Parts (V.I.P.) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize themselves with the machine and handle safely. Use caution when inspecting and replacing oils and grease.

  • Page 23: Basic Instructions - Precaution For Disassembly And Assembly

    INTRODUCTION Basic instructions - Precaution for disassembly and assembly Preparations for disassembly • Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine com- ponents, as well as decreased efficiency in service work.
  • Page 24 INTRODUCTION Reassembling hydraulic equipment • Clean parts in a well ventilated room. • Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly. • Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling. •...

  • Page 25: Basic Instructions - Electrical Equipment Precautions

    INTRODUCTION Basic instructions - Electrical equipment precautions WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. An- tidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk.

  • Page 26: Consumables

    Total system capacity 178 L (47 US gal) Reservoir capacity 90.8 L (24 US gal) Transmission Type of oil NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL Technical specifications SAE 10W - 30 API GL-4 ISO VG-32/46 NEW HOLLAND CONSTRUCTION specifications...

  • Page 27: Consumables - Biodiesel Fuel

    INTRODUCTION Consumables - Biodiesel Fuel Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters. NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751.

  • Page 28: Hydraulic Contamination

    INTRODUCTION Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: • When you drain the oil or disconnect any line •...

  • Page 29: Product Identification

    INTRODUCTION Product identification The terms right-hand, left-hand, front, and rear are used in this manual to indicate the sides as they are seen from the operator's seat. 1. Front 2. Right-hand 3. Rear 4. Left-hand RCPH10WHL003BAH 48144035_EN 03/07/2017...
  • Page 30 INTRODUCTION Product identification LEIL17WHL1061FA 1. Roll Over Protection System (ROPS) cab 5. Steps 2. Door handle 6. Bucket 3. Electric disconnect and battery jump post 7. Loader lift arms 4. Battery access 8. Bucket cylinder 48144035_EN 03/07/2017...
  • Page 31 INTRODUCTION LEIL17WHL1060FA 1. Pre-cleaner 5. Bucket 2. Sliding access panel 6. Cab air filters door 3. Cab side window 7. Windshield washer reservoir 4. Driving lights 8. Diesel Exhaust Fluid (DEF)/AdBlue® fill tank 48144035_EN 03/07/2017...
  • Page 32 SERVICE MANUAL Engine W190D XR - EH, NEW CAB Tier 4B W190D ZBAR - EH, NEW CAB Tier 4B 48144035_EN 03/07/2017...
  • Page 33 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.202] Air cleaners and lines .
  • Page 34 Engine - 10 Engine and crankcase - 001 W190D XR - EH, NEW CAB Tier 4B W190D ZBAR - EH, NEW CAB Tier 4B 48144035_EN 03/07/2017 10.1 [10.001] / 1...
  • Page 35 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine General specification ............... 3 Engine horse power .
  • Page 36 Engine - Engine and crankcase Engine - General specification Engine with 4 Speed Transmission A. Low idle 870 RPM to 930 RPM Alternate low idle 670 RPM to 730 RPM Alternate Accelerated Idle 1270 RPM to 1330 RPM B. Maximum No Load RPM 2065 RPM to 2185 RPM C.
  • Page 37 Engine - Engine and crankcase LEIL17WHL0358GA NOTE: performances detected at engine test bench. NOTE: BSFC indicates the Brake Specific Fuel Consumption. 48144035_EN 03/07/2017 10.1 [10.001] / 4...
  • Page 38 Engine - Engine and crankcase Engine - Remove NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen- erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors.
  • Page 39 Engine - Engine and crankcase 4. Raise the grill located above the cooler box just behind the cab. Then slowly loosen the hydraulic reservoir filler cap to release pressure in the reservoir. RCPH10WHL099BAL 5. Locate the timed disconnect switch and the hood raise switch in the battery box.
  • Page 40 Engine - Engine and crankcase 8. Place a suitable container below the radiator drain plug, remove the radiator cap and the radiator drain plug (see the arrow in figure) to drain the engine coolant. Then reinstall the radiator drain plug and the radiator cap after coolant has drained.
  • Page 41 Engine - Engine and crankcase 12. Place a solid steel bar or pipe through the strap loop inside the engine hood and attach the strap to a suit- able lifting device. Raise the engine hood with the strap to release ten- sion on the lifting motor.
  • Page 42 Engine - Engine and crankcase 16. Tag and disconnect the engine hood wiring harness connector (1) from the rear chassis wiring harness connector. Remove the engine hood wire harness clamp (2) from the fan guard. LEIL13WHL0150AB 17. Have another person to balance the hood and LOOSEN the hood hinge mounting bolts (see the arrows in figure) from the cooler frame.
  • Page 43 Engine - Engine and crankcase 19. Put the timed disconnect switch (1) in OFF position. Remove the battery cover and disconnect ground lead from the batteries (2). RAPH12WEL0608AA 20. Have another person to balance the hood and remove the hood hinge mounting bolts (see the arrows in fig- ure) from the cooler frame.
  • Page 44 Engine - Engine and crankcase 23. Tag and disconnect the engine wiring harness con- nector from the air inlet humidity sensor (1). LEIL13WHL0143AB 24. Loosen the clamp (1) on the crankcase ventilation hose (2) and disconnect the hose. LEIL13WHL0144AB 25. Loosen the clamps on the turbocharger and air filter housing.
  • Page 45 Engine - Engine and crankcase 27. Loosen the clamp on the hose at the after cooler inlet and remove the tube. LEIL13WHL0147AB 28. Loosen the clamp on the air inlet hose at the air filter housing. LEIL13WHL0148AB 29. Loosen the clamp (1) on the air inlet hose (2) at the exhaust support bracket.
  • Page 46 Engine - Engine and crankcase 31. Remove the four mounting bolts from the belt cover. Then remove the cover. NOTE: after removing the belt cover, remove the cover mounting bracket from the left rear side of machine frame. LEIL16WHL0566AB 32. Remove the drive belt from the engine. LEIL13WHL0155AB 33.
  • Page 47 Engine - Engine and crankcase 35. Remove the return line of the SCR coolant. LEIL16WHL0568AB 36. Tag and remove the wires from the starter solenoid (1), the ground cable (2), and ground strap (3) from the starter. NOTE: move the starter cables away from the engine. LEIL16WHL0569AB 37.
  • Page 48 Engine - Engine and crankcase 39. If the machine is so equipped, unplug the engine block heater and set it aside. LEIL15WHL0016AB 40. Loosen the clamp (see the arrow in figure) and dis- connect the pipe. LEIL15WHL0015AB 41. Loosen the clamps and remove the lower coolant hose from the engine.
  • Page 49 Engine - Engine and crankcase 43. Remove the return radiator hose (1) and the engine coolant vent hose from the top of the radiator. LEIL13WHL0141AB 44. Remove the overflow tank of the engine coolant. LEIL16WHL0574AB 45. Remove the bracket of the overflow tank. LEIL16WHL0575AB 46.
  • Page 50 Engine - Engine and crankcase 47. Loosen the clamp (1) on the intake manifold for the output hose of the after cooler. Loosen the clamp (2) from the body of the DEF/A ® tank vent filter. LEIL13WHL0613AA 48. Loosen the clamp on the after cooler, and remove the output hose of the after cooler from the machine.
  • Page 51 Engine - Engine and crankcase 51. Remove wire harness support clamp. LEIL16WHL0490AB 52. Remove the P-clamp and cut the cable ties by the sup- ply module. Disconnect the end of the jumper harness (near the supply module) from the Diesel Oxidation Catalyst (DOC) support.
  • Page 52 Engine - Engine and crankcase 55. Tag and disconnect the wire harness of the tempera- ture sensor (1) for the Selective Catalytic Reduction muffler (SCR) and cut the connector wire clamps. Loosen the screws and remove the bar (2). LEIL14WHL0407AB 56.
  • Page 53 Engine - Engine and crankcase 59. Remove the DEF/A ® storage tank cover lo- cated on the right-hand side of the machine. LEIL13WHL0170AB 60. Tag and disconnect the wire harness and DEF/ ® supply return lines from DEF/A ® storage tank. Install a protective cap in the supply lines.
  • Page 54 Engine - Engine and crankcase 63. Disconnect the main connector of the supply module. LEIL13WHL0171AB 64. Attach suitable lifting straps to the support structure (1) of the Diesel Oxidation Catalyst (DOC). The sup- ply module and the coolant control valve are also at- tached to this support structure.
  • Page 55 Engine - Engine and crankcase 67. Remove the bolts that secure the support structure of the Diesel Oxidation Catalyst (DOC). Use a suitable lifting device and carefully lift the sup- port structure of the Diesel Oxidation Catalyst (DOC) (with SCR system components attached) from the ma- chine.
  • Page 56 Engine - Engine and crankcase LEIL15WHL0017FB 71. Remove the upper and lower covers for the drive shaft. RAPH12WEL0079AA 72. Remove the drive shaft bolts (1) from the flywheel. Move the drive shaft clear of the flywheel. RAPH12WEL0080AA 48144035_EN 03/07/2017 10.1 [10.001] / 23...
  • Page 57 Engine - Engine and crankcase 73. Connect and turn on vacuum pump to hydraulic reser- voir. Tag and remove the hydraulic lines from the brake system pump (arrow), plug the lines and cap the fittings. LEIL13WHL0178AB 74. Connect suitable lifting equipment to engine lifting brackets.
  • Page 58 Engine - Engine and crankcase Engine - Install WARNING Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap.
  • Page 59 Engine - Engine and crankcase 2. Attach a suitable lifting device to the engine and slowly move it into position over the rear chassis. Be sure all harness connections and hoses are out of the way or positioned correctly for reconnecting, before lowering engine.
  • Page 60 Engine - Engine and crankcase 5. Connect vacuum pump to the hydraulic reservoir and turn it on. Remove the caps from fittings and the plugs from hoses. Connect hoses to brake pump following tags installed during removal. Remove and discard tags.
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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