SM W190 EN

Copyright New Holland
W190
Workshop Manual
Workshop
Manual
Print No. 604.13.502.01

English - Printed in Italy
W190
PROVEN PERFORMANCE
W190
WHEEL LOADER
Workshop Manual
Print N 604.13.502.01 English
IX - 2005
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING - Cautions directed to avoid improper repair interventions involving potential consequences
for the operators safety.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the
Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever
necessary, the recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own,
for the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national,
regional or local distributors, are responsible for any liability arising from any damage resulting from defects
caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products
manufactured or merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandized by the Factory, when failures are caused by the use of parts and/or components not approved
by the Factory.
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
SAFETY RULES .............................................................................................. page 1

SPECIFICATIONS - WHEEL LOADER ............................................................ page 8
TABLE OF FLUID CAPACITIES ...................................................................... page 11
UNITS OF MEASURE ..................................................................................... page 12
TORQUE TABLES ........................................................................................... page 13
ENGINE ................................................................ Section 1

TRANSMISSION .................................................. Section 2
BRAKE SYSTEM ................................................. Section 3
STEERING SYSTEM ........................................... Section 4
BUCKET BOOMS AND FRAME ........................ Section 5
EQUIPMENT HYDRAULIC SYSTEM ................. Section 6
ELECTRICAL SYSTEM ...................................... Section 7
CAB ...................................................................... Section 8
W190
0-1
SAFETY RULES
GENERALITIES
Read this Manual carefully before starting, operating,
maintaining, fuelling or servicing the machine.
Read and comply with all safety precautions before any
intervention.
Do not allow unauthorised personnel to operate or service
this machine.
Ensure that nobody is in the machine operating range

before moving off or operating the attachment. WALK
COMPLETELY AROUND the machine before mounting.
Sound the horn.
Before starting machine, check, adjust and lock the driver's
seat for maximum comfort and control of the machine.
Fasten your seat belts(when fitted).
Do not wear rings, wrist watches, jewellery, loose or

hanging garments, such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that can get caught in
moving parts. Wear certified safety clothes such as: hard
hat, no-slip footwear, heavy gloves, ear protection, safety
glasses, reflector vests, respirators. Ask your employer
about specific safety equipment requirements.
Obey all flag signals and signs.
Keep the operators compartment, step plates, grab-rails

and handles clean and clear of foreign objects, oil, grease,
mud or snow to minimize the danger of slipping or stumbling. Remove mud or grease from your shoes before
attempting to mount or operate the machine.
DO NOT PUNCTURE OR BURN CONTAINERS.
Do not jump on or off the machine. Always keep both hands

and one foot, or both feet and one hand in contact with
steps and grab rails.
Never use these products near fires, open flames, or

sparks.
Do not use controls or hoses as hand holds when climbing

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

never check or fill fuel tanks or accumulator batteries near
fires, open flames, or sparks.
REMEMBER THAT SPECIAL STARTING FLUIDS ARE
FLAMMABLE. Scrupolously follow recommendations
printed on the containers and in this Manual.
Containers must be stored in fresh, well ventilated places
and out of the reach of unauthorised persons. Strictly
follow the instructions provided by the Manufacturer.
OPERATING
Check wheel and rim retainers before each working shift.
If necessary, tighten to the torque specified.
Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
exhaust gases.
Roll Over Protective Structures (ROPS) are required on
wheel or crawler loaders, dozers, or graders. NEVER
OPERATE the machine if such protective structure is
removed.
Keep the operators compartment free of foreign objects,
especially if not firmly secured. Never use the machine to
transport objects, unless proper securing points are provided.
DO NOT CARRY RIDERS ON THE MACHINE
Study and familiarize with escape routes alternate to
normal exit routes.
STARTING
NEVER START OR OPERATE A FAILED MACHINE. Before operating the machine, always ensure that any unsafe
condition has been satisfactorily corrected.
Check brakes, steering and attachment controls before
moving off. Report any malfuctioning part or system to the
maintenance managers for proper action.
Ensure all protective guards and panels as well as all
safety devices provided are in place and in good operating
condition.
According to law provisions, seat belts must be fitted with

Roll Over Protection Structures or cabs. Keep safety belts
fastened during operation.
For your personal safety, do not climb on or off the machine
while it is in motion.
Make sure that bystanders are clear of the machine operating range before starting the engine and operating the
attachment. Sound the horn. Obey all indications provided
by flags, signs and signals.
DO NOT COAST OR FREEWHEEL down hills. Engage the
most suitable gear speed to keep the machine under control.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-2
W190
SAFETY RULES
Do not operate the machine if you are extremely tired or feel

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

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

start suddenly at full throttle. Take-up slack carefully.
Do not lift and move loads overhead where persons are

standing or working, nor downhill when working crosswise
on slopes. In this case, the bucket should be unloaded on
the uphill side, whenever possible.
Carefuly inspect the towing items for flaws or problems

before proceedig.
Start and stop the machine carefully when the bucket is full.
Do not move off without first reducing engine speed.
Avoid kinking or twisting chains or cables. Do not pull

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

absolutely necessary and unavoidable. Beware possible
uneven terrains, poor visibility, presence of other machinery or persons out of sight.
Operate the machine at a speed adequate to the working
site conditions and in any case slow enough to ensure
complete control at all times.
Check instruments at start-up and frequently during
operation. Stop the machine immediately should any
malfunction be signalled.
Never use the bucket as a man lift or to carry riders.
Never use the machine as a work platform or scaffolding,
nor for other improper use (such as pushing railway cars,
trucks or other machines).
Pay attetion to people within the machine operating range.
Load trucks from the drivers side whenever possible.
Prior to operating the machine, check which obstacles
and/or difficulties you will encounter, such as narrow
streets, overhead doors, cables, piping, as well as ground,
bridges, paving and ramps bearing load limitations.
In case of road transfers, find out beforehand what conditions are likely to be encountered, such as size restrictions,
heavy traffic, paving type, etc. . Beware fog, smoke or dust
that obscure visibility.
When crossing gullies or ditches, move at an angle with
reduced speed after ensuring ground conditions will permit a safe traverse.
W190
0-3
SAFETY RULES
Always inspect the working area to identify potential risks

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

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

when working on slopes.
Always switch off the battery isolator switch before servicing the machine in whatever manner (i.e., cleaning,
repairing, maintaining, etc.). Do the same when the
machine is to remain parked for prolonged periods of time
to avoid accidental or unauthorized starting.
Avoid operating the attachment too close to an overhang

or high wall, either above or below the machine. Beware
of caving edges, falling objects and landslips. Remember
that such hazards are likely to be concealed by bushes,
undergrowth and such.
Never lower the attachments other than sitting in the

operators seat. Sound the horn. Make sure that nobody is
within the machine operating range. Lower the attachment
slowly. DO NOT USE FLOAT POSITION in case of hydraulic controls.
When pushing-over trees, the machine must be equipped

with proper overhead guards. Never drive a machine up
the roots, particularly while the tree is being felled. Use
extreme care when pushing over any tree with dead
branches.
Securely block the machine and lock it every time you

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

NEVER DRIVE OVER THEM, nor over any other surface
irregularities that discontinue adherence or traction with
the ground, especially near slopes or drop-offs.
MAINTENANCE
Be alert to avoid changes in traction conditions that could

cause loss of control. AVOID driving on ice or frozen
ground when working on steep slopes or near drop-offs.
GENERALITIES
Working in virgin rough terrains is characterized by the

presence of all the perils and risks listed above. In these
conditions, it is emphasised the danger represented by
large tree limbs (possibly falling on the machine), large
roots (which may act as a leverage under the machine
when up-rooted and cause the unit to overturn), etc.
- carefully read all the norms contained in this Manual;
Before operating or performing any intervention on the

machine:
- read and observe all safety plates and instructions
located on the machine.
Do not allow unauthorized personnel to service the machine. Do not carry out any maintenance work without prior
authorization. Follow all recommended maintenance and
service procedures.
STOPPING
Keep the operators compartment free of loose objects that

are not properly secured.
When the machine is to be stopped for whatever reason,

do so following the instructions given in chapters Stopping the machine and Shutting off the engine" in the
Operation and Maintenance Instruction Manual.
Do not wear rings, wrist watches, jewellery, loose or

hanging garments, such as ties, torn clothing,
scarves,unbuttoned or unzipped jackets that can get
caught in moving parts.
0-4
W190
SAFETY RULES
Wear certified safety clothes such as: hard hat, no-slip

footwear, heavy gloves, ear protection, safety glasses,
reflector vests, respirators. Ask your employer about specific safety equipment requirements.
The fuel filler pipe nozzle must be constantly kept in contact

with the filler neck. Keep this contact from the beginning to
the end of the fuelling operation to avoid possible generation of sparks due to static electricity.
Never service the machine with someone sitting in the

driver's seat, unless this person is an authorized operator
assisting in the maintenance being carried out.
Tow the machine only from the attaching points provided.

Use care in making connections and ensure pins and/or
bolt are firmly secured before pulling. Stay clear of drawbars, cables or chains under load.
Keep the operators compartment, step plates, grab rails

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

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

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

glasses with side shields. Limit pressure to max 2 bars, in
accordance with local safety regulations in force.
Shop and/or field service platforms or ladders should be

manufactured in accordance with safety regulations in
force.
Do not smoke, use open flames or produce sparks nearby

while refuelling the unit or handling highly flammable
materials.
Disconnect batteries and label all controls to warn that

service work is in progress. Block the machine and all
attachments to be raised.
Do not use any flame as a light source during maintenance

work or to look for leaks anywhere on the machine.
Do not check or fill fuel tanks, batteries and accumulators,

nor use the starting liquid if you are smoking or near open
flames. These fluids are flammable!
BRAKES ARE INOPERATIVE when manually released for
servicing. Provisions must be made to maintain control of
the machine using suitable blocks or other means.
Do not run the engine in closed buildings without proper

ventilation capable to remove lethal fumes.
Make sure that all tools provided are in good condition at

all times. NEVER USE tools with mushroomed or damaged heads. Always wear eye protections.
Move with extreme care when working under the machine,
its attachments, and even on or near them. Always wear
protective safety equipment as required, such as hard hat,
goggles, safety shoes, and ear plugs.
W190
0-5
SAFETY RULES
In case tests during which the engine should be kept

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

appropriate protections (heavy gloves, goggles, etc.)
while handling them.
Handle all parts carefully. Keep hands and fingers away
from gaps, gears, and similar. Always use and wear the
appropriate protections.
Water can build up in pneumatic systems from condensate
moisture due to changes in atmospheric conditions. If
necessary, drain such deposits following instructions.
Before carrying out any maintenance work or service, lock
the machine articulated frame modules using the appropriate safety device. Remember to remove and store it
properly at the end of work.
If the machine is equipped with hydraulic brakes, make
sure that the reservoir is always filled up to the correct level.
Always block all wheels, front and rear, before bleeding
the braking system or disconnecting control hoses and/or
cylinders.
STARTING
Do not pile up oily or greasy rags as they represent a major

fire hazard. Always store them in closed metal containers.
Do not run the engine in closed buildings without proper

ventilation capable to remove lethal exhaust fumes.
Before starting the machine or its attachment, check, adjust

and lock the operators seat. Also ensure that nobody is
within the machine operating range. Sound the horn.
Do not place head, body, limbs, feet, hands or fingers near

rotating fans or belts.
Be especially careful near blower fans.
Rust inhibitors are volatile and flammable. Use them only

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

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

shoes, heavy gloves when metal particles or similar may
be ejected and hit you.
Wear appropriate protective equipment such as dark
safety glasses, hard hat, protective clothing, special
gloves and footwear while welding. Nearby persons
should also wear dark safety glasses even if they are not
welding. DO NOT LOOK THE WELDING ARC WITHOUT
PROPER EYE PROTECTION.
Become acquainted with all your jacking equipment and
its capacity. Remember that the jacking point on the
machine should be appropriate for the load applied. Also,
be sure the support area of the jack at the machine and on
the ground is appropriate and stable.
Any load supported by a jack represents a possible hazard. Always transfer the load onto appropriate support
means according to local or national safety requirements
before proceeding with service or maintenance work.
ENGINE
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant level
with the engine off.
Avoid that flammable materials could touch exhaust parts.
If not possible, provide necessary protections.
Do not refuel with the engine running, especially if hot, as
this increases fire hazard.
Never attempt to check or adjust fan belt tensions when the
engine is running.
Do not adjust the fuel pump when the machine is motion.
Do not lubricate the machine with the engine running.
Do not run the engine with air intakes, door or guards open.
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.
Do not use the machine to transport loose objects, unless

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

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

Make sure that the tyre inflation pressure corresponds to
specifications issued by the Manufacturer. Regularly
check inflation pressure.
Should pressure be changed, do this while staying on the
tyre side and at a safe distance.
Pressure checks should always be carried out with the
machine unloaded and cold tyres.
Never use reconditioned tyre rims, since possible
weldings, incorrect heat-treatments or repairs can
weaken the wheels and cause damages or failures.
Do not cut, nor weld rims with inflated tyres installed.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to penetrate
the skin. Always check any suspected pressure leaks
using a piece of cardboard or wood. DO NOT USE HANDS.
If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop.
Stop the engine and relieve all system pressure before
removing panels, housings, caps, plugs or covers.
Always use gauges of adequate capacity (end-of-scale
reading) and follow recommended procedures.
The spare tyre should be inflated only enough to keep the

rim components assembled. Remember that when not
installed on the disc, a tyre inflated to maximum pressure
can explode.
Therefore, maximum care must be taken when handling a
fully inflated tyre.
Before servicing tyres, block all wheels, front and rear. After
jacking up the machine, block it in the raised position using
suitable stands conforming to current safety regulations.
Deflate the tyre before removing objects from the tyre tread.
Never inflate tyres with flammable gas: explosions and
severe bodily injuries may result.
When starting your work shift, check for loose wheel or rim
bolts and brackets and retighten to correct torque as
necessary.
TOOLS
Always keep head, body, limbs, feet, or hands away from
bucket, blade, or ripper when in the raised position. Prior
to any intervention, install all safety devices according to
current regulations. In case the attachment is to be operated through the machine hydraulic system for maintenance purposes, remember to do so only while sitting in the
driver's seat. Make sure that nobody is within the machine
operating range. Before operating the attachment, alert
people by sounding the horn and by voice. Raise the
attachment slowly.
W190
0-7
SAFETY RULES
DECOMMISSIONING THE MACHINE

For the decommissioning of the machine, the availability
of particular tooling (hoists, hydraulic presses. containers for liquids etc.) is required as well as specific tools
listed in the Repair Manuals, available from FIAT
KOBELCO Dealers.
This has the purpose of avoiding that during disassembly operations, dangerous situations may arise both for
the personnel involved and the environment.
In the machine are present:
Fluids under pressure (hydraulic system, cooling
system etc.)
Gases (air conditioning system and accumulator, if
installed)
Mechanical devices mounted under pressure (track
tensioner etc.)
Heavy machine components (frames, blades, buckets etc.)
WARNING
The decommissioning of the machine must be
performed exclusively by personnel trained,
qualified and authorised to perform such operation.
Start the disassembly of hydraulic components
only after the same, the hydraulic oil and lubricants have fully cooled-off and after all residual
pressures have been released, as described by
the Repair Instruction Manual.
Prior to proceeding with disassembly operations, comply with the GENERAL SAFETY RULES
and drain each components of the machine filled
with fluids, both in the reservoirs and the relevant systems.
WARNING
Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing
machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators,
loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically,
mechanically, or cable controlled attachment to gain access to certain items, make sure the attachment
is adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or
mechanical devices used for controlling it.
0-8
W190
SPECIFICATIONS - WHEEL LOADER W190

IDENTIFICATION - 530.130.190
MARKING: ZEF00W19100940XXX
ENGINE
Make and model ................... IVECO NEF-TEKTOR
Net power at the flywheel .......... (ISO 9249) 151 kW
Max power speed ...................................... 2175 rpm
Max torque .................................................. 860 Nm
Max torque speed ..................................... 1500 rpm
Diesel type, 4 stroke, direct injection, turbocharged
Number of cylinders .............................................. 6
Bore x stroke .................................... 102 x 120 mm
Total displacement ................................ 5880 cu cm
Valve/rocker operation lash:
- intake .......................................... 0.25 0.05 mm
- exhaust ....................................... 0.50 0.05 mm
Firing order .............................................. 1-5-3-6-2-4
Minimum starting temperature: ........... - 20 C (-4 F)
Engine coolant high temperature sender setting
...................................... 107 + 2 C (224 + 35.6 F)
Pressure, engine oil at low idle ................. 1.2 bar
Thermostat: starts opening ............ (177.8 F) 81 C
max, opening ............. (204.8 F) 96 C
ENGINE SPEEDS
Minimum idle speed (no load) ...................... 850 rpm
Maximum idle speed (no load) ................... 2300 rpm
Converter stall speed ........................ 2110 50 rpm
Steering stall at idle speed > .......................840 rpm
Attachment stall ................................ 2190 50 rpm
Full stall .......................................... 1900 100 rpm
TORQUE CONVERTER
Type ... : single stage, single phase, three elements
Torque converter pressure ........................... 4.3 bar
Conversion ratio at stall ............................... 2.813:1
TRANSMISSION
Maximum ground speeds (forward/reverse) in kph
(with 23.5 R25 tyres):
Forward
speed
km/h
(Mp/h)
Reverse
speed
km/h
(Mp/h)
1
2
3
4
7.4 (4.5)
12.9 (8)
23.8 (14.7)
36.6 (22.7)
1
2
3
7.8 (4.8)
13.7 (8.5)
25.2 (15.6)
Main pressure on the control valve .......... 16 + 2 bar

Transmission disengagement sensor ...... 15 1 bar
Transmission induction sensors to gear teeth adjust
clearance ........................................... 0,5 0,8 mm
Transmission oil high temperature sensor setting ....
...................................... 119 3 C (246 37.4 F)
AXLES
Axles complete w/ oil-bath disc brakes.
Self-locking differentials.
Limited slip differential (as alternative).
Planetary final drives.
Stiff front axle, support structure type
- reduction ratio ........................................ 1 : 24.05
Oscillating rear axle, support structure type
- reduction ratio ........................................ 1 : 24.05
TYRES
Type ................................... 23.5 R25 XHA tubeless
Inflating pressure
- Work:
front = 3.25 bar
rear = 2.00 bar
- Transfer:
front = 2.00 bar
rear = 2.00 bar
Wheel tightening torque ............................... 788 Nm
BRAKES
Delivery brakes pump
at nominal speed ............... 32 lt/min (7.03 USG/min)
Accumulator recharge start pressure ....... 90 5 bar
Accumulator recharge end pressure ...... 130 5 bar
Pre-charge pressure, service brake accumulator
(1.4 lt) ............................................................ 45 bar
Pre-charge pressure, parking brake accumulator
(1.4 lt) ........................................................... 70 bar
Setting of pressure switch, transmission cut-off . 15 bar
Setting of sensor, brake oil low pressure ...... 73 bar
Setting of pressure switch, stop lights ........ 1.8 bar
Setting of pressure switch, parking brake ...... 82 bar
STEERING SYSTEM
Type ..................... Orbitrol, hydraulically controlled
with integrated priority valve
Pump ....................it uses one body of the hydraulic
system pump
Max. flow ...................... 162 lt/min (35.63 USG/min)
Max. operating pressure ............................... 210 bar
Cylinders ........................................ 2, double stroke
bore x stroke .................................... 80 x 422 mm
Emergency steering w/ bi-directional gear pump actuated by the transmission.
W190
0-9
EQUIPMENT HYDRAULIC SYSTEM

Type ................ sealed w/ anti-cavitation and safety
valve
Pumps ............. gear, steel made w/ wear automatic
compensation
A sequence valve cuts-off the pump when the pressure exceeds 175 bar.
- max. flow ..... 325 lt/min between (71.49 USG/min)
175 and 210 bar
- max. operating pressure ............................ 210 bar
Control valve ................................................ 2-spool
3-spool
Control ......................................... piloted, dual lever
piloted, single lever
Hydraulic cylinders, double stroke
boom control ...................................................... 2
bore x stroke .................................... 140x960 mm
bucket control .................................................... 1
bore x stroke .................................... 190x505 mm
Times of equipment manoeuvres
lifting ........................................................ 6.2 sec.
lowering .................................................... 3.1 sec.
dumping ................................................... 1.4 sec.
Pipes and connecting flanges are equipped with
O-Ring seals.
L.T.S. device
Electronic Load Travel Stabiliser device. Ideal during
loading applications and travel over rough ground.
- Setting of accumulator safety valve ............ 120 bar
ELECTRICAL SYSTEM
Operating voltage ........................................ 24 Volt
Batteries in series ............................. 2 - 160 Amph
- Maintenance-free
Starter motor ............................................... 24 Volt
Alternator w/ voltage regulator ...... 24 Volt - 70 Amp
WEIGHT
Weight of machine with tyres 23.5 R25 and 3.1 cu m
bucket, supplied and w/operator 17,200 kg (37,920
lbs).
0 - 10
W190
DIMENSIONS AND WEIGHT
40
3350
45
1230
49
445
322
1600
95
2065
2160
2760
3200
Dimensions in mm (in)
Operating weight: 17.200 kg (37919 lbs)
Note Machine equipped with tyres 23.5R25XHA, fluids and operator.
* Please refer to the table
Type of bucket
With teeth and
segments
3.2
3.5
With suppl. cutting

edge
3.2
3.5
With teeth
Bucket capacity
cu cm
3.1
3.4
Bucket weight
kg (lbs) 1520 (3351) 1605 (3538) 1465 (3229) 1550 (3417) 1425 (3141) 1510 (3328)
Bucket width
mm (in) 2960 (116.5) 2960 (116.5) 2920 (114.9) 2920 (114.9) 2960 (116.5) 2960 (116.5)
Dumping height at 45 mm (in) 2890 (113.7) 2810 (110.6) 2980 (117.3) 2895 (113.9) 2890 (113.7) 2810 (110.6)
Dumping reach at 45
mm (in) 1135 (44.6)
Max. length
(w/ bucket on ground)
mm (in) 8030 (316.1) 8110 (319.3) 7920 (311.8) 8000 (314.9) 8030 (316.1) 8110 (319.3)
Max. height
(w/ bucket raised)
mm (in) 5380 (211.8) 5435 (213.9) 5380 (211.81) 5435 (213.9) 5380 (211.8) 5435 (213.9)
Turning radius (in

transportation position) m (ft)
6.5 (21.3)
1200 (47.2)
6.5 (21.3)
1060 (47.7)
6.5 (21.3)
1125 (44.2)
6.4 (21)
1135 (44.6)
6.5 (21.3)
1200 (47.2)
6.5 (21.3)
0.2 (0.05)
AIR CONDITIONER
COMPRESSOR
L BAR 134
Ambra-MG-2
QFH 585 GR, NLG12
85W-90
40 To 50 C (-40 To 122 F)
20 To 50 C (-4 To 122 F)
20 To 50 C (-4 To 122 F)
30 To 20 C (-22 To 68 F)
35 To 50 C (-31 To 122 F)
10 To 50 C (14 To 122 F)
10 To 50 C (14 To 122 F)
30 To 20 C (-22 To 68 F)
OUT DOOR TEMPERAT.

OF REFERENCE (C)
W190
Oil quantities indicated are those required for periodical changes following the draining and filling procedures indicated in detail for each group.
* In the event engine oil with "CH4" classification is used, the change interval can be prolonged to 500 hours providing that the outer temperature of operation
does not exceed 38 C (100 F) and that the percentage of sulphur in the fuel does not exceed 0.5 %.
In the event of really heavy duty conditions, reduce the greasing intervals.
GREASE FITTINGS
252 (66.57)
FUEL
TANK
API GL5
QFH 584 TR
Ambra-TX Fluid
front 31 (8.2)
rear 31 (8.2)
AXLES
ISO VG 46, DIN 51524

Part. 1 and 2, QFH583/HD
Ambra-Hydrosystem
or
Ambra Hi-Tech 46
135 (35.7)
HYDRAULIC SYSTEM
10W-30
Ambra-Super Gold
22 (5.8)
TRANSMISSION
15W-40
API CH-4
ACEA E3
API CF-4/SG
MIL-L-2104E
ACEA E2
Ambra-Agriflu (50%)
15W-40
10W-30
VISCOSITY
(SAE)
API CF-4/SG
MIL-L-2104E
ACEA E2
CLASSIFICATION
SPECIFICATIONS
27 (7.1)
RADIATOR
Ambra-Super Gold HSP*
or
Ambra Master Gold
Ambra Super Gold
FLUIDS OR LUBRICANT
NH-900A
1 (3)
16 (4.2)
QUANTITY
LITRES (USG)
OIL FILTER
ENGINE
ITEM
TABLE OF FLUID CAPACITIES
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:
newton x meter (Nm)
CLASSIFICATION OF STANDARD COMPONENTS TO DETERMINE THE TIGHTENING TORQUES
Note - In case, in the different sections, the tightening

torque is not listed, refer to the table TIGHTENING TORQUES, only after identifying exactly the component.
The latter is identified by a coded eight digit number,

allowing a complete description of the item.
Example.
I / a
d e / f
I - Standard index digit

It is always represented by the digit 1. This number
indicates that the item can be fabricated in a number
of versions differing for material and coating.
a - b - c - d - e - Standard base digits

It is a number always composed of five digits identifying dimensional specifications of the item.
f - Material index digit

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

It indicates the coating applied to a defined item.
W190
0 - 13
Resistance class and material
Material
index (f)
FIAT
R40
R50
R80
R100
Brass
Aluminium
Copper
UNI
DIN
SAE
BSI
42
56
80
10K
100
Messing
Brass
Brass
Laiton
Aluminium
Aluminium
Aluminium
Copper
Copper
Cuivre
4D - 4S - 4A
5S - 6S
8G
100
Brass
Aluminium Aluminium
Copper
Kupfer
BNA
Blank for other metallic materials
WARNING
TORQUE TABLES
- Lubricate all hardware until 24 dia., with engine oil.

Use grease for larger diameters.
If correct torque is not specifically indicated in the

relevant pages, refer to the following tables.
- Tolerance on torque: 5%
- Resistance classes R80, R100, R120 must be
understood as follows:
10.9 replaces R100

for screws
12.9
10
"
R120
replaces R80
for nuts
12
"
R100
CDT= cadmed; FOSF= phosphated; ZNT= galvanised.
0 - 14
W190
NUTS (ZNT)
SCREWS (ZNT/DEIDR)
Strength grade: 10 (R80)
Strength grade: 10.9 (R100)
normal
Diameter
and pitch
low type
with polyamide ring
Diameter
and pitch
mm
normal
ZNT
Nm
self-locking
ZNT
Nm
M6 x 1
13
Nm
normal
Nm
low type
Nm
13
12
M8 x 1.25
32
26
39
32
M8 x 1.25
13
35
M10 x 1.25
72
52
82
62
M10 x 1.25
71
79
M10 x 1.5
65
50
77
60
M10 x 1.5
65
70
M12 x 1.25
130
87
145
102
M12 x 1.25
127
139
M12 x 1.75
110
81
129
96
M12 x 1.75
110
120
M14 x 1.5
195
130
216
150
M14 x 1.5
200
220
M14 x 2
180
125
200
146
M14 x 2
180
190
M16 x 1.5
300
170
340
200
M16 x 1.5
300
330
M18 x 1.5
450
250
500
290
M18 x 1.5
450
480
M18 x 2.5
M18 x 2.5
M20 x 1.5
600
305
645
350
M20 x 1.5
600
650
M20 x 2.5
M20 x 2.5
M22 x 1.5
800
410
M22 x 1.5
800
900
M22 x 2.5
M22 x 2.5
M24 x 2
1000
470
1080
525
M24 x 2
1000
1100
M24 x 3
M24 x 3
M27 x 2
950
401
M27 x 2
1000
M30 x 2
1300
494
M30 x 2
1400
M33 x 2
1700
M33 x 2
1900
M36 x 3
2200
M36 x 3
2400
mm
Nm
M6 x 1
M16 x 2
M16 x 2
SECTION 1
ENGINE
INDEX
PARAGRAPH
SUBJECT
1.1
ENGINE IDENTIFICATION ..................................................................................... 1-1
1.2
GENERAL FEATURES ........................................................................................... 1-5
1.3
DESCRIPTION OF ENGINE OPERATION ............................................................. 1-14
1.4
1.4.1
1.4.2
1.4.3
1.4.4
DESCRIPTION OF MAIN GROUPS .......................................................................

Lubrication ..............................................................................................................
Cooling ....................................................................................................................
Fan Drive System ...................................................................................................
High pressure electronic fuel injection system (Common Rail) ................................
1-16
1-17
1-18
1-19
1-21
1.5
1.5.1
1.5.2
1.5.3
TROUBLESHOOTING GUIDE ................................................................................

Troubleshooting with PT-01 instrument ...................................................................
Troubleshooting with blink code ..............................................................................
Diagnosis of main malfunctions ..............................................................................
1-33
1-34
1-35
1-37
1.6
ENGINE SUPPORTS ............................................................................................. 1-46
1.7
1.7.1
1.7.2
ENGINE OVERHAUL ..............................................................................................

Repair interventions ................................................................................................
Cylinder group ....................................................................................................
Timing ................................................................................................................
Bushes ..............................................................................................................
Crankshaft .........................................................................................................
Conrod-Piston assemgly ....................................................................................
Pistons ..............................................................................................................
Flywheel ............................................................................................................
Cylinder head .....................................................................................................
Valves ...............................................................................................................
Guide valves ......................................................................................................
Valve seats ........................................................................................................
Valve seats in cylinder head ..............................................................................
Valve springs .....................................................................................................
Assembly of the cylinder head ...........................................................................
Rods ..................................................................................................................
Tightening torques ..................................................................................................
1.8
TOOLING ................................................................................................................ 1-107
PAGE
1-47
1-59
1-59
1-61
1-62
1-65
1-69
1-70
1-80
1-86
1-87
1-88
1-88
1-89
1-91
1-91
1-93
1-104
W190
ENGINE
1.1 ENGINE IDENTIFICATION

Engine data plate
The engine data plant provides specific information
about your engine.
Note The engine plate must not be replaced without the
authorisation by the manufacturer.
TYPE - SERIAL NUMBER - APPROVAL
IVECO N. V.
ENGINE
TYPE
ENGINE
FAMILY
EEC
APPR. N
F4AE0684F*D101
F4AE43B00A
E3
SERIAL
NUMBER
000000
e3*97/68EA*0005*00
e3*85R02*1507
e3*24R03*1503
Fig. 1-1
ENGINE DATA
Fig. 1-2
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.
The illustrations and the configuration of components

described in these diagrams are of a general nature.
the locations of some components can change, depending upon the arrangement.
Engine oil
dipstick
Air intake (from after-cooler)

Common rail
Engine oil
filler neck
High pressure
pump
Engine flywheel
cover
VIEW INJECTION
PUMP SIDE
Turbine exhaust
(silencer)
Exhaust
manifold
Electronic
controller (EDC)
Fuel filter
Turbocharger
Pressure relief
valve
Alternator
Engine oil
filter
VIEW TURBOCHARGER
SIDE
Fig. 1-3
W190
1-3
ENGINE
Flex-disc
mounting holes
Flywheel
Fig. 1-4 Rear view
Water pump
pulley
Alternator pulley
Belt tensioner
Drive belt
Fig. 1-5 Front view
1-4
W190
ENGINE
Engine coolant
by-pass seat
Tappet cover
Injector
Fig. 1-6 Top view
W190
GENERAL FEATURES
Type
IVECO NEF F4AE0684F
Cycle
Diesel 4-stroke
Air intake
Turbocharged w/aftercooler
Injection
Direct
Number of cylinders
6 in-line
Bore
mm
102
Stroke
mm
120
+.. = Total displacement
5900
cu cm
1.2
1-5
ENGINE
Compression ratio
Max. power
17 : 1
kW
(CV)
155
211
rpm
2175
Nm
(kgm)
860
87.6
rpm
1500
rpm
850
rpm
2300
Torque converter stall rpm
2110
Equipment stall
rpm
2190
Total stall
rpm
1960
Max. torque
Engine speed at
low idle
Engine speed at
high idle
1-6
W190
ENGINE
TURBOCHARGING
w/after-cooler
Turbocharger type
Radial play of turbocharger shaft
Axial play of turbocharger shaft
Minimum stroke of pressure
relief valve:
Maximum stroke of pressure
relief valve:
Pressure corresponding to minimum stroke:
Pressure corresponding to maximum stroke:
HOLSET HY 35 W
mm
mm
bar
bar
LUBRICATION
Forced by gear pump, pressure relief valve,

oil filter
bar
Oil pressure
w/hot engine:
at low idle
at high idle
bar
bar
COOLING
1.2
3.8
By centrifugal pump, regulating
thermostat, radiator,
heat exchanger, after-cooler
Water pump drive

Thermostat
begins to open at:
max. opening at
Belt driven
81 C (177 F)
96 C (204.8 F)
CAPACITY
Total capacity
of first filling:
litres (USG)
kg (lbs)
23 (6.07)
Ambra Super Gold or

Ambra Master Gold
15W40 10W30
W190
1-7
ENGINE
TIMING
beginning BTDC
end ATDC
A
B
8.5
8.5
beginning BBDC
end ABDC
D
C
51
12.5
For timing check

X
X
mm
mm
Operational
mm
0.25 0.05
mm
0.50 0.005
FUEL
Injection
Type:
Bosch CP3.3
high pressure, common rail

EDC7 controller
Nozzle type
Electric injectors
Firing order
1-5-3-6-2-4
bar
Injection pressure
Setting of injector
bar
bar
1350
1-8
W190
ENGINE
DATA - MOUNTING PLAYS

(1 mm = 0.03937 in)
CYL. GROUP & CRANKING COMPONENTS
mm
Cylinder sleeves
102.009 102.031
2
L
Cylinder sleeves - seats in

cylinder block (interference)
Outer diameter
Cylinder sleeves:
L
outer diameter
length
3
X Cylinder sleeves:
1
X
inner diameter
Spare pistons type:

Dimension
for measurement
Outer diameter
Pin seat
X
1
2
Piston - cylinder sleeve
Piston diameter
12
101.883 101.897
40.008 40.014
0.116 0.134
0.5
X
Position of pistons
from cylinder block
Piston pin
Piston pin - pin seat
0.28 0.52
39.996 40.003
0.005 0.018
W190
1-9
ENGINE
(1 mm = 0.03937 in)
X 1 Piston ring seat
X2
X3
S1
S2
S3
mm
X 1*
X 2*
X 3*
* measured on 99 mm
Piston rings
S 1*
S 2*
S 3*
1
2
3
Piston rings
X3
0.100 0.175
0.040 0.90
0.020 0.065
0.5
Gap of tips piston

rings in cyl. sleeves:
X3
2.560 2.605
2.350 2.380
3.975 4.000
* measured on 99 mm
Piston rings - seats
X3
2.705 2.735
2.420 2.440
4.020 4.040
X1
X2
X3
Seat of conrod small
end bush
1
Seat of conrod bearing
2
0.20 0.32
0.60 0.80
0.25 0.45
42.987 43.553
72.987 73.013
4
3
S
Diameter of conrod small

end bush
Outer
4
Inner
3
Spare conrod half
bearing
S
43.279 43.553
40.019 40.033
1.955 1.968
Conrod small end bush seat
0.266 0.566
Piston pin - bush
0.037 0.016
Conrod half-bearings
1 - 10
W190
ENGINE
(1 mm = 0.03937 in)
X
Measuring dimension
Max. out-of-line
of parallelism
of conrod centre lines
1
2
82.99 83.01
68.99 69.01
S1
2.456 2.464
S2
1.955 1.968
S1
S2
Crankshaft journals
Conrod journals
mm
Crankshaft half
bearings
Conrod half
bearings
* supplied as spare part
Crankshaft journal supports

3 Nos. 1 - 5
3
nos. 2 - 3 - 4
3
87.982 88.008
87.977 88.013
Crankshaft journal half

bearings - journals
Nos. 1 - 5
nos. 2 - 3 - 4
0.041 0.119
0.041 0.103
Half bearings conrod journals
0.033 0.041
Crankshaft half bearings

Conrod half bearings
Thrust crankshaft
journal
X1
37.475 37.545
X1
Thrust crankshaft journal

support
X2
25.98 26.48
Thrust half
bearings
37.28 37.38
X2
X3
Crankshaft thrust
X3
0.068 0.41
W190
1 - 11
ENGINE
(1 mm = 0.03937 in)
CYLINDER HEAD - TIMIMG
mm
1
Valve guide seats on
cylinder head
7.042 7.062
2
Valve guide
Valve guides and seats

on head
Valve guide
Valves:
6.970 6.999
60 0.25
6.970 6.999
45 0.25
Valve stem and

relevant guide
0.052 0.092
Seat on head for valve

seat:
1
Outer diameter of
valve seat;
Angle of valve seat
on cylinder head:
X Sinking
60
45
0.59 1.11
0.96 1.48
Between valve seat

and head
Valve seats
1 - 12
W190
ENGINE
(1 mm = 0.03937 in)
mm
Height of valve spring:
H1
free spring
47.75
H 2 under a load of:

339.8 9 N
741 39 N
H1
H2
35.33
25.2
Protrusion of injectors
X
1 2 3 4
Sets for camshaft bushes

nos. 1-5
59.222 59.248
Seats for camshaft

nos. 2-3-4
54.089 54.139
Camshaft support
pins:
15
53.995 54.045
Outer diameter of
camshaft bushes:
Inner diameter of
bushes
54.083 54.147
Bushes and seats

in cylinder block
Bushes and support

pins
0.038 0.162
Cam lift:
H
H
H
6.045
7.582
W190
1 - 13
ENGINE
(1 mm = 0.03937 in)
1
2
3
Seat of tappet in
cylinder block
mm
16.000 16.030
2
3
15.924 15.954
15.960 15.975
Outer diameter of
tappet:
Between tappets and seats
Tappet rods
0.025 0.070
1
Rocker arm shaft
21.965 21.977
Rocker arms
22.001 22.027
2
Between rocker arms
and shaft
0.024 0.162
1 - 14
1.3
ENGINE
W190
DESCRIPTION OF ENGINE OPERATION
The illustrations the configuration and the shape of

some components illustrated in these diagrams can
show some differences, being they indicative only.
ENGINE CROSS SECTION
Fig. 1-7
W190
ENGINE
ENGINE LONGITUDINAL SECTION
Fig. 1-8
1 - 15
1 - 16
1.4
W190
ENGINE
DESCRIPTION OF MAIN GROUPS
CYLINDER HEAD
On the pig iron made heads, the seats of the following items are located:
Valve seats:
A directly machined for lower power engines;
B inserted, on higher power 4 or 6 cylinder engines.
Fuel discharge duct from the electric injectors, obtained directly during the casting inside the cylinder
head.
Electric injectors (2).

Thermostat (4).
Fuel neck (9) for electric injectors.
Also, on the cylinder heads are mounted:
Exhaust manifold (1):
Support (7) for the electric injectors wiring 3.
Intake manifold (5) with seat for cold starting air
heater (6).
5
1
7
2
9
4
For engines with valve seats directly machined in

the cylinder head
B
For engines with valve seats inserted in the
cylinder head
Fig. 1-9
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;
oil pressure relief valve (1) incorporated in the filter support;

by-pass valve (4) cutting-off the oil filter when
clogged, incorporated in the filter support;
cartridge oil filter (2).
2
3
Flow of oil under pressure

Return flow of oil by gravity
Oil filler
Fig. 1-10
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;
a heat exchanger cooling lubricating oil (see

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

thermostat
Water re-circulating the
engine
Water entering the pump
Fig. 1-11
W190
1 - 19
ENGINE
1.4.3 FAN DRIVE SYSTEM

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

controlling valve block (2) and through solenoid valve
(3) it reaches bi-directional hydraulic motor (4) driving
the main fan.
Also through solenoid valve (3) oil under pressure
reaches the second hydraulic motor (5) driving the
aftercooler fan, then it is discharged.
TO DISCHARGE LINE
BI-DIRECTIONAL MOTOR (14 cu cm/rev.)

(ENGINE RADIATOR)
SINGLE DIRECTION MOTOR (14 cu cm/rev.)

(AFTERCOOLER)
4
5
1/2 BGP
10
220 BAR
1/2 BGP
11
220 BAR
7
G1
1/4 BGP
200 BAR
A
6
P1 3/4"BSP
Fig. 1-12
1. Pump - 2. Fan hydraulic control block - 3. Solenoid valve - 4. Bi-directional hydraulic motor - 5. Single direction hydraulic
motor - 6. Proportional valve - 7. Safety valve - 8. Orifice (2 mm) - 9. Safety valve - 10. Safety valve - 11. Safety valve.
1 - 20
W190
ENGINE
FAN HYDRAULIC CONTROL BLOCK
DIMENSIONS OF PORTS
P1 T
A B
G1 MT
THREADED 3/4" BSP

T1
THREADED 1/2" BSP
THREADED 1/4" BSP
T1
MT1
P1
A
C1
Fig. 1-13
1. Drilled block - 2. Safety valve - 3. Proportional valve - 4. Safety valve - 5. Solenoid valve - 6. Anti-cavitation valve 7. Safety valve - 8. Safety valve - 9. Dowel.
W190
1 - 21
ENGINE
1.4.4 HIGH PRESSURE ELECTRONIC FUEL

INJECTION SYSTEM (COMMON RAIL)
DESCRIPTION OF SYSTEM
Electrical system
The system is composed of the electrical system and

the hydraulic system.
The controller directs the operation of the engine

through the sensors installed on it.
6
2
7
3
8
9
4
10
Fig. 1-14
1. Fuel pressure sensor - 2. Engine coolant temperature sensor - 3. Engine oil temperature and pressure sensor 4. Engine crankshaft sensor - 5. Electric injector - 6. Air pressure temperature sensor - 7. Camshaft sensor - 8. Fuel heater
and fuel temperature sensor - 9. Pressure regulator - 10. EDC 7 controller.
1 - 22
ENGINE
INJECTION SYSTEM ASSEMBLY

REF. DESCRIPTION
1
Position sensor on accelerator pedal
Key switch
Parking brake engaged switch
Gearshift in neutral switch
EDC main fuse (20 Amp)
Diagnostic connector
Blink-Code button
Engine oil pressure
Coolant temperature
10
Revolution counter
11
Pre-heater ON indicator
12
Starter motor
13
Crankshaft sensor
14
Pre-heater activation solenoid switch
15
Fuel temperature sensor
16
Fuel heater resistor
17
Timing sensor
18
Pressure regulator solenoid valve
19
Coolant temperature sensor
20
Pre-heater resistor
21
Electric injectors
22
Air temperature/pressure sensor
23
Fuel pressure sensor
24
Oil temperature/pressure sensor
W190
W190
1 - 23
ENGINE
INJECTION SYSTEM ASSEMBLY
21
22
20
19
23
18
16
17
15
24
14
12
13
7
6
8
10
5
MEGA
FUSE
w \
w \ E H@
w \ E H@
w \
w w
11
CAN LINE
1
OFF
ACC.
ON
ACCELERAT. PEDAL
START
PEDAL PROXIMITY SENSOR

POTENTIOMETER
Fig. 1-15
1 - 24
ENGINE
W190
DESCRIPTION OF INJECTION SYSTEM

Control of engine pre-heater resistor
Limitation of maximum speed
The pre-heater is activated every time even just one

of the coolant, air or fuel sensors measures a temperature < 5 C (41 F).
At 2300 rpm, the controller limits the delivery of fuel

by reducing the opening time of the electric injectors.
Timing recognition
Through the signals of the sensor on the camshaft
and the one on the crankshaft, the starting cylinder
where the fuel must be injected is identified.
Cut-off
The cutting-off of fuel during the engine slow down or
when used to brake is managed by the controller by
performing these logics:
it cuts-off supply to the electric injectors;
Control of injection
The controller, in accordance with the information provided by the sensors, controls the pressure regulator,
changing the modes of the pre-injection and the main
injection.
On tector engines, the pre-injection is activated at all
engine speeds.
Closed circuit control of the injection pressure
Depending upon the engine load, determined by the
processing of the signals provided by the various sensors, the controller controls the regulator to provide
constantly an optimised pressure.
Control of pilot and main injection advance
The controller, depending upon the signals provided
by the various sensors, defines the optimised injection point in accordance with an internal mapping.
it reactivates the electric injectors just before reaching low idle speed;
it controls the fuel pressure regulator.
Control of smoke emission during accelerations
When high loads are required, the controller, depending upon the signals provided by the air intake measuring device and the crankshaft speed sensor, controls the pressure regulator and changes the actuation time of the electric injectors, to prevent the engine from smoking.
After Run
When cutting-off the engine, the microprocessor of
the controller memorises some data in the EPROM
including a trouble memory, so that the data are available when a new starting occurs.
Control of low idle speed

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

injection pressure calculated by the controller is always available.
3
1
4
2
5
6
7
Low pressure
High pressure
Fig. 1-16
1. Electric injector - 2. Common rail - 3. Pressure limit device for fuel return - 4. Common rail pressure relief valve 5. Pre-filter installed on the frame - 6. High pressure pump - 7. Rotor type mechanical pump - 8. Fuel filter.
The high-pressure circuit is composed of the following pipes:

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

the controller heat exchanger, the manual priming
pump and the pre-filter;
pipes supplying the high pressure pump through the
fuel filter.
The fuel system is completed by the fuel discharge
circuit from the common rail, the injectors and the
high-pressure pump cooling circuit.
fuel suction pipe from tank to pre-filter;
1 - 26
W190
ENGINE
Hydraulic diagram
7
DISCHARGE
SUCTION (LOW PRESSURE)
HIGH PRESSURE PUMP SUPPLY
(LOW PRESSURE)
HIGH PRESSURE
3
18
8
13
17
ECU
EDC7
9
10
16
11
15
12
14
Fig. 1-17
1. High pressure pump - 2. High-pressure pump pressure relief valve, 5 bar - 3. Modulating valve installed on fuel return
from the injectors 1,3 - 2 bar - 4. Common rail pressure relief valve - 5. Common rail - 6. Pressure sensor - 7. Electric
injector - 8. Return pipe - 9. Controller heat exchanger - 10. Mechanical priming pump - 11. Pre-filter mounted on frame 12. Fuel tank - 13. Mechanical fuel pump - 14. Fuel filter - 15. Pressure regulator - 16. High-pressure pump cooling pipe 17. By-pass valve - 18. By-pass valve.
The pressure regulator, located after the high-pressure pump, regulates the flow of fuel required by the
low-pressure system. Subsequently, the high-pressure
system supplies correctly the common rail. This solution, pressurising the fuel required only, improves
the energetic performance and limits the heating of
the fuel in the system.
Pressure relief valve (2) installed on the high-pressure pump, keeps the pressure at the inlet of the pressure regulation constantly at 5 bar (71.51 psi).
Pressure relief valve (3) located on the cylinder head,

installed on the return of the electric injectors, regulates the fuel return flow from the electric injectors at
a pressure of 1.3 to 2 bar (18 to 29 psi).
Two by-pass valves are located in parallel to the fuel
pump.
By-pass valve (18) makes the fuel to re-flow from the
outlet of the mechanical pump to its inlet, when the
pressure at the inlet of the fuel filter exceeds the allowed value.
By-pass valve (17) allows the filling of the fuel system by manual priming pump (10).
W190
1 - 27
ENGINE
HIGH PRESSURE PUMP CP3
FUEL MECHANICAL PUMP

A
Sect. A-A
Fig. 1-18
A
Pressure regulator on inlet
Located on the inlet of the high-pressure pump,
(3, Fig. 1-19) on the low-pressure system, it modulates the quantity of fuel supplied to the high-pressure pump in accordance with the commands received
from the controller.
B
C
3
It is mainly composed of the following components:

trapezoidal section plunger;
valve control pin;
pre-load spring;
solenoids.
D
E
When no command signal is received, the pressure

regulator is normally open, thus the high-pressure
pump is in maximum flow condition.
Fig. 1-19
The controller modulates a PWM command to control

in a larger or smaller manner the fuel passage section
toward the high-pressure pump.
A. Connection for fuel discharge outlet to filter support. B. Connection for fuel inlet from controller heat exchanger C. Connection for fuel inlet from fuel filter - D. Connection
for fuel outlet from fuel pump to filter - E. Fuel outlet connection to rail - 1. High pressure pump - 2. Fuel pump 3. Pressure regulator (solenoid valve NA modulated by
controller with PWM signal).
The component cannot be replaced individually; thus

it must not be removed.
3-radial piston pump driven timing gear, without need

for timing setting, with fuel rotor pump mounted on
the rear side.
1 - 28
W190
ENGINE
Internal structure of the high pressure pump

Sect. B-B
7
B
1
5
Sect. C-C
Fig. 1-20
1. Cylinder - 2. Three lobe element - 3. Plate type inlet valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft - 7. Lowpressure fuel inlet - 8. Fuel ducts for pumping element supply.
Each pumping group is composed of:

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

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

is dosed by the pressure regulator, located on the
low-pressure system; the pressure regulator is controlled by the EDC7 controller through a PWM signal.
When fuel is forwarded to the pumping element, the
relevant piston is moving downward (suction stroke).
Once the stroke of the piston is inverted, the intake
valve closes and the fuel in the pumping element
chamber, being prevented from getting-out, is compressed over the value of the supply pressure in the
rail.
The pressure generated in this manner causes the
opening of the discharge valve and compressed fuel
reaches the high-pressure circuit.
The pumping element compresses the fuel until it
reaches the TDC (delivery stroke). Then, the pressure decreases until the discharge valve closes.
The piston of the pumping element returns toward the
BDC and the residual fuel decompresses.
Once the pressure in the pumping element chamber
becomes lower than the supply pressure, the intake
valve opens again and the cycle is repeated.
Delivery valves must always be free in their movement, free from impurities and oxidation.
Fig. 1-21
1. Rail - 2. Flow limiters - 3. Fuel inlet from high pressure
pump - 4. Pressure sensor - 5. Pressure relief valve.
The volume of the rail has reduced dimensions to provide a fast pressurisation when starting, at low idle
and in case of large flows.
It has anyway, a volume sufficient to minimise the
fluctuations caused by the opening and the closing of
the injectors and the operation of the high-pressure
pump. This function is further eased by a calibrated
orifice located after the high-pressure pump.
A fuel pressure sensor (4) is screwed on the rail. The
signal forwarded by this sensor to the controller provides a feedback information, on which the pressure
value in the rail is measured and corrected, if required.
The delivery pressure to the rail is modulated between

250 and 1350 bar (3625 to 19580 psi) by the controller, through the solenoid valve of the pressure regulator.
The pump is lubricated and cooled by the fuel itself.
The cut-off/reactivation time of the radialjet pump on
the engine is greatly reduced compared with traditional
injection pumps, since it does not require timing setting.
In case of removal-reinstallation of the piping between
fuel filter and high-pressure pump, keep your hands
and components perfectly clean.
1 - 30
W190
ENGINE
Pressure relief valve

The pressure relief valve (1750 bar) (25381 psi) on
the common rail protects the components of the
4
system in the event a flow limiter intervenes.
B
A
Fig. 1-21
1. Body - 2. Piston - 3. Stop - 4. Spring - 5. Discharged directed to tank - 6. Seat on rail.
A. Normally, the tapered end of the piston keeps the

discharge toward the tank closed.
B. In case the fuel pressure of 1750 bar (25381 psi)

in the rail is exceeded, the piston moves and the
pressure excess is discharged into the tank.
Flow limiters
They are located on the rail fuel outlet connections.
Their function is to protect the integrity of the engine
or the vehicle in the event of internal spills (example
injector stuck open) or external (example: damaged
high-pressure pipes).
If this occurs, the operation of the system is provided,
within certain limits, by the components of the other
cylinders in operational conditions.
WARNING
After the intervention to block the leakage of fuel
from the rail, the flow limiter is automatically reset under the action of the spring. However, f the
cause of its intervention is not eliminated, at the
next starting tentative the engine could operate
only at low idle or at low speed or to be cut-off
again, depending upon the entity of the leakage.
1
1
3
5 2
5 2
Fig. 1-22
1. Body - 2. Piston - 3. Fuel inlet - 4. Spring - 5. Securing thread on rail.
A. The passage of fuel from the rail to the electric

injectors occurs through holes drilled on the small
diameter of the piston.
Under normal conditions, the fuel pressure is on
both sides of the piston, kept by the spring in open
position.
B. In the event of a large pressure drop after the

limiter, the inlet pressure prevails and moves the
piston toward the opposite side, cutting-off the
outflow of fuel.
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:
The solenoid valve controls the lifting of the injector

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

control solenoid valve composed of coil (4) and pilot valve (5).
Injector in rest condition
12
7
11
1
10
13
2
8
3
Fig. 1-23
1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball plunger - 7. Control area - 8. Pressure chamber 9. Control volume - 10. Supply-control duct - 11. Outlet of control fuel - 12. Electric connector - 13. Spring.
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
returning needle (2) into closed position, terminating

the injection.
W190
ENGINE
1.5 TROUBLESHOOTING GUIDE

FOREWORD
Experience is the factor facilitating the solution of troubles.
To partially overcome the lack of experience by the
repair engineer on this new electronic device, since
no previous systems to which refer existed, we list in
the pages to follow a TROUBLESHOOTING GUIDE.
The troubleshooting guided is composed of two sections, neatly defined:
the first one, organised by Blink Code, refers to
troubles that can be directly identified by the EDC7
controller. These troubles are of are mostly of an
electric- electronic nature;
the second, organised by symptom, describes possible troubles not directly identifiable by the controller. These troubles are mostly of a mechanical-hydraulic nature.
The troubleshooting guides do not replace the diagnosis with electronic diagnostic equipment, but should
be considered as integration to the same.
1 - 33
1 - 34
W190
ENGINE
1.5.1 TROUBLESHOOTING WITH PT-01

INSTRUMENT
The PT-01 380001218 diagnostic instrument shown
in the illustration is supplied with a set of connecting

cables as well as an Operation Manual.
1. outer power connection

2. diagnostic connecting cable
1.
2.
3.
4.
5.
P T- 0 1
HW failure
transm. K line comun.
transm. line K reception
transmission L line communication
line bus CAN
1. serial port
2. porta USB
CAN
6. power
7. navigation buttons
8. communication status
indicators
1
4
7
2
5
8
0
3
6
9
X
1010
9. numerical buttons
10. CANCEL button

11. USB port indicator
12. OK button
13. serial port indicator
Controller-instrument
connecting cable
Connection point
P T- 0 1
CAN
Fig. 1-25
W190
1 - 35
ENGINE
1.5.2 TROUBLESHOOTING WITH BLINK

CODE
Performance of the EDC indicator lights
The panel with the trouble indicator light is located in
the cab and can be reached after removing the plastic cover behind the operator's seat.
ON
ENGINE
DIAGNOSTIC
1-26
Fig. 1-26
ACTIVATION/READING THE BLINK CODE

By actuating the "ENGINE DIAGNOSTIC" switch it
is possible to monitor the operational condition of the
controller and to identify the presence of the error
codes activated.
Method:
Engine inoperative
Key on second click (ON)
"Diagnostic" switch ON
The code is composed of two digits divided by a dot

(Ex. "2.3") and it is shown by slow flashes followed
by fast flashes.
If no troubles are identified in the system, the EDC
indicator light does not provide any information and
comes ON once only. If, as an example, the first active code is "2.3" we have:
a. 2 slow flashes;
b. pause;
c. 3 fast flashes.
Important The connection and disconnection operations of the controller must be performed with the positive
terminal of the battery disconnected.
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
Bank 1 (cylinders 1-2-3)
Bank 2 (cylinders 4-5-6)
ENGINE RPM
Signal, crankshaft sensor
Signal, camshaft sensor
Engine speed conformity
Engine over-speed
Starter motor relay
INTERFACES
Line CAN
DASHBOARD
Indicator light, oil pressure
Indicator light, coolant temperature
FUEL PRESSURE
Fuel pressure control
Signal, fuel pressure
Solenoid valve, pressure regulator
Monitoring of rail press. regulation valve
Pressure drop in rail
CONTROLLER
Main relay
Internal error in the controller
Sensors power
TYPE OF FLASHING:
POWER REDUCTION:
2 = Intermittent
1 = Continuous
0 = 0% reduction 1 = Power curve reduced
4 = Engine inoperative
CODE
SAE
CODE
TYPE OF
FLASH
POWER
REDUCTION
APP1
LP6
0120
1675
1
0
3
0
CTS
BTS
FTS
BPS
APS
OPS
OTS
HP7
HP1
0115
0110
0180
0235
0105
0520
0195
1686
1680
1
0
0
1
0
1
0
0
0
0
0
0
0
0
1
0
0
0
BAT
LP1
TGHV
0560
1670
1875
1
0
0
2
0
0
SV1
SV2
SV3
SV4
SV5
SV6
C1
C2
0201
0202
0203
0204
0205
0206
1606
1607
1
1
1
1
1
1
1
1
2
2
2
2
2
2
3
3
CRK
CAM
ESS
CMOL
HP8
0335
0340
0320
0219
1687
1
1
1
2
0
2
2
0
0
0
CANDEF
1611
LP4
LP5
1673
1674
0
0
0
0
MPROP
FPS
HPC1
MPRV
DRV
0233
0190
1690
0231
0233
2
2
2
2
2
3
3
3
3
4
MMR
STSP
PSS
1625
1285
0561
1
1
1
0
3
0
0 = OFF
2 = 50% torque
3 = Engine speed reduced
W190
1 - 37
ENGINE
1.5.3 DIAGNOSIS OF MAIN MALFUNCTIONS

The main malfunctions of the engine are:
1 The engine fails to start;
2 The engine overheats;
3 The engine is low powered;
4 The engine produces black or dark grey smoke;
5 The engine produces grey smoke (tending to
white);
6
7
8
9
10
The engine produces blue smoke;

The engine makes unusual knocks;
The engine stops;
Excessive or insufficient oil pressure;
Excessive fuel consumption.
THE ENGINE FAILS TO START
Connections of the battery terminals efficient.
NO
Clean, check, tighten or replace terminal nuts.
NO
Perform checks described in Repair Manual.
YES
Batteries efficient.
YES
Starter motor efficient.
NO
Perform checks described in Repair Manual ".
YES
No air leakages in low pressure supply system.
NO
Eliminate cause of leakage.

Bleed system.
YES
No traces of water in supply system.
NO
Eliminate causes for infiltration.Clean fuel

system, including tank.
NO
Replace.
YES
Fuel pre-filter - filter efficient.
1 - 38
W190
ENGINE
Pre-post heater system efficient.
NO
Diagnose with PT-01.
YES
High-pressure pump efficient.
NO
Test engine with PT-01.
NO
Test engine with PT-01.

Check efficiency of O-Ring.
YES
Injector efficient.
YES
Compression ratio correct.
NO
Overhaul the engine or restrict intervention to

components involved, (valves, piston rings
etc.).
NO
Check for possible spills and top-up level.
NO
Check, adjust tension and replace parts as

required.
THE ENGINE OVERHEATS
Coolant level correct.
YES
Water pump and fan drive belts efficient.
W190
1 - 39
ENGINE
Water pump efficient.
NO
Overhaul or replace group.
YES
Thermostat efficient.
NO
Replace.
NO
Perform an accurate washing; check if there

are spills. Replace item if required.
NO
Clean or replace defective parts.
NO
Check and replace as required.
NO
Replace.
NO
Replace.
YES
Radiator efficient.
YES
Air cleaner and circuit piping efficient.
YES
Engine brake disengages.
YES
Cylinder head gasket efficient.
YES
Fan efficient.
1 - 40
W190
ENGINE
THE ENGINE LACKS POWER
Fuel filters efficient.
NO
Replace, proceeding as described in

"Operation and Maintenance" Manual.
YES
Low and high-pressure supply systems

efficient.
NO
Check tightness of system connections.
YES
Thermostat efficient.
NO
Replace.
YES
Tank filled with fuel.
NO
Check fuel level.
NO
Check transfer pump and clean suction form

possible impurities.
NO
Engine test with PT-01, replace as required.
NO
Engine test with PT-01, replace

required.Check tightness of O-Ring.
NO
Disconnect the fuel return pipe from the rail

and check if leaking.
YES
Fuel suction in tank efficient.
YES
High-pressure pump efficient.
YES
Injectors efficient and flow limiter correctly

operating.
as
YES
Rail pressure relief valve efficient.
W190
1 - 41
ENGINE
Compression rate correct.
NO
Engine test with PT-01.
NO
Repair or replace the group.
NO
Check - recondition.
YES
Turbocharger efficient (integrity of blades,

bearings, actuators).
YES
Valve clearance correct.
THE ENGINE PRODUCES BLACK

OR DARK GREY SMOKE
Air cleaner efficient.
NO
Replace.
YES
Injectors efficient.
NO
Engine test with PT-01.Check tightness

of O-Ring.
NO
Engine test with PT-01.
YES
Compression rate correct.
1 - 42
W190
ENGINE
THE ENGINE PRODUCES GREY

SMOKE (TENDING TO WHITE)
Injectors efficient.
NO
Engine test with PT-01.Check tightness of ORing.
YES
Level of coolant correct.
NO
Probable passage of coolant into the

combustion chambers. Replace cylinder head
gasket or overhaul engine.
THE ENGINE PRODUCES BLUE SMOKE
Presence of oil in the cylinders.
YES
Excessive oil consumption.Oil leaking from the

turbine. Leakage from valve guides.
W190
1 - 43
ENGINE
THE ENGINE MAKES

UNUSUAL KNOCKS
Knock in crankshaft.
YES
Check: plays and out-of round of main journals,

securing of main journal caps and flywheel; oil
pressure. Replace parts or overhaul engine.
NO
Knock in conrods.
YES
Check: plays and out-of round of conrod

journals, securing of conrod journal caps
conrod square; oil pressure. Replace parts or
overhaul engine.
NO
Knock in pistons.
YES
Check: play between pitons - cylinder sleeves;

integrity of piston rings; play pins-piston
seats.Replace parts or overhaul engine.
NO
Knock in cylinder heads.
YES
Check: clearance between rocker arms and

valves, timing. Adjust.
NO
YES
Knock in timing.
Check gears and replace as required.
NO
Knock in air compressor.
YES
Overhaul or replace air compressor.
YES
Check and calibrate them as prescribed by S.I.

1094 or replace them.
NO
Knock in injectors.
1 - 44
W190
ENGINE
THE ENGINE STOPS
Tank filled with fuel.
NO
Refuel and bleed, if required.
YES
Fuel filters efficient.
NO
Replace.
YES
Fuel supply circuit efficient.
NO
Check the circuit and bleed.
INSUFFICIENT OR ESCESSIVE
OIL PRESSURE
Pressure relief valve works correctly.
NO
Check and replace, if required.
YES
Oil pump and delivery piping efficient.
NO
Check and replace, if required.
YES
Main and conrod journals efficient.
NO
Replace bearings and grind crankshaft, if

required.
NO
Change engine oil with other with appropriate

viscosity.
YES
SAE viscosity of engine oil correct.
W190
10
1 - 45
ENGINE
EXCESSIVE FUEL CONSUMPTION
Fuel tank and pipes efficient.
NO
Eliminate possible leakages and replace faulty

parts.
YES
Air cleaner efficient.
NO
Replace.
1 - 46
W190
ENGINE
1.6 ENGINE SUPPORTS

The engine is secured to the rear module of the frame
in four points by brackets.
1
6
Frontally by the torque converter-transmission group

and rearward by the engine itself. All the brackets, in
turn, rest on elastic pads.
5
1
3
8
9
7
10
1
6
11
12
5
Fig. 1-27 Engine supports
Notes - 1
224 Nm
110 Nm
110 Nm
380 Nm
1. Screw M16 x 110 - 2. Screw M12 x 40 - 3. Screw M20 x 45 - 4. Screw M10 x 100 - 5. Nut - 6. Rear bracket - 7. Rear
bracket - 8. Washer - 9. Upper plate - 10. Elastic pad - 11. Lower plate - 12. Washer
W190
1 - 47
ENGINE
1.7 ENGINE OVERHAUL

4
Remove fuel filter (5) from support (1);
Disconnect the low-pressure fuel pipes (2 - 3 - 4)
from support (1);
Remove support bracket (1) from the cylinder block.
10
Fig. 1-30
5
Disconnect fuel piping (2) from the rail and high-pressure pump (9) and remove from the cylinder block by
removing securing screws (4 and 6).
Note When loosening connection (7) of piping (2) it is

necessary to prevent the rotation of connection (10) of
high-pressure pump (9) with an appropriate wrench.
Fig. 1-28
1-31
Fig. 1-29
Fig. 1-31
Note To disconnect the low-pressure fuel pipes (2 - 3

- 4 Fig. 28) from the relevant connecting joints, it is
necessary to press stop (1) as shown in Figure B.
Remove screws (2) and disconnect oil piping (3) from

compressor pipe (1) and from the cylinder block.
Remove starter motor (4) from the flywheel cover.
After disconnecting the piping, return stop (1) into locking position of Fig. A to prevent that it could be deformed.
1 - 48
ENGINE
Fig. 1-32
Install brackets (1) on the engine cylinder block and
secure them to an overhaul stand (2).
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
Note When disconnecting connections (4) securing

pipes (6) to rail (2) it is necessary to prevent the rotation of
flow limiters (3) with an appropriate wrench.
Remove screws (1) and remove rail (2).
6
Fig. 1-34
1 - 50
W190
ENGINE
1
2
2
3
9
10
11
12
5
6
7
8
13
Fig. 1-37
Fig. 1-35
Disconnect fuel return pressure relief device (1), piping (2) as described in Fig. 29.
Loosen nuts (1) securing tappet adjustment and loosen

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

fume pipe (9).
Remove screws (2), remove rocker arm group (3) composed of support (6), rocker arms (4) pins (5) and remove bridges (7) from the valves.
Remove connections (13-11) and remove piping (12).
Remove tapped rods (8).
Remove nuts (7) and remove tappet cover (8) complete with gaskets.
1
7
2
8
3
4
Fig. 1-36
Fig. 1-38
Remove nuts (7) and disconnect the electric wiring of

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

tool 380001099 (1) and extract electric injectors (2)
from the cylinder head.
Note The fuel manifolds (4) removed, must not be reused, but replaced by new ones.
W190
1 - 51
ENGINE
3
2
2
3
6
6
5
7
Fig. 1-40
Fig. 1-39
Remove screw (4) securing oil piping retainer (5).
Disconnect oil piping (5) from oil heat exchanger/filter
support (7).
Remove nuts (2) and remove turbocharger (3) from
exhaust manifold (1).
Remove screws (1) and remove the air conveyor assembly from the heater. Remove screws (3) remove
cover (2) and the thermostat underneath (5).
Note The outer screws marked are shorter.
Remove securing screws (6) and remove the exhaust

manifold in two pieces with the relevant gaskets.
1
2
Fig. 1-41
Sling brackets (1) with steel ropes and a hoist to remove cylinder head (2) from the cylinder block.
1 - 52
W190
ENGINE
1
2
1
3
Fig. 1-42
Fig. 1-44
Remove cylinder head gasket (1).
Remove screws (2) and remove alternator support (3).
Using the appropriate wrench on the automatic belt

tensioner (3) loosen the tension of belt (2) and remove it.
Remove oil filter (1).
Remove screw (4) and remove automatic belt

tensioner (3).
6
1
2
3
Fig. 1-45
Fig. 1-43
Remove screws (4) and remove oil temperature sensor (3).
Remove screws (2) and remove alternator (1).
Remove screws (1) and remove oil heat exchanger

filter support (2), intermediate plate (6) and the relevant gaskets.
Remove oil level sensor (5).
W190
1 - 53
ENGINE
1
1
4
2
2
Fig. 1-46
Fig. 1-48
Remove screws (1) and remove controller (2) complete with heat exchanger.
Install tool (2) on flywheel housing (1) to prevent the

rotation of flywheel (3).
Loosen screws (4).
1
4
3
5
6
3
Fig. 1-47
Fig. 1-49
Remove nut (1) and remove timing sensor (2).
Remove screws (2) and remove pulley (3) and damper

flywheel (1).
Remove nuts (3) and remove high-pressure pump (4)

complete with fuel pump (5).
Remove screws (6) and remove hub (5) and phonic

wheel (4).
1 - 54
W190
ENGINE
1
2
5
1
2
6
4
Fig. 1-50
Fig. 1-52
Remove screws (1) and remove water pump (2).
Remove screws (1) and remove oil pump (2).
Remove screw (3) and remove roller (4).
Note Oil pump (2) cannot be overhauled.
Remove screw (5) and disconnect rpm sensor (6).
1
1
2
4
2
Fig. 1-51
Fig. 1-53
Remove screws (1) and remove front cover (2).
Remove tool (2).
Note Record the installation position of screws (1) since

they have different length.
Remove screws (1) securing flywheel (3) to crankshaft (4).
W190
1 - 55
ENGINE
2
2
3
Fig. 1-54
Fig. 1-56
Install two pins (2) of appropriate length in the holes

of crankshaft (3).
Turn the engine upside down.
Pullout engine flywheel (1) so that it is possible to

sling it with a hoist and store it.
Remove screws (2) to remove plate (3) and remove

oil sump (1).
1
2
1
4
2
Fig. 1-55
Fig. 1-57
Remove screws (1) and remove rear cover (2).
Remove screws (1) and remove oil suction strainer

(3).

they have different dimensions.
Remove screws (2) and remove stiffening plate (4).
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
Remove screws (2) and remove timing gear housing

(1).
Fig. 1-61

they have different dimensions.
Remove screws (1) and remove main journal caps
(2).
W190
1 - 57
ENGINE
3
Fig. 1-62
Fig. 1-64
The last but one main journal cap (1) and the relevant
support have half- bearing (2) equipped with a thrust
ring.
Remove main journal half-bearings (1).

Remove screws (2) and remove oil jets (3).
Note Record the installation position of the upper and

lower half-bearings, since in case of reinstallation they must
be placed in the same location they had before being removed.
1
3
Fig. 1-63
Fig. 1-65
With tool (1) and a hoist remove crankshaft (2) from

the cylinder block.
Remove screws (1) and remove plate (2) retaining

camshaft (3).
Note Record the installation position of plate (2).
1 - 58
ENGINE
W190
Fig. 1-66
Extract carefully camshaft (1) from the engine cylinder block.
1
1
Fig. 1-67
Extract tappets (1) from the cylinder block.
W190
1 - 59
ENGINE
1.7.1 REPAIR INTERVENTIONS

CYLINDER GROUP
Inspections and measurements
Once the engine disassembly is over, proceed with a
thorough cleaning of the cylinder- cylinder block group.
Use the appropriate rings to handle the cylinders group.
Check accurately that the cylinder block is free from
cracks.
Check the condition of machining plugs. If they are
rusty or there is a slightest doubt about their sealing,
replace them.
Examine the surfaces of the cylinder sleeves; they
must be free from signs of seizing, scratches,
ovalisation, tapering and excessive wear.
Measure the inner diameter of the cylinder sleeves,
to identify the amount of ovalisation, tapering and wear
using bore gauge (1) equipped with dial meter previously zeroed on ring caliper (2) for the cylinder sleeve
diameter.
The measurements must be performed for each single cylinder at three different sleeve heights and on
two planes perpendicular between them: one parallel
to the longitudinal centre line of the engine (A) the
other perpendicular (B). On the latter plane and in
correspondence with the first measurement the maximum wear is normally found.
When an ovalisation, tapering or any wear is found,
proceed with a grinding and reconditioning of the
sleeves. The reconditioning of the cylinder sleeves
must be performed in relation to the diameter of the
spare pistons oversized 0,5 mm from the nominal
value and at the prescribed installation play.
Note In the event a ring caliper is not available, use a

micrometer for the zeroing.
1st
B
2nd
3rd
1
1
2
Fig. 1-69
2
Fig. 1-68
1 - 60
W190
ENGINE
Check that the mounting face of the cylinder head,

on the cylinder group, is not deformed
102,02 + 0,01
0,4 S F S W D
SEE NOTE
0,06 F
0,015
1,25 + 0,25
Rz 12,0 ISO CUT OFF 2,5
(25 - 30)
1
(25 - 30)
Fig. 1-71
This check can be performed, after removing dowel
(4) with calibrated ruler (2) and feeler gauge (3).
After identifying deformed zones, grind flat the mounting face.
The flatness error must not exceed 0.075 mm.
Fig. 1-70
Note In case of reconditioning, all the cylinder sleeves
must have the same over-sizing (0.5) (mm).
Note The grinding of the cylinder block can be made

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

follows:
install the main journal caps without bearings;
tighten the securing screws to the prescribed torque;
using an appropriate bore gauge, check that the diameter of the seats has the prescribe value.
In the event a larger dimension is found, replace the
cylinder block.
W190
1 - 61
ENGINE
TIMING
Camshaft
54.005
54.035
Fig. 1-72
CAMSHAFT MAIN DATA

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

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

the relevant bushes.
1
2
Fig. 1-73
1 - 62
W190
ENGINE
BUSHES
Camshaft bushes (2) must force into the relevant
seats.
The inner surfaces must be free from traces of seizing or wear.
Measure the diameter of the camshaft front and rear
bushes (2) and intermediate seats (1) with bore gauge
(3).
The measurements must be made on two lines perpendicular between them.
2
1
Fig. 1-74
Sect. A-A
A
54.089
54.139
59.222
59.246
54.083
54.147
Fig. 1-75
MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT SEATS

* Dimension to be obtained after pressing the bushes.
W190
1 - 63
ENGINE
Replacing the bushes

To replace the front and rear bushes use to remove
and reinstall them puncher 380000667 (2) and handle
380000668 (3).
Installation of tappets - camshaft
Note During the installation bushes (1) must be oriented that lubrication holes (2) coincide with the ones on
the seats of the cylinder block.
Fig. 1-78
1
3
Lubricate tappets (1) and install them in the relevant

seats of the cylinder block.
2
Fig. 1-76
Tappets
16.000
16.030
15.924
15.954
15.960
15.975
11
29
47
15.924
15.954
Fig. 1-77
MAIN DATA OF TAPPETS AND RELEVANT SEATS
ON THE CYLINDER BLOCK
Fig. 1-79
Lubricate the camshaft support bushes and install

camshaft (1) taking care during the operation, the
bushes or the support seats in the cylinder block are
not damaged.
1 - 64
W190
ENGINE
1
1
3
2
Fig. 1-80
Fig. 1-82
Position plate (1) retaining camshaft (3) with the groove

directed toward the upper side of the cylinder block
and the stamping toward the operator, tighten screws
(2) to the prescribed torque.
Install jets (2) and tighten securing screws (1) to the

prescribed torque.
Fig. 1-81
Check the axial play of camshaft (1).

It must be 0.23 0.13 mm.
W190
1 - 65
ENGINE
CRANKSHAFT
Measuring main and conrod journals
CAUTION
All the main and conrod journals must always be

ground to the same reduced diameter class.
The diameter reduction of the main and conrod
journals must be recorded by an appropriate stamping on the side of crank no. 1.
For reduced conrod journals digit M.
For reduced main journals digit B.
For reduced conrod and main journals digits MB.
Fig. 1-83
In the event excessive traces of seizing, scratches
or ovalisation are identified, it is necessary to regenerate the journals, by grinding them. Prior to proceeding with the journal (2) grinding operation, measure
the crankshaft journals with micrometer (1), to define
the diameter to which the journals must be reduced.
Note It is recommended to record the value measured on a table. See Figure 85.
The reduction classes are:
82.99
83.01
MIN
MAX
68.99
69.01
Fig. 1-84
TABLE ON WHICH THE VALUES RELATIVE TO THE MEASUREMENT OF THE MAIN AND CONROD
JOURNALS OF THE CRANKSHAFT
* Nominal value
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
*
**
Measured on a radius exceeding 45.5 mm
0.500 between adjacent main journals

MAIN CRANKSHAFT TOLERANCES
FRAME ON TIMING SIDE
45
INTERMEDIATE
FRAMES
2 x 45
FIRST FRAME
FRONT SIDE
45
Fig. 1-86
TOLERANCES
OF SHAPE
OF ORIENTATION
OF POSITION
OF OSCILLATION
FEATURES SUBJECT OF THE TOLERANCE

Roundness
Cylindricality
Parallelism
Perpendicularity
Straightness
Concentricity
Circular oscillation
Total oscillation
Taper
CLASS OF IMPORTANCE GIVEN TO THE FEATURES

OF THE PRODUCT
GRAPHIC SYMBOL
/
/
//
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
W190
1 - 67
ENGINE
Replacement of oil pump drive gear
Main journal installation protrusion
2
3
Fig. 1-87
Fig. 1-89
Check that the teeth of gear (1) are not damaged or

worn, otherwise pull it out with the appropriate puller
(3). When installing a new gear, it is necessary to
warm it up for 10 minutes in an oven at 180 C
(355 F) and key it on the crankshaft.
Install crankshaft (2).

Check the play between main journal and the relevant
Installation of crankshaft bearings

1
2
3
Fig. 1-90
Fig. 1-88
Note When it is found that the bearings do not need
to be replaced, it is necessary to re-install them in the
same order and position found when disassembling.
Main journal bearings (1) are supplied as spares reduced on the inner diameter 0.25 - 0.500 mm.
Note Do not attempt adapting the bearings.
Clean accurately main journal half-bearings (1) with
lube hole and install them in their seats.
The last but one main journal bearing (1) is equipped
with thrust washers.
bearings as follows:
clean accurately all the components and eliminate
all traces of oil;
place on the main journals (4) of the crankshaft a
piece of calibrated wire (3);
install caps (1) complete with half-bearings (2) on
the relevant caps.
1 - 68
W190
ENGINE
1
2
Fig. 1-91
Fig. 1-93
Install screws (1) pre-lubricated and tighten them in

three subsequent phases.
1st phase with torque wrench at 50 6 Nm.
2nd phase with torque wrench at 80 6 Nm.
remove the caps from the supports.

The play between the main bearings and the relevant
journals is measured by comparing the width of calibrated wire (2) in the max. squeezing point with the
graduated scale printed on wrapping (1) of the calibrated wire.
The numbers listed on the scale indicate the play in
mm of the matching.
In the event a play value is measured different from
the one prescribed, replace the bearings and repeat
the measurement. Once the correct play is obtained,
lubricate the main journal bearings and install permanently the supports, tightening the securing screws
as previously described.
Fig. 1-92
3rd phase with tool (1) positioned as indicated in the

figure and tighten further screws (2) with an angle of
90 5.
1
2
3
Fig. 1-94
Checking the end play of the crankshaft
The endplay check is done by placing a magnetic
base dial gauge (2) on crankshaft (3) as indicated in
the figure. Normal play is 0.068 0.41.
In the event a larger play is measured, replace the
journal half bearings of the last but one rear support
(1) with thrust washers and repeat the play check
between crankshaft main journals and half-bearings.
W190
1 - 69
ENGINE
CONROD - PISTON ASSEMBLY
3
1
2
1
2
7
8
6
Fig. 1-95
Fig. 1-97
COMPONENTS OF THE CONROD PISTON ASSEMBLY
The removal of circlips (2) retaining piston pin (2) is

done sing scribing point (3).
1. Circlips - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws 6. Half bearings - 7. Conrod - 8. Bush.
Note Spare pistons oversized 0.5 mm are provided

as spare parts.
1
2
Fig. 1-96
Removal of piston rings (1) from piston (2) using pliers (3).
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.
The play between piston and cylinder sleeve can be

measured also as indicated in the figure with a feeler
gauge (1).
Note The diameter must be measured at 12 mm

from the base of the skirt of the piston.
1.5
2.705
2.735
2.560
2.605
2.350
2.380
3.975
4.000
2.420
2.440
4.020
4.040
220'
40.008
40.014
39.996
40.003
Fig. 1-100
MAIN DATA OF KS. PISTON PINS AND PISTON RINGS

* The dimension is measured on a diameter of 99 mm
W190
1 - 71
ENGINE
Piston pins
Piston rings
1
1
2
Fig. 1-101
Fig. 1-103
Measurements of the diameter of piston pin (1) using

micrometer (2).
Check the thickness of piston rings (2) using micrometer (1).
Conditions for a correct pin-piston matching
1
2
1
3
Fig. 1-104
Fig. 1-102
Lubricate pin (1) and the relevant seat on the piston

with engine oil. The pin must enter the piston with a
slight pressure of the fingers and must not come-out
from it under its own weight.
Check the play between piston rings (3) of the second and third grooves and the relevant seats on piston (2) with feeler gauge (1).
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
Due to the peculiar shape of the first trapezoidal ring,

the play between groove and the ring itself must be
measured as follows: have piston (1) protruding from
the cylinder block so that ring (2) protrudes about half
from cylinder sleeve (3).
In this position, use a feeler gauge to check play (X)
between ring and seat: this play must be within the
prescribed value.
72.987
73.013
1.955
1.968
Fig. 1-107
MAIN DATA OF CONROD, PISTON PIN BUSH AND
HALF BEARINGS
*
Dimension of inner diameter to be obtained after

pressing into the conrod small end and boring.
** Dimension not measurable at free conditions.
1
2
Fig. 1-106
Measurement of the play between the tip of piston

rings (2) installed in cylinder sleeve (3) using feeler
gauge (1).
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
Checking the conrods
CAP
1234
A
CONROD NO. YEAR
0001
A 1998
B 1999
9999
C 2000
D 2001
123
DAY
001
366
Fig. 1-108
1
Each conrod is marked:
On the body and on the big-end cap indicating the
matching and the cylinder in which it is installed.
Thus, in case of replacement it is necessary to proceed with the numbering of the new conrod with the
same numbers of the old one.
A letter on the conrod body indicating the weight
class of the conrod mounted in production:
V, 1820 1860 (marked yellow);
W, 1861 1900 (marked green);
X, 1901 1940 (marked blue);
Spare conrods are provided in class We marked
green*.
No removal of material is allowed.
2
5
3
4
Fig. 1-109
Check the parallelism of the conrod centre lines (1)

using device (5) operating as follows:
install conrod (1) on the mandrel of tool (5) and lock
it with screw (4);
place mandrel (3) on "V" prisms resting conrod (1)
on stop bar (2).
1 - 74
W190
ENGINE
Checking the torsion
Checking the flexion
1
2
2
B
3
5
4
4
Fig. 1-110
Fig. 1-111
Check the torsion of conrod (5) comparing two points

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

points C and D of pin (3) on the vertical plane of the
conrod centre line.
Position vertical support (1) of dial gauge (2) so that
the latter rests on pin (3) in point C.
Swing the conrod for and back trying to find the highest position of the pin and zero dial gauge (2) under
this condition.
Move the mandrel (4) with conrod (5) and repeat on
the opposite side D of pin (3) the position of the highest point. The difference between point C and point D
must not exceed 0.08 mm.
W190
1 - 75
ENGINE
Installation of conrod-piston group

Conrods-pistons matching
1
2
2
3
4
Fig. 1-114
Position piston (1) on the conrod following the configuration of the figure, insert pin (3) and secure it with
circlips (2).
Fig. 1-112
On the crown of the piston the following references

are engraved:
1. Spare part number and design modification number;
2. Arrow indicating the installation sign of the piston
into the cylinder sleeve; it must be oriented toward the front side of the cylinder block;
3. Etching indicating the inspection of the 1st groove
insert;
4. Date of manufacture.
Installation of piston rings
1
2
1
2
3
4
Fig. 1-115
5
To reinstall piston rings (1) into piston (2) use pliers
(3).
The rings must be installed with the wording "TOP"
upward. Also, the ring gaps must be placed so that
they are shifted 120 among them.
Fig. 1-113
Install piston (2) on conrod (4) with pin (3) so that

reference arrow (1) for installation of piston (2) in the
cylinder sleeve and digits (5) etched on conrod (4) are
seen as indicated in the figure.
Note Piston rings are provided as spares in the following dimensions:

standard, marked by yellow paint;
oversized 0.5 mm and marked by yellow/green paint;
1 - 76
W190
ENGINE
Fig. 1-116
Fig. 1-118
CONROD - PISTON ASSEMBLY IN THE PASSAGE
Install half bearings (1) both on the conrod and the

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

cylinder sleeves
the gap of the piston rings are shifted 120 among

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

To measure the play perform the following operations:
1
2
3
2
Fig. 1-117
Fig. 1-119
Lubricate well the pistons, including the piston rings

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

of oil;
place a piece of calibrated wire (2) on the journals;
install conrod caps (3) with the relevant half bearing
(4).
W190
1 - 77
ENGINE
2
1
Fig. 1-122
Fig. 1-120
tighten screws (1) previously lubricated with engine

oil, with torque wrench (2) to the prescribed torque.
remove the cap and determine the play comparing

the width of calibrated wire (1) with the data of the
scale printed on wrapping (2) containing the wire.
1
1
Fig. 1-123
Fig. 1-121
install tool (1) on the ratchet wrench and tighten

screws (2) 60 further.
In the event a play value is measured different from

the one prescribed, replace the bearings and repeat
the measurement. Once the correct play is obtained,
lubricate the main journal bearings and install permanently the supports, tightening the securing screws
as previously described.
Note Prior to the final installation of the securing
screws of the conrod cap, check that their diameter,
measured in the centre of the thread length, is not 0.1
mm smaller than the diameter measured at about 10
mm from the tip of the screw.
Check manually that conrods (1) slide axially on the
crankshaft journals and that the their axial play measure with feeler gauge (2) is 0.10 0.33 mm.
1 - 78
W190
ENGINE
Check of piston protrusion
It must be uniform (no crumbs) free from air bubbles,

thin or discontinued zones.
Imperfections must be corrected in the shortest time.
Avoid using excess material to seal the joint.
Excessive sealant tends to escape on both sides of
the joint and clog the passage of lubricants.
After completing the application of sealant, the joints
require an immediate installation (10 - 20 minutes).
1
Fig. 1-124
6
4
Once the reassembly of the conrod-piston assemblies

is completed check with dial gauge (1) equipped with
base (2) the protrusion of pistons (3) at TDC with respect to the upper face of the cylinder block.
It must be 0.28 0.52 mm.
10
8
3
Timing gear housing

Fig. 1-126
1
TIGHTENING DIAGRAM OF GEAR REAR SECURING SCREWS
Reinstall housing (1) on the engine cylinder block.

Install the securing screws in the position found at
the disassembly and tighten them to the torque indicated here below, in the sequence illustrated in the
figure.
Screws M12 65 89 Nm
Screws M8 20 28 Nm
Screws M10 42 52 Nm
Fig. 1-125
DIAGRAM OF APPLICATION ZONE FOR LOCTITE
5999 SEALANT
Clean accurately the mounting faces of flywheel housing (1) and of the timing gear housing.
The cleaning of the surfaces to be sealed is required
and absolutely required to ensure an effective sealing.
Apply LOCTITE 5999 sealant on housing (1) so that a
seam a few mm thick in diameter is formed.
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
Turn crankshaft (4) and camshaft (2) so that when

installing on the latter driven gear (1) the signs engraved on gears (1 and 3) coincide.
Clean accurately the mounting faces of flywheel housing (1) and of the timing gear housing.
The cleaning of the surfaces to be sealed is required
and absolutely required to ensure an effective sealing.
Apply LOCTITE 5999 sealant on housing (1) so that a
seam a few mm thick in diameter is formed.
It must be uniform (no crumbs) free from air bubbles,
thin or discontinued zones.
Imperfections must be corrected in the shortest time.
Avoid using excess material to seal the joint.
Excessive sealant tends to escape on both sides of
the joint and clog the passage of lubricants.
After completing the application of sealant, the joints
require an immediate installation (10 - 20 minutes).
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
Check the mounting face of the clutch disc. If signs

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

Check the conditions of the teeth of ring gear (2). If
failures or excessive wear of the teeth are found remove it from the flywheel (1 Fig. 134) with a punch
and install a new one, previously heated to 150 C
(302 F) for 15 20 minutes. The bevel on the inner
diameter must be directed toward the flywheel.
3
1
4
6
5
Fig. 1-132
Install item (5) of tool 380000666 on the tail (6) of the

crankshaft, secure it with screws (4) and key a new
seal (3) on it.
Place item (1) on item (5) tightening nut (2) until seal
(3) is fully installed in flywheel housing (7).
3
Fig. 1-134
Install two pins (2) of appropriate length in the holes

of crankshaft (3) and install flywheel (1) using a sling
and a hoist (1).
W190
1 - 81
ENGINE
Fig. 1-135
Fig. 1-137
Install screws (4) securing flywheel (3) to the crankshaft.

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

Tighten securing screws (2) to the prescribed torque.
1
2
Fig. 1-136
Fig. 1-138
Tighten screws (1) securing flywheel (2) in two phases:

1st phase, tightening with torque wrench to a torque
of 30 4 Nm;
2nd phase, tightening to an angle of 60 5.
Install a new seal (2) on water pump (1).
Note The angular tightening is performed using the

appropriate measuring tool.
1 - 82
W190
ENGINE
1
1
2
2
Fig. 1-139
Fig. 1-141
Install water pump (1).

Install screws (2) and tighten them to the prescribed
torque.
Clean accurately the mounting face of the cylinder

block front cover (2) and install it.
Install screws (1) and tighten it to the prescribed torque.
2
1
2
3
4
6
5
Fig. 1-140
Fig. 1-142
Remove seal (2) from front cover (1) clean accurately

the mounting face and apply LOCTITE 5999 sealant
on it.
Install item (5) of tool 380000666 on the tail (6) of the

crankshaft, secure it with screws (4) and key a new
seal (3) on it.
Place item (1) on item (5) tightening nut (2) until seal
(3) is fully installed in flywheel housing (7).
W190
1 - 83
ENGINE
2
1
2
3
Fig. 1-143
Fig. 1-145
Install plate (1) suction strainer (2) install securing

screws (3) and tighten them to the prescribed torque.
Install oil sump (1) and install plate (3) on it.

torque.
5
6
1
1
2
2
3
4
Fig. 1-144
Fig. 1-146
Arrange gasket (1) on oil sump (2).
Key phonic wheel (1) and hub (2).

Install securing screws (3) and tighten them in two
phases.
1st phase with torque wrench to a torque of 50 5
Nm
2nd phase, tightening to an angle of 60 5.
Note The gaskets free from defects can be reused.
Note The angular tightening is performed using the

appropriate measuring tool (4).
1 - 84
W190
ENGINE
1
4
2
1
3
2
3
Fig. 1-147
Fig. 1-149
Install anew sealing ring on rpm sensor (3).

Install rpm sensor (3) in front cover (1) and tighten
securing screw (2) to the prescribed torque.
Lubricate sealing ring (2) with engine oil and place it

on oil filter (3).
Tighten manually oil filter (3) on the connection of
support (1) until it contacts it; tighten oil filter (3) 3/4
turn further.
Install a new sealing ring on oil temperature/pressure
sensor (4) and install it on support (1).
torque.
Install a new sealing ring (6) in the seat in the cylinder
block.
1
2
3
4
5
2
3
4
Fig. 1-148
Install on the cylinder block: a new seal (1) heat exchanger (2) a new seal (3) and oil filter support (4).
torque.
Fig. 1-150
Position alternator support (1) so that pins (3 and 4)
are against the engine block.
torque.
W190
1 - 85
ENGINE
4
1
2
2
3
6
Fig. 1-151
Fig. 1-153
Reinstall alternator (1).

Install screw (2) and tighten it to the prescribed torque.
Reinstall high-pressure pump (6) complete with fuel

supply pump (5) and tighten nuts (3) to the prescribed
torque. Install support (4) with a new sealing ring, timing sensor (2) with a new sealing ring and tighten the
relevant securing nut (1) to the prescribed torque.
1
2
1
2
3
3
Fig. 1-152
Fig. 1-154
Reinstall automatic belt tensioner (2).

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

to the cylinder block and tighten screws (2) to the
prescribed torque.
Note It is advisable to replace support elastic pads (1).
1 - 86
W190
ENGINE
CYLINDER HEAD
Disassembly of valves
2
A
1
2
Fig. 1-157
S
Remove sealing rings (1 and 2) from the relevant valve

guides.
Fig. 1-155
Intake (1) and exhaust (2) valves have the head with
the same dimensions.
The central slot () of the head of exhaust valve (2)
discriminates it from the intake valve.
Note Sealing rings (1) for the intake valve are yellow;
sealing rings (2) for exhaust valves are green.
Hydraulic test of the cylinder head
Note Prior to disassembling the valves from the cylinder

head number them so that, in case they are not replaced, it
is possible to reinstall them in the original position.
A = suction side
S = exhaust side
2
1
1
4
Fig. 1-158
Check the hydraulic tightness using an appropriate

tooling.
Inject, using a pump, water heated to ~ 90 C (195 F)
at a pressure of 2 3 bar.
If spills occur at cup plugs (1) replace them, using an
appropriate punch to remove and reinstall them.
Fig. 1-156
The disassembly of the valves is performed with tool
(1) pressing plate (3) so that, compressing springs (4)
it is possible to remove cotters (2). Then remove:
plate (3) springs (4).
Repeat the operation for all the valves.
Turn the cylinder head upside down and extract valves
(5).
Note Prior to installing the plugs, apply a hydro-reactive

sealant to the sealing face.
In case of spills from the cylinder head it is necessary to replace it.
W190
1 - 87
ENGINE
The check of the mounting face of cylinder head
VALVES
MAIN DATA OF THE INTAKE AND EXHAUST
VALVES
EXHAUST
VALVE
INTAKE
VALVE
6.970
6.990
6.970
6.990
1
Fig. 1-159
59.75
60.25
44.75
45.25
The check of the mounting face of cylinder head (1)
on the cylinder block is done using ruler (2) and feeler
gauge (3).
The deformation measured along the entire of the
cylinder head must not exceed 0.2 mm.
For higher values, recondition the cylinder head in
accordance with the values and precautions indicated
in the figure.
0.025/25x25
04 C
32.87
33.13
32.87
33.13
Fig. 1-161
De-scaling inspection and grinding of the valves
D
A
B
C
0 3 TOTAL
0.01/50 x 50
Fig. 1-160
Nominal thickness A of the cylinder head is 105

0.25 mm. The maximum amount of metal B allowed
to be removed must not exceed 1 mm.
Note After the reconditioning, check the depression of
the valves and recondition the valve seats if required to reobtain the valve prescribed depression.
Fig. 1-162
Remove carbon scaling from the valves using an appropriate metal brush.
Check that the valves do not show signs of seizing,
cracking or burning.
Regrind, as required, the valve seats with grinder adequate removing as little material as possible.
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
Check of play between valve stem, valve guide and

valve roundness
Use a bore gauge to measure the inner diameter of

the valve guides. It must be the value indicated in the
figure.
VALVE SEATS
Regrinding - replacement of valve seats
1
2
1
2
Fig. 1-164
The inspections must be done using dial gauge (1)
with a magnetic base place as illustrated. The play
must be 0.052 0.092 mm.
Turn valve (2) to check that the out-of-round does not
exceed 0.03 mm.
Fig. 1-166
Check valve seats (2). When slight scratches or
burnings are found, regrind using adequate (1) in accordance with the angle values indicated in the Figure.
W190
1 - 89
ENGINE
VALVE SEATS IN CYLINDER HEAD
30.8
EXHAUST
69.5
70.5
69.5
70.5
45
60
29.5
30.5
29.5
30.5
30.7
3.4
3.6
INTAKE
3.02
3.28
Fig. 1-167
MAIN DATA OF VALVE SEATS
The valve seats are obtained when casting the cylinder head and subsequently machined.
1.1
1.5
EXHAUST
27.25
27.75
INTAKE
27.25
27.75
39.5
40.5
34.837
34.863
34.837
34.863
36.78
36.78
Fig. 1-168
The valve seats are obtained when casting the cylinder head and subsequently machined. In the event it
is not possible to recondition the valve seats by just
regrinding them, it is possible to use inserts supplied
as spare parts.
Under these conditions, the seats with the dimensions
indicated in the figure must be obtained, then install
the valve seats.
To install the valve seats into the cylinder heads, warm

the cylinder head to 80 100 C (176 212 F) and,
using an appropriate puncher, install new valve seats
(2) previously cooled.
Then, regrind the valve seats adequate in accordance with the values listed in Fig. 169.
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
After the reconditioning operations, use dial gauge (1)

with base (2) to check valve depression (3) is at the
prescribed value.
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
Prior to the installation, check the flexion of the valve

springs using the spring load device. Check the load
and elastic deformation data with those of new valves
indicated in the table here below.
H
H1
H2
Height
mm
47.75
35.33
25.2
Under a load of
kg
Free
P 339.8 9 Nm
P1 741 39 Nm
Install on the cylinder head: spring (4) upper cup (3).

Use tool (1) to press spring (4) and secure the valve
parts with cotters (2).
Reinstallation of the cylinder heads
ASSEMBLY OF THE CYLINDER HEAD
Fig. 1-173
Fig. 1-174
Fig. 1-172
Lubricate the stem of valves (1) and insert them into
the relevant valve guide in accordance with the position recorded during the disassembly.
Install sealing rings (2 and 3) on the valve guides.
Check that the mounting faces of the cylinder head

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

1st phase, pre-tightening with torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75x150 ( ) 55 5 Nm
2nd tightening phase with angle 90 5
3rd tightening phase with angle 90 5
Front side
Fig. 1-175
Before re-using screws (2) securing the cylinder heads,

measure the diameter of the thread of the screws with
micrometer (1) checking that it is no less than ..
mm in all points, otherwise replace them.
Tightening of cylinder head securing screws
3
1
2
1
2
Fig. 1-177
Install a new O-Ring (2) lubricated with vaseline and a
new sealing washer (3) on electric injector (1).
1
Fig. 1-176
2
Install cylinder head (1) install screws (2) and tighten
them in three subsequent sequences, following the
sequence and the procedures indicated in the figure
to follow.
3
Note The angle tightening is done using tool (3).
Fig. 1-178
Install electric injectors (1) in the seats on the cylinder heads, oriented so that fuel inlet hole (2) is directed toward seat side (3) of the fuel manifolds.
W190
1 - 93
ENGINE
Fig. 1-179
Fig. 1-181
Use tool 380001099 (1) to set electric injector (2) in

its seat.
Install the electric injector securing screws without
tightening them.
Using a torque wrench, tighten gradually and alternatively screws (1) securing the electric injectors to a
torque of 8.5 0.8 Nm.
Tighten nuts (2) securing fuel manifolds (3) to a torque
of 50 Nm.
1
4
RODS
3
Fig. 1-180
Install a new O-Ring (3) lubricated with vaseline on
fuel manifold (2) and introduce it into the cylinder head
seat so that positioning ball (5) coincides with the relevant seat (4).
Note The fuel manifolds (2) removed must not be reinstalled. Replace them with new parts.
Fig. 1-182
Install securing nuts (2, Fig. 181) without tightening

them.
The rocker arm rods must be free from deformations;

the spherical contact seats with the setting screw and
the tappet (arrows) must be free from traces of seizing or wear, otherwise replace them. The rods controlling the intake and exhaust valves are identical
and interchangeable.
Note During the operation, handle electric injector (1)

so that manifold ( 2 ) enters fuel intake hole
(2, Fig. 179) of the same correctly.
1 - 94
W190
ENGINE
Rocker arm group
1
4
Fig. 1-183
Fig. 1-185
COMPONENTS OF THE ROCKER ARM GROUP:

1. Screws - 2. Support - 3. Pins - 4. Rocker arms.
Install rods (2).

Install the valves on bridges (1) with mark () directed toward the exhaust manifold.
1
22.001
22.027
2
21.965
21.977
3
4
5
Fig. 1-184
Fig. 1-186
MAIN DATA OF PIN - ROCKER ARM

Check the pin / rocker arm mating surfaces that must
be free from excessive wear or damages.
Check that rod setting screws (1) are fully loosen to

prevent stiffening of the same on rods (2, Fig. 186)
when installing the rocker arm group. Then install the
rocker arm groups composed of support (5) rocker
arms (3) pins (4) and secure them on the cylinder
head tightening securing screws (6) to a torque of 36
Nm.
W190
ENGINE
Setting of the valve clearance
3
1
2
Fig. 1-187
Set the clearance between rocker arms and valves

using Allen wrench (1) wrench (3) and feeler gauge
(2).
The operating clearance is:
0.05
intake valves 0.25 0.05 mm
exhaust valves 0.51 0.05 mm.
Note To speed-up the setting of the rocker arm-valve
clearance, proceed as follows:
Turn the crankshaft, balance the valves of cylinder no. 1
and adjust the valves marked by an asterisk as indicated in
the table:
cylinder no.
intake
exhaust
1
-
2
*
3
*
-
4
*
5
*
-
6
*
*
Turn the crankshaft, balance the valves of cylinder

no. 6 and adjust the valves marked by an asterisk as
indicated in the table:
cylinder no.
intake
exhaust
1
*
*
2
*
-
3
*
4
*
-
5
*
6
-
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.
Install a new O-Ring (8) to air temperature/pressure

sensor (7) and install the latter on intake manifold (4)
tighten screws (6) to the prescribed torque.
Note Insulating washer (2) must be replaced with a new

one. Nuts (1) must be tightened to the prescribed torque.
W190
1 - 97
ENGINE
1
3
2
Fig. 1-189
Fig. 1-191
Apply LOCTITE 5999 to the mounting face of intake

manifold (1) and install it on the cylinder head.
Tighten screws (2) to the prescribed torque.
Connect new fuel pipes (1) to rail (3) and electric injector manifolds (2).
Note Pipes (1) must always be replaced when removed.
5
1
2
3
4
6
7
Fig. 1-190
Fig. 1-192
Install rail (2) and tighten securing screws (1) to the

prescribed torque, connect ground cable (3) to intake
manifold (4) and tighten securing nut (5) to the prescribed torque.
Note The connections of pipes (7) must be tightened to

a torque of 20 Nm, using the appropriate wrench (5) and
torque wrench (4).
Connections (6) must be tightened holding the key section of flow limiters (1) with the appropriate wrench (1).
Connect fuel pipe (3) to rail (2) following the procedures described in the figure to follow.
1 - 98
W190
ENGINE
1
2
Fig. 1-193
Fig. 1-195
Press holder (1) in the direction of the arrow (Fig. B)

and connect the pipe to rail (2, Fig. 190) return the
holder into the initial locking position "A".
Install harness support (2) install screws (1) and tighten

them to the prescribed torque.
Note make sure that the fuel pipe is connected correctly.
4
2
1
Harness support
3
1
Fig. 1-196
4
3
Connect electric wires (1) to electric injectors (3) and

tighten securing nuts (2) with the torque wrench
380000158 (4) to the prescribed torque.
Fig. 1-194
Check the conditions of electric wires (5); if damaged,

replace them cutting the bands tightening them to
support (2) removing screws (4) securing it to connectors (3).
Install a new gasket (1) on support (2).
W190
1 - 99
ENGINE
1
7
3
2
1
2
5
6
Fig. 1-197
Fig. 1-199
Install a new gasket (2) on rocker arm cover (1).
Re-install exhaust manifold (1) with new gaskets.

Install securing screws (7) and tighten them to the
prescribed torque.
Re-install exhaust manifold (1) turbocharger (3) with
anew gasket and tighten securing nuts (2) to the prescribed torque.
Connect oil pipe(5) to heat exchanger support (6) and
secure it to exhaust manifold (1) with screw (4).
1
2
Fig. 1-198
Install rocker arm cover (1) install nuts (2) and tighten
1 - 100
1
2
W190
ENGINE
10
11
12
13
14
6
7
15
8
Fig. 1-200
Fig. 1-201
Connect piping (14) with connections (13-15) and new

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

and connect the piping.
Return the holder into the original locking position A.
Note Make sure that fuel piping is correctly installed.
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).
Install the lifting device to the engine lifting eyes, sling

it to the hoist and remove the engine from the rotary
stand. Remove the securing brackets to the stand.
1 - 102
W190
ENGINE
2
1
2
3
3
1-31
Fig. 1-203
Fig. 1-205
Complete the assembly of the engine:

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

(1) to the cylinder block, install screws (3) and tighten
4
1
2
9
6
7
10
2
3
4
5
Fig. 1-204
Fig. 1-206
From the left side.

Connect fuel pipe (2) to the rail and to high-pressure
pump (9) and secure it to the cylinder block with
screws (4 and 6) tightening them to the prescribed
torque.
Tighten manually the fuel filter on support (1) until it

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

torque of 20 Nm using an appropriate wrench and torque
wrench.
Connection (7) must be tightened holding at the same
time the wrench pattern (10) of the high-pressure pump.
Piping (2) must always be replaced with a new one during
the reassembly.
W190
ENGINE
Fig. 1-207
Press holder (1) as indicated in figure B.

After disconnecting the piping, return holder (1) into
the locking position of figure A to prevent possible
deformation of the same.
Once the assembly is completed, fill the engine with
lube oil in the prescribed quantity and quality.
1 - 103
1 - 104
W190
ENGINE
1.7.2 TIGHTENING TORQUES

ITEM
TORQUE
Screw M8 securing the cylinder sleeve lube jets

Screw M12 securing the crankshaft main journal caps
1st phase
2nd phase
3rd phase
Studs M6 for camshaft sensors

Studs M8 for supply pump
Screw M12 securing gear rear housing
Nut M6 securing camshaft sensor
Screw M8 securing front cover
1st phase
2nd phase
Screw M8 securing camshaft longitudinal retaining plate

Screw M8 securing camshaft longitudinal retaining plate
Screw M8 securing camshaft gear
Screw M11 securing conrod caps
1st phase
2nd phase
Screw M10 securing under cylinder block plate

Nut M18 securing high-pressure gear
Nuts M8 securing fuel pump
Plug 1/2 in on cylinder head
90 5
82
12 2
77 12
47 5
24 4
10 2
81
24 4
24 4
24 4
36 4
60 5
0.8 0.2
1.2 0.2
7.7 1.2
4.7 0.5
2.4 0.4
1 0.2
0.8 0.1
2.4 0.4
2.4 0.4
2.4 0.4
3.6 0.4
6 0.5
60 5
4.3 0.4
10.5 0.5
2.4 0.4
2.4 0.4
3.6 0.5
1.2 0.2
0.35 0.035
75 5
1st phase
50 5
82
24 4
77 12
24 4
20 2
35 5
55 5
2nd phase
3rd phase
Screw securing rocker arm support
Nuts valve clearance setting
Nuts M14 securing supply piping from high-pressure
pump to Common rail
Screw M8 securing high pressure pipe connection
Screw M6 securing wall hole head for harness
Screw M8 securing electric injector
harness support
Nuts securing electric injector single harness
Screw M12 securing fuel filter bracket holder
Screw M8 securing fuel filter holder
Fuel filter
kgm
1.5 0.3
5 0.6
8 0.6
43 5
105 5
24 4
24 4
36 5
12 2
3.5 0.35
Screws M6 securing electric injectors

Nut securing connection for injector supply
Nut M6 pre-heater grill on intake manifold
Screw M8 securing intake manifold
Screw M12 securing rear brackets for engine lifting
Screws M8 securing Common rail
Connections M14 high pressure fuel pipes
Screw M12 (12 x 1.75 x 130) securing cylinder head
Screw M12 (12 x 1.75 x 150) securing cylinder head
Nm
15 3
50 6
80 6
5 0.5
0.8 0.2
2.4 0.4
7.7 1.2
2.4 0.4
2 0.2
3.5 0.5
5.5 0.5
90 5
90 5
36 5
24 4
3.6 0.5
2.4 0.4
20 2
2 0.2
24 4
10 2
2.4 0.4
1 0.2
24 4
2.4 0.4
1.5 0.25
0.15 0.025
77 8
7.7 0.8
24 4
2.4 0.4
contact + 3/4 turn
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
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
W190
1.8
ENGINE
TOOLING
TOOL NUMBER
DESIGNATION
P T- 0 1
380001218
PT-01 Diagnostic software

!
1
4
7
2
5
8
0
CAN
3
6
9
X
1010
380000665
Puller for crankshaft front seal
380000663
Puller for crankshaft rear seal
380001099
Injector puller
380000666
Tool for the installation of crankshaft front seal
380000664
Tool for the installation of crankshaft rear seal
380000732
Tool for crankshaft cranking
380000667
Punch for the removal and installation of camshaft bushes

(use with 380000668)
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
Handle for interchangeable punches
380000158
Dynamometric screwdriver for the setting of injector

solenoid valve securing nut
380000216
Engine lifting hook
380000301
Engine overhaul rotary stand
380000661
Engine support brackets to be used with 380000301
380000362
Crankshaft lifting tool
W190
ENGINE
TOOLING
TOOL NUMBER
DESIGNATION
380000304
Angle tightening measuring tool
380000221
Piston ring removal and installation pliers (65 - 110 mm)
380000302
Engine valve spring compression tool
380001223
Hydraulic steering pump securing screw wrench
380000228
Dial gauge (0 - 5 mm)
380000669
Seal puller tool
380000670
Oil filter wrench
1 - 109
1 - 110
ENGINE
TOOLING
TOOL NUMBER
DESIGNATION
380000144
Engine flywheel retaining tool
380000364
Dial gauge holder base
W190
SECTION 2
TRANSMISSION
INDEX
PARAGRAPH
SUBJECT
2.1
GENERAL CHARACTERISTICS ............................................................................. 2-1
2.2
GENERAL DESCRIPTION ...................................................................................... 2-1
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
TRANSMISSION ASSEMBLY ................................................................................

Internal configuration of the transmission ................................................................
Transmission power diagram ...................................................................................
Pressure pick-up points and connections ................................................................
Transmission hydraulic diagram (1st speed forward) ................................................
Transmission control valve .....................................................................................
2-3
2-4
2-5
2-6
2-7
2-8
2.4
2.4.1
2.4.2
2.4.3
AUTOMATIC TRANSMISSION CONTROL SYSTEM .............................................

"Est-37" electronic controller ...................................................................................
Start-up procedure of transmission electronic controller ..........................................
Transmission pilot valve .........................................................................................
2-11
2-12
2-13
2-16
2.5
AUTOMATIC TRANSMISSION ELECTRIC DIAGRAM ........................................... 2-18
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.4.1
2.6.4.2
TROUBLESHOOTING GUIDE ................................................................................

Display during the operation of the machine ............................................................
Display, during the start-up procedure with ab instrument ........................................
Table of trouble codes .............................................................................................
Troubleshooting using the "TESTMAN" device .......................................................
Connections and settings of the DPA-03 ............................................................
Configuration of testman software menu ............................................................
2.7
2.7.1
2.7.2
TRANSMISSION OVERHAUL ................................................................................ 2-46

Disassembly of control valve .................................................................................. 2-46
Re-assembly ........................................................................................................... 2-49
2.8
2.8.1
2.8.2
2.8.3
DISASSEMBLY OF THE TRANSMISSION ............................................................

Removal of the transmission control valve and the oil ducts plate from the transmission
housing ...................................................................................................................
Disassembly ...........................................................................................................
Assembly ................................................................................................................
2.9
PROPELLER SHAFTS ........................................................................................... 2-108
2.10
2.10.1
2.10.2
2.10.3
2.10.4
2.10.5
2.10.6
2.10.7
2.10.8
AXLES ....................................................................................................................
General description .................................................................................................
Differential description .............................................................................................
"LSD" differential .....................................................................................................
Final drives description ...........................................................................................
Disassembly of the axle ..........................................................................................
Axle reassembly .....................................................................................................
Installation and inspection of the pinion bearings pre-load .......................................
Correct mounting position of the pinion ...................................................................
2-110
2-110
2-115
2-117
2-118
2-120
2-132
2-155
2-156
2.11
2.12
2.13
2.13.1
WHEEL/TYRES ......................................................................................................
TROUBLESHOOTING ............................................................................................
VALUES OF REFERENCE FOR THE MAINTENANCE ..........................................
Tithtening torque values for main bolts ....................................................................
2-157
2-158
2-160
2-161
2.14
LIST OF OVERHAUL SPECIAL TOOLS ................................................................. 2-162
PAGE
2-19
2-20
2-21
2-22
2-43
2-44
2-45
2-55
2-55
2-55
2-72
W190
TRANSMISSION
2-1
2.1 GENERAL CHARACTERISTICS

TORQUE CONVERTER
- Name
- Type
- Radiator
- Minimum operating pressure
ZF - F&S 340
3 elements, single stage, single phase
Water cooling, with multiple radiating fins
4,3 bar
TRANSMISSION PUMP
- Name
TRANSMISSION
- Name
- Control
- Type
- Speeds
ZF WG 210
Manual or automatic
Controlled by solenoid valves, Integral Power-Shift, with constant
mesh gears with controlled modulation
4 forward and 3 reverse
CLUTCHES (TRANSMISSION)
- Type
- Actuation
- Pressure setting
- Oil capacity
- Weight (torque converter-transmission)
Oil-bath, multiple disc

Hydraulic
16 + 2 bar
26 l
470 kg
2.2 GENERAL DESCRIPTION

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

torque differential (limited slip on request).
Front
Engine
Torque
Front
Transmission
Rear
Rear
Torque converter cover

Transmission ZF 4WG210
Hydraulic pumps
Front axle
Support
Front shaft
Fig. 2-1
Intermediate shaft
Rear shaft
Rear axle
Composition of the transmission
2-2
TRANSMISSION
W190
POWERSHIFT TRANSMISSION
The multi-speed reversible countershaft transmission
is hydraulically controlled by multiple disc clutches.
Al the gears are constant mesh and are supported by
anti-friction bearings.
The gears, bearings and clutches are cooled and lubricated by oil.
The 4-speed reversible transmission is equipped with
6 multiple disc clutches.
When shifting gear, the clutch pack involved is compressed by the mobile piston in an axial direction,
under the effect of pressurised oil.
A reaction spring controls the return of the piston,
releasing the clutch pack.
Transmission control
The transmission pump required to supply oil to the
torque converter and to control the transmission is
mounted on the input shaft of the transmission itself.
The pump delivery is Q = 105 lt/min at 2000 engine
rpm.
The pump sucks oil through a mesh filter from the oil
sump and forwards it through a delivery filter to the
pressure relief valve.
In case of clogging of the delivery filter, the flow is
diverted by the by-pass valve p = 5.5 bar to ensure
lubrication.
If this occurs, the indicator on the display is activated.
Delivery filter
Filtering ratio in accordance with ISO 4572:
15 = 25
10 = 5.0
30 75
Filtering surface, at least: 6700 sq. cm
Collecting capacity in accordance with ISO 4572 at
least: 17 g
The six transmission clutches are selected through proportional valves from P1 through P6 (Fig. 2 - 6).
The proportional valve (pressure regulating unit) is composed of pressure regulator (Y6) mobile element and
vibration damper.
The 9 bar pressure controlling the mobile element is

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

W190
TRANSMISSION
2-3
2.3 TRANSMISSION ASSEMBLY
2
14
16
13
13
12
3
11
10
5
9
15
17
18
19
Fig. 2-2
1. Lifting eyes - 2. P.T.O - 3. Electro-hydraulic control valve - 4. Connection of return line from parking brake M26x1.5 - 5. Hydraulically actuated parking brake - 6. Transmission mounting holes M20 - 7. Connection for oil filler neck and dipstick - 8. Brake disc - 9. Output
flange - 10. Delivery filter (fine) - 11. Filter head - 12. Pressure system connection M16 x 1.5 - 13. P.T.O. 1 - 14. Torque converter - 15. Steering emergency pump -16. Breather - 17. Transmission output front shaft - 18. Oil draining plug - 19. I.D. plate
2-4
TRANSMISSION
W190
2.3.1 INTERNAL CONFIGURATION OF THE TRANSMISSION

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

W190
TRANSMISSION
2-5
2.3.2 TRANSMISSION POWER DIAGRAM
1st speed forward
2nd speed forward

KR
KR
KV
Turning direction
106
Z=51
113
Z=23
104
Z=32
Engine speed
induction sensor
KR
KV
K4
K2
AN
K4
K2
K1
K1
K1
K3
K1
K3
K1
K3
204
Z=63
AB
AB
KR
115
Z=52
101
Z=54
102
Z=55
Gear set speed

induction sensor
AN
K4
108
Z=58
AN
K4
K2
4th speed forward
KR
KV
AN
K4
K2
K3
112
Z=36
KV
AN
3rd speed forward
103
Z=56
201
Z=55
110
Z=52
KV
111
Z=23
Turbine speed
induction sensor
Legenda:
KV = Forward clutch
KR = Reverse clutch
K1 = 1st speed clutch
K2 = 2nd speed clutch
K3 = 3rd speed clutch
K4 = 4th speed clutch
AN = Input
AB = Output
AB
AB
1st speed reverse
2nd speed reverse
K2
105
Z=44
K3
Transmission output
speed sensor
AB
Idle gears
AN
Clutch diagram
Travel direction
Forward
107
Z=49
AB
Reverse
Legenda: Power flow
KV
AN
KV
AN
KR
KR
KR
KV
114
Z=55
3rd speed reverse
Speed
1
2
3
4
1
2
3
Clutch
KV/K1
KV/K2
KV/K3
K4/K3
KR/K1
KR/K2
KR/K3
Ratio
3,745
2,089
1,072
0,636
3,551
1,981
1,017
K4
K2
K1
K3
AB
K4
K2
K1
K3
AB
K4
K2
K1
K3
AB
Fig. 2-4

2-6
TRANSMISSION
2.3.3 PRESSURE PICK-UP POINTS

AND CONNECTIONS
48
47
W190
21
VIEW X
The locations indicated (53) correspond to the positions of Fig. 2-6.

The measurements are performed with hot transmission (about 80 95 C) (176 203 F).
65
51
69
H
G
57
54
68
49
60
53
34
55
58
56
16
Y
No. DESIGNATION OF POSITION
51 =
52 =
53 =
55 =
56 =
57 =
58 =
60 =
63 =
65 =
15 =
16 =
21 =
34 =
47 =
48 =
54 =
49 =
68 =
69 =
70 =
71 =
CONNECTION
HYDRAULIC OIL AND TEMPERATURE MEASURING POINTS:

Front side of converter - opening pressure
11 bar
M10x1
Rear side of converter - opening pressure
4.3 bar
M14x1.5
Forward clutch
16 + 2 bar
KV
M10x1
Reverse clutch
16 + 2 bar
KR
M10x1
Clutch
16 + 2 bar
K1
M10x1
Clutch
16 + 2 bar
K2
M10x1
Clutch
16 + 2 bar
K3
M10x1
Clutch
16 + 2 bar
K4
M10x1
Rear side of converter
M14x1.5
temperature 100 C (212 F) for short time 120 C - 248 F)
System pressure
16 + 2 bar
M10x1
Flow measuring points:
Connection to heat exchanger
1 5/16"-12 UN-2B
Connection from heat exchanger
1 5/16"-12 UN-2B
INDUCTION SENDERS, SPEED SENSOR AND SWITCHES:
Induction sender
n Turbine
M18x1.5
Speed sensor
n Output and tachometer
Induction sender
n Central gear train
M18x1.5
Induction sender
n Engine
M14x1.5
Filter contanimation switch
M14x1.5
CONNECTIONS:
Connection plugs on electric-hydraulic control
Pressure system
(Optional)
M16x1.5
Control
(Optional)
M16x1.5
Steering emergency pump - Pressure line
M22x1.5
Steering emergency pump - Pressure line
M22x1.5
INDICATION ON
VALVE BLOCK
VIEW Y
15
52/63
16
70
B
E
D
A
C
F
D
S
15
71
52/63
K
CODES
Travel direction
FORWARD
REVERSE
J
G
NEUTRAL
Clutches engaged
Location on block
Number of measuring point
Speed
1
2
3
4
1
2
3
Pressure regulator active

Y1
Y2
Y3
Y4
K4
F
60
KR
E
55
K1
D
56
Clutch engaged
Y5
K3
C
58
Y6
KV
B
53
K1
KV
K3
K4
KR
KR
KR
KV
K2
KV
K3
K1
K2
K3
K2
A
57
Fig. 2-5

W190
TRANSMISSION
2-7
2.3.4 TRANSMISSION HYDRAULIC DIAGRAM (1st speed forward)

The locations indicated (53) correspond to locations of Fig. 2-5.
Legenda:
WT
= Heat exchanger
WGV = Torque converter rear pressure valve 4.3 bar
WSV = Torque converter safety valve 11 bar
HDV
= Main pressure relief valve 16 + 2 bar
RV-9 = Pressure reduction valve 9 bar
NFS
= Mobile element
D
= Vibration damper
B
= Orifice
P1
= Proportional valve K4
P2
= Proportional valve KR
P3
P4
P5
= Proportional valve KV
P6
Y1..Y6 = Pressure regulators
TEMP = Temperature sensor
FDV
= Filter differential pressure valve (by-pass valve)
p = 5.5 bar
K4
P1
B
60
KR
Y1
P2
B
NFS
Y2
55
K1
P3
B
NFS
Y3
56
K3
P4
B
NFS
Y4
58
KV
P5
Y5
NFS
53
K2
P6
Y6
NFS
57
NFS
RV-9
TEMP
HDV
Hydraulic control valve

diagram
65
Torque converter
51
Legenda:
63
= Main pressure
= Main regulated pressure
= Piloting pressure
= Converter inlet pressure
= Converter outlet pressure
= Lubrication
= Oil return to sump
Travel direction
FORWARD
REVERSE
NEUTRAL
Clutches engaged
Location on block
Number of measuring point
Speed
1
2
3
4
1
2
3
K4
F
60
KR
E
55
K1
D
56
52
By-pass
valve p=1.5
bar
15
16
Transmission pump
p = 16 + 2 bar
Qp 0 105 lt/min
n = Engine at 2000 rpm
Oil sump
Lubrication
Y5
KV
B
53
Main hydraulic
diagram
Clutch engaged
Y6
K3
C
58
Fine filter
Filtering ratio in accordance with ISO 4572:
30 75 15 25 10 5
Collecting capacity in accordance with
ISO 4572 at least: 17 g
Filtering surface, at least:
6700 sq. cm
FDV
WGV
CODES
Pressure regulator active
Y1
Y2
Y3
Y4
WSV
K1
KV
K3
K4
KR
KR
KR
KV
K2
KV
K3
K1
K2
K3
K2
A
57
Fig. 2-6
2-8
TRANSMISSION
W190
2.3.5 TRANSMISSION CONTROL VALVE

Main pressure relief valve 16 + 2 bar
Pressure reduction valve 9 bar
Housing
Connector/harness
Cover
Cover
Cover
Control valve body
SECTION A - A
Main pressure relief valve
16 + 2 bar
Control valve body
Pressure reduction valve 9 bar
Connector/
harness
Intermediate plate
Oil ducts plate
Power socket
SECTION B - B
PROPORTIONAL VALVE P5
Pressure
regulator
Vibration
damper
Follow-up
plunger
Discharge
line
Fig. 2-7
Pressure
reduction
Operating
pressure
W190
TRANSMISSION
2-9
TRANSMISSION CLUTCH ENGAGEMENT PRESSURE VARIATION GRAPHS
Clutch 1 beginning of
disengagement
G ra d ie n t
(nEng)
= f
Pressure
Clutch 2 End
of engagement
Clutch 2 Beginning
of engagement
Clutch disc slipping phase
Fast filling
Time
Modulation
2-8
Fig. 2-8
Gearshifting
The fast filling time depends upon:

- dimension of clutch
- play of clutch
Pressure
Clutch filling
Clutch
filling
Fast filling time
Modulating time
The modulating pressure depends

upon:
- pressure regulator
- flow amplification valve
- clutch spring
- clutch ring
Pressure
Compensazione
Pressione
Veloce
The piston moves

against the discs
Fig. 2-9
Time
Clutch filling
2 - 10
TRANSMISSION
W190

W190
TRANSMISSION
2 - 11
2.4 AUTOMATIC TRANSMISSION CONTROL SYSTEM
Kick-down + down shift

button
Direction reverser
auxiliary switch
Transmission
gearshift lever
Automatic transmission
selector switch
"EDC" engine
controller
"Brown Box"
controller
"est-37" transmission
controller
Auxiliary direction
inversion actuation
switch
"LTS" switch
Multi function
display
Transmission sensors
COOLANT TEMP
"LTS" solenoid valve
T\M OIL TEMP
20
F
30
10
40
50
FUEL
1\10 h
HOURMETER
HOUR
km\h
Dashboard
Fig. 2-10
2 - 12
TRANSMISSION
W190
2.4.1 "EST-37" ELECTRONIC

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

ensures a high quality of the gearshifting.
Also, the software includes extended functions to ensure the line of command and to support the diagnostic system. The control electronic unit has a CAN interface for the exchange of data with the vehicle and
engine electronic system.
Technical specifications:
Nominal voltage: 24 Volt
Max. current absorbed: 10 Amp
Operating temperature: -40 C (- 40 F)
through + 70 C (158 F)
Protection class: IP54
Weight: 0.9 kg
Identification
plate
Connection
Protections:
The controller is protected against
- short-circuits
- voltage jumps
- wrong connections
Fig. 2-11
W190
TRANSMISSION
2 - 13
2.4.2 START-UP PROCEDURE OF

TRANSMISSION ELECTRONIC
CONTROLLER
In order to optimise the operational parameters of the
transmission it is necessary to start-up the controller
every time one of the following conditions occur:
- disassembly/assembly of the transmission;
- replacement of an electronic component or a transmission component.
The same procedure should be performed when the
modulation of the gearshifting is insufficient.
In fact, the clutch packs, after a certain use, have different plays from the original values.
The determination of the filling parameters, in fact, provides the optimisation of the tolerances, the disc play,
the pressure level inside the clutches and the filling speed
of the clutches during the gearshifting.
The start-up of the controller is possible using the following tooling:
AEB Starter (tool No. 380000818)
DISPLAY (tool No. 380001297)
DISPLAY
380001297
AEB-STARTER
380000818
W190-2R001
Fig. 2-12 Connection of the transmission start-up tooling.

The display and the AEB must be connected to the sockets indicated, located behind the plastic panel
of the cab, behind the operator's seat.
2 - 14
1.
TRANSMISSION
W190
Introduction
The AEB starter is a tool for the start-up of Ergopower

transmissions.
It is especially useful when used together with the ZFDisplay, since it provides all the messages on the
conditions of the AEB.
The AEB "per se" does not provide any information.
2.
List of abbreviations
AEB: setting of automatic filling parameter

TCU: transmission control unit
3.
Procedure for the start-up of the AEB
Note The AEB does not start when any trouble

code is present on the display, except trouble "F6".
Step to do
Display message
Remarks
Transmission heating
normal operating messages
Disengage starting
none
Connect the AEB-Starter
move gearshift lever into N

engage parking brake
Start the engine
"PL"
Bring the engine speed

to 800 rpm
"PL" if starting conditions

OK
Press the AEB-Starter

button
"ST" if starting conditions

OK
The button must not be released

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

AEB starts
"K1"
(Information about
the AEB conditions)
TUC started the AEB and moves to

regulate K1, K2, KR.
(the button can be released)
Wait until the AEB finishes
"OK"
(AEB successful)
10
Disengage the starting and

disconnect the AEB-Starter
none
TCU must identify PL for at least 2

sec.s before it is possible to press the
button
W190
4.
TRANSMISSION
2 - 15
Display
Symbol
Meaning
PL
AEB-Starter is connected to diagnostic

pick-up
ST
The AEB-Starter is pressed
K1,..K4,KV,KR
Calibration of clutches K1, K4,KV,KR
e Kx
Remarks
Wait for starting, start-up of

clutch Kx
= e Kx
Fast filling time determination

clutch Kx
= e Kx
Determination of compensation
pressure of clutch Kx
OK
Calibration of all clutches terminated
The transmission stays in neutral, the TCU must be

restarted (starting on/off) after removing the AEB
STOP
AEB cancelled (activation stopped)
The transmission stays in neutral, the TCU must

be restarted (starting on/off)
STOP e Kx
AEP stopped, clutch Kx cannot be

calibrated

Wrench e Kx
Kx cannot be calibrated,
AEB terminated

Engine speed too low

increase engine speed
Engine speed too high

reduce engine speed
Transmission oil temperature too low

warm-up transmission
Transmission oil temperature too high

cool-down transmission
FT
Transmission temperature not in the

range defined during the calibration

FB
ABNORMAL operating mode or

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

FO
Output speed is not zero

FN
Gearshift lever not in position Neutral

FP
Parking brake not engaged

STOP
AEB-Starter used in incorrect manner

or defective

2 - 16
TRANSMISSION
W190
2.4.3 TRANSMISSION PILOT VALVE
N-LOCK
3
4
ND
IN N (NEUTRAL) POSITION F.
R. CANNOT BE SELECTED
A BC D
RED
Y E L LOW
PINK
GREEN
BLACK
GREEN
BLUE
VIOLET
A BC D
A B C D
A B C D
X2
X1
F
N
R
D
1
2
3
4
1
2
3
ZF
=
=
=
=
=
=
=
=
FORWARD
NEUTRAL
REVERSE
NEUTRAL MECHANICAL LOCKING
1st SPEED
2nd SPEED
3rd SPEED
4th SPEED
ZF
TECHNICAL SPECIFICATIONS
CONNECTION DIAGRAM OF RANGE SELECTOR
NOMINAL VOLTAGE
UN =12 Volt
UN =24 Volt
OPERATING VOLTAGE
UDIR =9 - 15 Volt
UDIR =19 - 23 Volt
TESTING VOLTAGE
UPR =14 o.5 Volt

28 0.5 Volt
OUTPUT CURRENT
(INDUCTIVE LOAD)
AD1 AD7
ILmin = 10 mAmp
ILPR = 0.6 Amox
OUTPUT LEVEL (ACTIVE)

OPERATING TEMPERATURE
UA = US - 0.3 Volt
- 30 C .. + 70 C
PROTECTION CLASS DIN 40050 BL.9

ELECTRIC COMPONET PARTS
IN THE ELECTRIC
CONNECTION BOX
IP 65
IP 20
(+)
X2,A
A2
X1,D
X1,C
X1,B
X1,A
X2,B
X2,C
X2,D
A1
K1
K2
(-)
K1
K2
A1
A2
=
=
=
=
STARING BLOCK RELAY

BACK-UP LIGHT RELAY
CONTROLLER EST-2/EST-17
GERASHIFT SELECTOR
Fig. 2-13
W190
TRANSMISSION
2 - 17
VALVE ENERGISING TABLE

OUTPUT SIGNAL
OUTPUT
SIGNAL
SPEED
GEAR
FORWARD
FORW.
KD
REVERSE
REV.
NEUTRAL
NEUTRAL.
1 2 3 4
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7
PILOT VALVE ELECTRIC DIAGRAM

CONNECTION
DIAGRAM
SW
S6
1
S4
2
1
2
1
S5
2
GN
BL
VI
XI
RT
S1
3
S2
3
S3
3
1
2
1
2
1
2
AD3 (B3)
AD2 (B2)
AD1 (B1)
AD7 (KD)
A ED1 (+/VP)
GR
D AD6 (N)
GE
B AD4 (AVANTI)
RS
X2
C AD5 (RETROMARCIA)
X1
CONTACT
PATTERN
X2
CONTACT
PATTERN
A B C D
A B C D
CABLE COLOUR CODE

WS
BR
GN
GE
GR
RS
BL
RT
SW
VI
WHITE
BROWN
GREEN
YELLOW
GREY
PINK
BLUE
RED
BLACK
VIOLET
Fig. 2-14
2 - 18
TRANSMISSION
W190
2.5 AUTOMATIC TRANSMISSION ELECTRIC DIAGRAM

F1
K1.38
K1.15
F2
# S35
no with
# S35 not
FNRI
with push
button FNR !
button
pressed
1
P
VP (+)
A2
F
N
R
B1
B2
Function B3
function button
button
S2
S35#
45
3
B4
VP (+) F
A2.2
R
N
SignalC-Signal
C
function
function button
button
B
C
D
E
F
62
4
44
31
20
30
X3:B
X3:D
X3:C
X2:C
X2:B
X2:A
X2:D
43
67
64
63
65
22
XX
86
K1
XX
85
B1
B2
B3
1
2
19
3
1
2
41
1
2
42
23
68
S31
S3
66
VP1 VPE1VPE2
EF4
21
ED3
ED18
H1
K2
29
52
ED11
ADM1
XX
S38
XX 2
XX
X3:A
K5
7
ADM2
VMG2
XX
5
ADM4
SD4
SDDK
ED9
3ED13
ED3
ED12
EUPR
36
A9
15
18
A5
3
SD1
ED4
ED6
ED5
ED1
ED2
AIP1
AIP2
AIP3
AIP4
AIP5
AIP6
VPS1
VPS1
ER1
VMGR2
A1
ED7
EF1
VMG1
EF2
ER2
EF3
VCS
28
CANF_H
CANF_L CANF_T
25
26
27
1
2
3
4
5
6
7
56
10
32
33
9
51
12
13
39
46
8
9
49 1
4
1
A6
3
Y1
Y2
Y3
Y4
Y5
Y6
VPS1(+)
A3
TEMP
TEMP
B15
VM1 VM2
1
14
1 2
A7
Recommended screening
K1.31
Twisted pair (38 rev/min)

for L > 2 m
Fig. 2-15
POS.
LEGENDA
A1
A2.1
A2.2
A3
A5
A6
A7
A9
EST-37 CONTROLLER
DM-3 CONTROL LEVER
SWITCH - FNR
TRANSM. HYDRAULIC LOCK
DIAGN. INTERFACE (CONNECTOR)
DISPLAY
INTERFACE-CAN (CONNECTOR)
TACHOMETER WITH FREQUECY DIVIDER
(CLIENT SCOPE)
ENGINE SPEED PICK-UP
TRBINE PICK-UP
INNER SPEED PICK-UP
OUTPUT SPEED SENSOR
SENSOR - CONVERTER TEMPERATURE
FUSE 7.5 Amp
FUSE 7.5 Amp
INDICATOR LIGHT
STARTING SAFETY REALY
INVERTER CONTROL RELAY
SPEED SIGNAL RELAY
B1
B2
B3
B4
B15
F1
F2
H1
K1
K2
K5
POS.
LEGENDA
S2
S3
S31
S35
S38
CLUTCH CUT-OFF SWITCH

AUTO7MANUAL MODE SELECTION SWITCH
PARKING BRAKE RETURN SWITCH
GEARSHIFT LEVER SWITCH
SPEED SIGNAL SWITCH
W190
TRANSMISSION
2 - 19
2.6 TROUBLESHOOTING GUIDE

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

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

First digit
f ed
a bc
left
digit
right
digit
Fig. 2-16
The display must be connected through harness

380001297 provided to the socket indicated located
behind the plastic panel in the cab, behind the operator's seat.
1 hex
2 hex
3 hex
4 hex
5 hex
6 hex
7 hex
8 hex
9 hex
A hex
B hex
C hex
D hex
E hex
F hex
Meaning of digit
Input digital signal

Input analogical signal
Speed signal
CAN error signal
CAN error signal
CAN error signal
Output current analogical signal
Output current analogical signal
Output analogical signal
Output analogical signal
Transmission error. Clutch error
Logic error
Power supply
High speed signal
General error
Please find here below some symbols relative to different operating conditions of the machine and the
list of trouble codes with their meaning and the possible repair intervention.
Fig. 2-17
2 - 20
TRANSMISSION
W190
2.6.1 DISPLAY DURING THE OPERATION OF THE MACHINE

Symbol
Meaning
1F, 1R
2F, 2R
3F, 3R
4F
5F
6F
LF, LR
F or R no speed
F or R
flashing
NN
Effective speed and direction

the left digit indicates the speed
the right digit indicates the direction
**
*N
1 bar (special
symbol)
2 bars
3 bars
4 bars
4 bars and 2
arrows
Flashing
lbars
Wrench
Defect code
WS
WR
WT
WE
PN
F or R
flashing
EE
flashing
recovery speed
clutch disengagement
F or R direction selected while the
turbine speed is too high
No neutral, wait for neutral after
supply or serious trouble
Oil temperature too low, no speed
available
Oil temperature too low, one speed
only available
Manual mode 1st speed
Remarks
WARNING The speed engages if the turbine

speed decreases
To engage speed, move gearshift lever into neutral
at first then into position F or R
Warm-up engine/transmission
Warm-up engine/transmission
Manual mode 2nd speed

Manual mode 3rd speed
Manual mode 4th speed
Automatic mode
4 WG: downshifting mode activated Engine and turbine speed differential exceeds a
certain limit and the clutch lock is not activated
At least one defect activated
Select neutral to read trouble code
See trouble code list
Alarm, sump temperature
Shifting between speeds/direction while moving, in neutral
only indicated if no defects monitored (wrench)
Alarm delay temperature
Shifting between speeds/direction while moving, in neutral
only indicated if no defects monitored (wrench)
Alarm, torque converter
Shifting between speeds/direction while moving, in
temperature
neutral only indicated if no defects monitored (wrench)
Alarm, high engine speed
Shifting between speeds/direction while moving, in
neutral only indicated if no defects monitored (wrench)
Direction F or R selected with
Transmission in neutral until the parking brake
parking brake engaged
is released
WARNING The machine starts moving after
releasing the parking brake
Selection of forward or reverse
Speed selected if engine speed is decreased
direction while the turbine speed is
too high
WARNING The rotor is
engaged when the turbine
speed decreases
No communication with
Check connections between TCU and display
display
W190
TRANSMISSION
2.6.2 DISPLAY, DURING THE START-UP PROCEDURE WITH AB INSTRUMENT

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

defective manner. Device wrong or
wrong cable.
ST
K1,..K4,KV,KR
- e Kx
= e Kx
= e Kx
OK
STOP
STOP and Kx
Chiave and Kx
E
E
T
FT
FB
Remarks
The transmission stays in neutral, TCU must be

restarted (starting off/on) after removing AEB
restarted (starting off/on)


2 - 21
TCU shifts transmission to neutral

OP mode:
transmission shutdown
LOGICAL ERROR AT GEAR RANGE SIGNAL

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

SIGNAL
wire from gearshift lever to TCU
cut-off
wire defective and connected to battery voltage or
ground of vehicle
gearshift lever defective
LOGIC ERROR IN THE PARKING BRAKE STATUS

Parking brake status signal monitored by TCU
and signal forwarded to CAN do not coincide
one of the wires from status switch to electronic
box defective
one of the status switches is defective
11
12
14
TCU moves the transmission into DCO status

OP-Mode: normal
check the cables from electronic boxes to status

switches
check signals of the status
switches
check cables between TCU to

gearshift lever
check combination of signals
of gearshift lever in positions
F-N-R
Failure cannot be detected in systems with DW2/DW3 shift lever
check the cables from TCU to

shift lever
check signal combinations of
shift lever positions for gear
range
The defect is identified if TCU

monitors a valid signal for the direction at the gearshift lever
Fault is taken back if TCU detects

a valid signal for the position
Remarks
Possible step or intervention
transmission control unit

Electronic control unit
power take-off
2 - 22
TCU moves transmission into neutral

OP mode:
transmission cut-off
Reaction TCU
TCU
EEC
PTP
MEANING OF TROUBLE CODE

Possible cause identification of trouble
open circuit
short circuit
mode of operation
Abbreviations:
Trouble
Code
(hex)
o.c.
s.c.
OP-Mode
2.6.3 TABLE OF TROUBLE CODES
TRANSMISSION
W190

LOGIC ERROR AT SIGNAL 2 GEARSHIFT LEVER DIRECTION SELECTION

TCU detected a wrong signal combination for the
direction
wire from gearshift lever 2 to TCU cut-off
wire defective and connected to battery voltage or
ground of vehicle
gearshift lever defective
S. C. TO BATTERY VOLTAGE AT CLUTCH

CUT OFF INPUT
the measured voltage is too high:
cable is defective and is contacted to battery voltage
clutch cut off sensor has an internal defect
connector pin is contacted to battery voltage
S. C. TO GROUND OR O.C. IN CLUTCH CUTOFF INPUT

voltage measure is too low:
wire defective contacting ground of vehicle
wire not connected to TCU
clutch cut-off sensor defective
connection terminal connected to battery
voltage
S. C. VOLTAGE BATTERY AT LOAD SENSOR

INPUT
the voltage measured is too high:
wire defective and connected to battery voltage
load sensor defective
the terminal is connected to battery voltage
Trouble
Code
(hex)
15
21
22
23
The delay function is

in trouble TCU uses
lack of load
OP-Mode: normal
check wire between TCU and

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

sensor
check connectors
check clutch cut-off sensor
Availability of retarder depends on

default load
The defect is identified if TCU

monitors a valid signal for the direction at the gearshift lever
check the cables from TCU to

shift lever 2
check signal combinations of
shift lever positions F-N-R
check the cable from TCU to

the sensor
check the connectors
check the clutch cut off sensor
Remarks
W190
The clutch cut-off

function is inoperative
OP-Mode: normal
Clutch cut off function

is disabled
OP-Mode: normal
TCU shifts transmission into neutral when

selector is activated
OP-Mode:
transmission inactive
when selector activated
Reaction TCU
TRANSMISSION
2 - 23
Reaction TCU
No reaction TCU use

lack of temperature
OP-Mode: normal
No reaction TCU use

lack of temperature
OP-Mode:
V
normal
No reaction TCU use

lack of temperature
OP-Mode: normal
No reaction TCU use

lack of temperature
OP-Mode: normal

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

OUTPUT TEMPERATURE SENSOR
temperature sensor defective
the terminal is connected to battery voltage or is
broken
S. C. TO GROUND OR O.C. AT CONVERTER

OUTPUT TEMPERATURE SENSOR
the voltage measured is too low:
connection terminal connected to ground
S. C. TO GROUND TO TRANSMISSION DISCHARGE LINE TEMPERATURE INPUT

S. C. TO BATTERY VOLTAGE OR O. C. TO
MODULATOR TEMPERATURE SENSOR INPUT
connection terminal connected to battery or broken
Trouble
Code
(hex)
24
25
26
27

sensor
check connectors
check temperature sensor
Remarks
2 - 24

sensor
check connectors

sensor
check connectors

sensor
check connectors
TRANSMISSION
W190

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

CONVERTER OUTPUT TEMPERATURE SENSOR INPUT
connection terminal connected to battery or broken
S. C. TO GROUND AT CONVERTER OUTPUT

TEMPERATURE SENSOR INPUT
S.C. BATTERY VOLTAGE OR O. C. ENGINE

SPPED INPUT
TUC monitors a voltage exceeding 7.00 Volt at
speed input terminal
speed sensor defective
Trouble
Code
(hex)
27
28
31

sensor
check connectors

sensor
check connectors

sensor
check connectors
Remarks
W190
No reaction TCU use

lack of temperature
OP-Mode: normal
No reaction TCU use

lack of temperature
OP-Mode: normal
No reaction TCU use

lack of temperature
OP-Mode: normal
Reaction TCU
TRANSMISSION
2 - 25
OP-Mode: replaces
clutch controlIf trouble
occurs at output
speed, TCU moves to
Neutral
OP-Mode: recovery
OP-Mode: replaces
occurs at output
speed, TCU moves to
Neutral
OP-Mode: recovery
LOGIC ERROR AT ENGINE SPEED INPUT

TCU monitors an engine speed higher than
threshold and immediately after it monitors zero
speed
wire/connection defective and grounding on vehicle
sensor gap wrong
S. C. TO BATTERY VOLTAGE OR O. C. AT
TURBINE SPEED INPUT
TCU monitors a voltage exceeding 7.00 Volt at
terminal connected to battery voltage or broken
S. C. TO GROUND AT TURBINE SPEED INPUT

TCU measures a voltage lower than 0.45 Volt at
33
34
35
No reaction TCU use

lack of temperature
OP-Mode: normal
S. C. TO GROUND AT ENGINE SPEED INPUT

TCU measures a voltage lower than 0.45 volt at
32
Reaction TCU

Trouble
Code
(hex)

sensor
check connectors
This trouble is reset after powering

TCU
Remarks
2 - 26

sensor
check connectors
check speed sensor

sensor
check connectors

sensor
check connectors
TRANSMISSION
W190
Reaction TCU
OP-Mode: replaces
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

LOGIC ERROR AT TURBINE SPEED INPUT

speed
sensor gap wrong
INNER SPEED INPUT
terminal connected to battery voltage or broken
S. C. TO GROUND AT INNER SPEED INPUT

TCU measures a voltage lower than 0.45 Volt at
LOGIC ERROR AT INNER SPEED INPUT

speed
sensor gap wrong
Trouble
Code
(hex)
36
37
38
39

sensor
check connectors
check engine speed sensor
check sensor gap
W190

sensor
check connectors

TCU

TCU

sensor
check connectors
check sensor gap

sensor
check connectors
Remarks
TRANSMISSION
2 - 27
Special mode for

speed selection
OP-Mode: replaces
clutch controlI trouble
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery
Special mode for
speed selection
OP-Mode: replaces
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery
S. C. TO GROUND AT OUTPUT SPEED

TCU measures a voltage lower than 1 Volt at
LOGIC ERROR AT OUTPUT SPEED INPUT

speed
sensor gap wrong

sensor
check connectors
check speed sensor
check sensor gap

sensor
check connectors
check speed sensor

sensor
check connectors
check speed sensor

TCU
Remarks
2 - 28
3C
3B
Special mode for

speed selection
OP-Mode: replaces
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery
OUTPUT SPEED INPUT
terminal connected to battery voltage or fails to
make contact
3A
Reaction TUC

Trouble
Code
(hex)
TRANSMISSION
W190
No reaction
No reaction
TCU moves to neutral

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

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

Signal CAN for AEB mode is wrong
I/O controller defective
interference on Can-Bus
S. C. ON BATTERY VOLTAGE AT K1 CLUTCH

The value of the resistance monitored by the valve
is off-limits, the voltage at valve K1 is too high.
wire/connection defective and connected to battery voltage
wire/connection defective and connected to another regulator output of TCU
regulator defective
59
61
71
Special mode for

speed selection
OP-Mode: replaces
occurs at turbine
level, TCU moves to
neutral
OP-Mode: recovery
ZERO OTPUT SPEED DOES NOT MATCH ANY

OTHER SPEED SIGNAL
TUC monitors zero output speed and turbine
speed or inner speed different from zero
sensor gap wrong
3E
Reaction TCU

Trouble
Code
(hex)

TCU
check signal of output speed

sensor
check output speed sensor gap
sensor
check wire from TCU to controller

check connections between
TCU and transmission
check resistance of regulator
check inner harness of transmission
W190
check I/O, Omron master

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

check CAN-bus wire
check wire to cluster controller
Remarks
TRANSMISSION
2 - 29

S. C. TO GROUND AT CLUTCH K1
is off-limits, the voltage at valve K1 is too low.
regulator defective
O. C. ON CLUTCH K1
The resistance value is off-limits.
regulator defective
S. C. ON BATTERY VOLTAGE AT CLUTCH K2

The value of the resistance monitored by the valve is
off-limits; the voltage at valve K2 is too high.
regulator defective
S. C. TO GROUND AT K2 CLUTCH
is off-limits; the voltage at valve K2 is too low.
regulator defective
Trouble
Code
(hex)
72
73
74
75

on other clutch TCU
moves to neutral
OP-Mode: stop TCU





Remarks
2 - 30

on other clutch TCU
moves to neutral
OP-Mode: stop TCU

on other clutchTCU
moves to neutral
OP-Mode: stop TCU

on other clutch TCU
moves to neutral
OP-Mode: stop TCU
Reaction TCU
TRANSMISSION
W190

on other clutchTCU
moves to neutral
OP-Mode: stop TCU

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
S. C. TO BATTERY VOLTAGE AT K3 CLUTCH

is off-limits; the voltage at valve K3 is too high.
regulator defective
regulator defective
77
78

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
O. C. ON CLUTCH K2
The value of the resistance is off-limits.
regulator defective
76
Reaction TCU

Trouble
Code
(hex)
Remarks
W190



TRANSMISSION
2 - 31

O. C. ON CLUTCH K3
regulator defective
S. C. TO BATTERY VOLTAGE AT K3 CLUTCH

is off-limits; the voltage at valve K3 is too high.
regulator defective
Trouble
Code
(hex)
79
81

Reaction TCU

on other clutchTCU
moves to neutral
OP-Mode: stop TCU

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
Remarks
2 - 32
TRANSMISSION
W190

on other clutchTCU
moves to neutral
OP-Mode: stop TCU

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
O. C. ON CLUTCH K4
regulator defective
S. C. TO BATTERY VOLTAGE AT KV CLUTCH

is off-limits; the voltage at valve KV is too high.
regulator defective
83
84

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
regulator defective
82
Reaction TCU

Trouble
Code
(hex)
Remarks
W190



TRANSMISSION
2 - 33

on other clutchTCU
moves to neutral
OP-Mode: stop TCU

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
O. C. ON CLUTCH KV
regulator defective
S. C. TO BATTERY VOLTAGE AT KR CLUTCH

is off-limits; the voltage at valve KR is too high.
regulator defective
86
87

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
S. C. TO GROUND AT KV CLUTCH
is off-limits, the voltage at valve KV is too low.
regulator defective
85
Reaction TCU

Trouble
Code
(hex)
Remarks
2 - 34



TRANSMISSION
W190

on other clutch TUC
moves to neutral
OP-Mode: stop TCU
TCU shifts to neutral

OP-Mode: limp home
if failure at another
clutch is pending
TCU shifts is neutral
OP-Mode:
TCU shutdown
O. C. ON CLUTCH KR
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

on other clutchTCU
moves to neutral
OP-Mode: stop TCU
S. C. TO GROUND AT KR CLUTCH
is off-limits, the voltage at valve KR is too low.
regulator defective
88
Reaction TCU

Trouble
Code
(hex)
Remarks
W190
check pressure at clutch K1

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


TRANSMISSION
2 - 35

low main pressure
clutch is defective
low main pressure
clutch is defective
Trouble
Code
(hex)
B2
B3

system
speed sensor
speed sensor
sensor
sensor
replace clutch
system
speed sensor
speed sensor
sensor
sensor
replace clutch
Reaction TCU

OP-Mode: limp home
clutch is pending
OP-Mode:
TCU shutdown

OP-Mode: limp home
clutch is pending
OP-Mode:
TCU shutdown
Remarks
2 - 36
TRANSMISSION
W190

low main pressure
clutch is defective
SLIPPAGE AT CLUTCH KV
clutch KV. If this calculated value is out of range,
low pressure at clutch KV
low main pressure
clutch is defective
Trouble
Code
(hex)
B4
B5

system
speed sensor
speed sensor
sensor
sensor
replace clutch
check pressure at clutch KV
system
speed sensor
speed sensor
sensor
sensor
replace clutch
Reaction TCU

OP-Mode: limp home
clutch is pending
OP-Mode:
TCU shutdown

OP-Mode: limp home
clutch is pending
OP-Mode:
TCU shutdown
Remarks
W190
TRANSMISSION
2 - 37
No reaction
OP-Mode: normal
OVERTEMP SUMP
TCU measured a temperature in the oil sump that
is over the allowed threshold.
CONVERTER LOCKING CLUTCH SLIPPING

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

TCU measures a temperature at the converter
output higher than allowable value.
B7
BB
C3
cool down machine

check oil level
check pressure at converter

lockup clutch
system
check sensor gap at engine
speed sensor
speed sensor
check signal at engine speed
sensor
sensor
replace clutch
cool down machine

check oil level
check pressure at clutch KR

system
speed sensor
speed sensor
sensor
sensor
replace clutch
Normal resistance to ambient

temperature: 1000-1500 .
Remarks
2 - 38
No reaction
OP: normal

OP-Mode: limp home
clutch is pending
OP-Mode:
TCU shutdown
SLIPPAGE AT CLUTCH KR
clutch KR. If this calculated value is out of range,
low pressure at clutch KR
low main pressure
clutch is defective
B6
Reaction TCU

Trouble
Code
(hex)
TRANSMISSION
W190
check wires and connectors to

sensors powered by AU1
check power to terminal AU1
(it must be about 5 Volt)
It moves to neutral
OP-Mode: Stops TCU
It moves to neutral
OP-Mode: Stops TCU
It moves to neutral
OP-Mode: Stops TCU
S.C. TO GROUND AT SENSOR POWERING

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

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

the voltage monitored at powering is higher than
18 Volt (12 Volt device)higher than 32.5 Volt (24
Volt device)
ERROR IN POWER VPS1

TCU switched on VPS1 monitoring VPS1 OFF or
TCU switched on VPS1 monitoring VPS1 still ON
wire/connection defective and connected to vehicle ground
lack of permanent power at KL30
TCU defective
D2
D3
D4
D5
check fuses
check wires between batteries
and TCU
batteries and TCU
replace TCU
check powering battery

and TCU
batteries and TCU
Remarks
W190
check powering battery

and TCU
batteries and TCU
check wires and connectors to

sensors powered by AU1
check power to terminal AU1
(it must be about 5 Volt)
S. C. VOLTAGE BATTERY TO SENSOR

POWERING
TCU monitors more than 6 Volts at terminal AU1
(5 Volt sensor power)
D1
Reaction TCU

Trouble
Code
(hex)
TRANSMISSION
2 - 39
No reaction
OP-Mode: normal
No reaction
OP-Mode: normal
It moves to neutral
OP-Mode: Stops TCU
S. C. BATTERY VOLTAGE AT DISPALY OUTPUT

TCU forwards data to the display and monitors
always a high voltage on connectors
display defective
S. C. TO GROUND AT DISPALY OUTPUT

TCU forwards data to the display and monitors
always a high voltage on connectors
display defective
COMUNICATIONS TROUBLE ON NET DEVICE
E3
E4
E5
check Omron Master

check cable of Device Net-Bus
check cable of Omron Master
Remarks
2 - 40

display
check connections at display
replace display

display
check connections at display
replace display
check fuse
check wires from transmission
to TCU
check connectors from gearbox to TCU
replace TCU
It moves to neutral
OP-Mode: Stops TCU
ERROR IN POWER VPS2

TCU switched on VPS2 monitoring VPS2 OFF or
TCU switched on VPS2 monitoring VPS2 still ON
lack of permanent power at KL30
TUC defective
D6
Reaction TCU

Trouble
Code
(hex)
TRANSMISSION
W190
Transmission stays in
neutral
OP-Mode: TCU stop

No reaction
OP-Mode: normal
CL1 OUT OF TIME

CAN CL1 message from cluster controller out of
time
interference on CAN-Bus
CAN cable/connector broken
CAN cable/connector defective or connected to
vehicle ground or battery voltage
ILLEGAL ID REQUEST TRHOUGH CAN
GENERAL DEFECT EEPROM

TCU unable to read a volatile memory
TCU defective
LOSS OF CONFIGURATION
TCU lost the correct configuration and is unable
to control the transmission
interference during saving of data or on a volatile memory
new TCU or from another machine
E5
E6
F1
F2
Often indicated by trouble code F2
Check display controller

Check CAN-Bus cable
Check cable of display controller
Reprogram the correct configuration for vehicle (ex. With cluster controller etc.)
Replace TCU
Check display controller

Check CAN-Bus cable
Check cable of display controller
Remarks
W190
Transmission stays in
neutral
OP-Mode: TCU stop
TCU keeps the old information for:

test status modeplock
statusgearshifting
quality selection
OP-Mode: normal
TCU selects parameter defined by ID0

OP-Mode: recovery
DISPID1-OUT-OF-TIME
Out of time of message DISPID1 from display
controller
interference on CAN-Bus
CAN cable/connector broken
CAN cable/connector defective or connected to
vehicle ground or battery voltage
E5
Reaction TCU

Trouble
Code
(hex)
TRANSMISSION
2 - 41
It moves to neutral
The transmission
stays in neutral
OP-Mode: stop TCU
No reaction
default values = 0 for
AEB
offset used
OP-Mode: normal
REQUEST FOR RECOVERY

No fault! Indicates that another computer requested the recovery via CAN
CLUTCH FAILURE
AEB was unable to regulate the correct clutch
load parameters
one of the AEB values off limits
LOSS OF CLUTCH REGULATION DATA

TCU was unable to monitor the correct clutch
regulation parameters
F4
F5
F6
TCU indicates the clutch involved

on the display
Remarks
2 - 42
perform AEB
check clutch
the outer controller cancelled

the request
re-configure with TCU configuration command (IDPC)
Speed range regulated

from 1st through 4th
LOSS OF CONFIGURATION fwd

TUC lost the FWD configuration
F2
Reaction TCU

Trouble
Code
(hex)
TRANSMISSION
W190
W190
TRANSMISSION
2 - 43
2.6.4 TROUBLESHOOTING USING THE "TESTMAN" DEVICE

A complete instrument for the troubleshooting and repair of ZF transmissions is represented by the
2TESTMAN"standard set:
Windows 95/98
Pentium
MB/NT 32 MB
RAM
Free Hard disk capacity
Floppy disk drive
SYTEM
90 Mhz
Windows 95/98 16
20 MB
3 1/2"
COM 1 or COM2
Basic - Software
Diagnostic set
380001217
ZF Diagnostic adapter DPA - 04
Ad
602
+
EST - 37
Diagnosis
Software
W190-2R002
Fig. 2-17
2 - 44
TRANSMISSION
W190
2.6.4.1 CONNECTIONS AND SETTINGS OF THE DPA - 03
n
e to
ctio cabl
e
n
ic
Con nost
g
a
i
D
pi
up
ck-
"A"
C
le P
tab OM2
r
o
p
C
On
1 or
M
CO
The DPA-03 adapter must be connected by the cable

provided to the pick-up indicated located behind the
plastic panel in the cab, behind the operator's seat.
Fig. 2-19
For
Fortroubleshooting
Diagnostic always
position
= OFF
always in
positio
= OFF
Diagnose- und Programmier-Adapter

DPA 03
Lighted during
the operation
Data
U Batt
AUS
UPRG
KL30
KL15
ECU
EIN
V-24
Fig. 2-20
ISO 9141
DATA
DATA
Flashing
during .
flashes
at operation
the operation
SAE J 1708
No
connections
L-Ltg.
unbenutz
L-Ltg.
KL15
Fzg.
0501 211 102
Diagnosis
- ERGOPOWER
Troubleshooting
always
on
posiitionalways
KL 30in
ERGOPOWER
position "KL 30"
W190
TRANSMISSION
2.6.4.2 CONFIGURATION OF TESTMAN SOFTWARE MENU
MAIN MENU
Repair assistance
Maintenance
To sub-programs
Tightening limit
To sub-programs
Setting values
To sub-programs
Special tools/Testers
To sub-programs
Repair
To sub-programs
Harnesses and connections diagrams
To sub-programs
Pressure
To sub-programs
Electric measurements values
To sub-programs
Troubleshooting
Reading of accumulation of defects
Cancellation of accumulation of defects
Reading of identification block
Inputs and Outputs - test
Test of system inoperative
Test of system in operation
Test device
Analogical display, speed, current etc.
Vehicle configuration
Starting AEB - Recording of values
Display AEB - Values K1, K2, K3
Display AEB - Values K4, KV, KR
ZF service telephone list
2 - 45
2 - 46
TRANSMISSION
W190
2.7 TRANSMISSION OVERHAUL

2.7.1 DISASSEMBLY OF CONTROL VALVE
The figure on the left illustrates the transmission control valve assembly.
Fig. 2-21
Mark the disassembly location of the various covers,
housings and cable connector with respect to the control valve body.
Fig. 2-22
Remove the recessed head screws using tool
380001295.
Remove the oil ducts plate from the control valve body,
the first gasket, the intermediate plate and the second gasket.
Fig. 2-23
W190
TRANSMISSION
2 - 47
Remove the retaining ring.
Fig. 2-24
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
380001295; remove the securing plates and pressure
regulators (x3).
Fig. 2-27
2 - 48
TRANSMISSION
Remove the two recessed head screws and secure

temporarily the housing with setting screws 380001276.
(The housing is subject to the action of the springs)
Remove the remaining screws.
W190
S
S
(S) setting screws.
Fig. 2-28
Separate the housing from the control valve body, loosening uniformly the setting screws.
S
(S) setting screws.
S
Fig. 2-29
Remove the components (fig. 2-30).
Remove in the same manner from the opposite side,
the pressure regulators, the housing and the relevant
components (Fig. 2-31).
Fig. 2-30
Fig. 2-31
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
(3x Spool and spring)

3
2
Fig. 2-33
Install the components as indicated in Fig. 2-33.
Note Press the spring of the follow-up sliders and
install temporarily the spools using the 5.0 mm diameter cylindrical pins as illustrated by the arrows in
Fig. 2-34.
Fig. 2-34
Install the two setting screws 380001276.

Install the gasket (arrow 1) and the housing cover
(Fig. 2-35). Install the cover tightening uniformly the
setting screws until it contacts the housing, then remove the cylindrical pins (mounting help) - See Fig.
2-36.
Note Pay attention with the different housing covers.
Install the cover with the 15 mm diameter cavity (arrow 2) oriented toward the pressure relief valve spring.
Fig. 2-35
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.
Fig. 2-38
W190
TRANSMISSION
2 - 51
Preliminary installation on the opposite side

The figure on the right illustrates the following components:
1 = Main pressure relief valve
2 = Follow-up slider
3 = Vibration damper
1

Fig. 2-39
Install the components as illustrated in Figure 2-39.
Press the springs of the follow-up sliders and install
temporarily the spools using the 0.5 mm cylindrical
pins (mounting help) as illustrated by the arrows.
Install the two setting screws.
2
Install the gasket (Arrow 1) and the housing cover and

move them uniformly to contact the housing using the
setting screws.
Note Pay attention with the different housing covers.
Install the cover with the 19 mm diameter cavity (Arrow 2) oriented toward the pressure main relief valve!
Secure the housing cover tightening the recessed hex
head screws.
Fig. 2-40

Remove the cylindrical pins (mounting help).
Install the pressure regulators and secure them using

the securing plates and tighten the recessed hex head
screws using tool 380001295.
Note Install the securing plates with the fork facing
downward.
Pay attention to the radial mounting position of the
pressure regulators. see Figure.
Fig. 2-41
2 - 52
TRANSMISSION
W190
Install the connector and the harness and connect

the pressure regulators (x 6).
Note pay attention to the mounting position of the
connector and harness, considering the marks as well
(Fig. 2-22).
Fig. 2-42
Insert the female connector into the housing with the
slide in correspondence with the guide in the cover.
Install the gasket (Arrow) and secure the cover with
the recessed hex head with tool 380001295.
Fig. 2-43
Secure the female connector using the retaining ring,
see Figure 2-44.
Install the opposite cover.
Fig. 2-44
W190
TRANSMISSION
2 - 53
Install the oil ducts plate and secure it uniformly using the recessed hex head screws.
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
2 - 54
TRANSMISSION
W190
Install the intermediate plate with the mesh filters oriented upward.
Fig. 2-49
Install gasket (2).
2
Fig. 2-50
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
2 - 56
TRANSMISSION
W190
Hold the transmission-torque converter housing slinging

it in four points (two frontally and two in the rear).
Remove the screws indicated and separate the transmission from the engine.
Note Be careful to prevent the converter from falling
out its seat.
Fig. 2-55
Remove the four screws indicated and remove the

flex disc.
Install four hooks in lieu of the screws and extract the
converter using a lifting device.
Extract the torque converter wheel drive shaft from

the cover (ball bearing).
Fig. 2-56
Remove the induction sender (Engine).
Fig. 2-57
W190
TRANSMISSION
2 - 57
Remove the recessed head hex screws and separate

the converter bell.
Fig. 2-58
Hydraulic pump
Remove the recessed head hex screws.
Fig. 2-59
Place a puller separator on the stator shaft and use a
two-leg puller to pull carefully the pump assembly from
the housing holes.
Fig. 2-60
Remove the hydraulic pump from the stator shaft.
Remove the timing plate from the pump.
Note In the event signs of wear are found on the pump
housing or the timing plate, the entire pump must be overhauled!
Reinstall the timing plate and secure it with the pins in the
slide (2x).
Fig. 2-61
2 - 58
TRANSMISSION
W190
Remove the recessed head hex screws with tool

380001296 and the two hex screws and remove the
oil supply housing.
Remove the seal.
Fig. 2-62
Torque converter pressure relief valve
Press the spring and remove the safety plant.
Then, remove the relevant components.
Fig. 2-63
Remove the recessed head hex screws.
Remove the cover and gasket.
Fig. 2-64
Disassembly of output and input shafts and clutches
Remove the safety plate, remove the recessed head
hex screws and extract the shaft, pushing with a pry
bar, the converter output flange.
Then, pushing again, extract the sealing ring from the
transmission housing hole.
Turn the transmission 180 and remove the rear output flange in the same manner.
Fig. 2-65
W190
TRANSMISSION
2 - 59
Remove the speed sensor and the induction sensors

(Arrows).
Fig. 2-66
Remove the hex nuts and remove both covers (Arrows).
Remove the screws securing the cover to the transmission housing.
Fig. 2-67
Extract the two cylindrical pins (arrow).
Fig. 2-68
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!
Hold all the clutches in their position with locking tools

(380001279) installed on the transmission housing
cover.
Install the lifting hooks and sling them to a lifting device.
Fig. 2-69
Use a lifting device to remove the transmission housing cover with the clutches from the housing.
Fig. 2-70
Install the transmission housing cover on a rotary stand.
Fig. 2-71
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TRANSMISSION
2 - 61
Remove the recessed head hex screws and extract

the output shaft with the two oil buffer plates.
Fig. 2-72
Extract the taper roller bearing.
Remove the opposite taper roller bearing in the same
manner.
Bush 380001293
Fig. 2-73
KR
Turn the transmission housing cover 180.
AN
KV
K4
K2
K1
K3
Fig. 2-74
The figure on the right illustrates the arrangement of

the single clutches and the output shaft in the transmission housing cover.
AN = Input
KV = Forward clutch
KR = Reverse clutch
K1 = 1st speed clutch
K2 = 2nd speed clutch
K3 = 3rd speed clutch
K4 = 4th speed clutch
Remove clutch locking tools (380001279).
Fig. 2-75
2 - 62
TRANSMISSION
W190
Slightly lift clutch K4 with a pry bar and remove

clutch K1.
Fig. 2-76
Remove clutch K2.
Fig. 2-77
Remove clutch K3.
Fig. 2-78
Lift clutches KV and KR with two pry bars and remove clutch K4.
Fig. 2-79
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
Turn the transmission housing cover 90.

Extract the retaining ring and remove the pump shaft
from the transmission housing cover.
Fig. 2-81
Remove the rectangular ring (arrow) and extract the

ball bearing from the shaft.
Fig. 2-82
2 - 64
TRANSMISSION
W190
Disassembly of KV and KR clutches

Note The figures to follow illustrate the disassembly of
clutch KV. The disassembly of clutch KR is similar.
Remove the ring (arrow).
Fig. 2-83
Remove the taper roller bearing from the shaft.
Then remove the opposite taper roller bearing.
Bush 380001289
Remove the retaining ring.
Fig. 2-84
Extract the disc drum from the shaft.
Fig. 2-85
Fig. 2-86
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TRANSMISSION
2 - 65
Remove the retaining ring and the clutch discs.
Fig. 2-87
Press the spring with tool 380001280; remove the
circlip and the components.
Fig. 2-88
Use compressed air to pullout the piston from the
cylinder.
Fig. 2-89
Remove both O-Rings (arrows).
Fig. 2-90
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
Remove the circlip and extract the ball bearing.

Note Clutch KR is disassembled in the same manner.
Fig. 2-93
W190
TRANSMISSION
2 - 67
Disassembly of clutches K1, K2 and K3

Note The figures here below illustrate the disassembly of clutch K3.
The disassembly of clutches K1 and K2 is similar.
Remove the rectangular ring.

Then remove the opposite taper roller bearing.
Bush 380001293
Fig. 2-94
Remove the sliding disc, the axial needle cage and
the axial thrust washer.
Fig. 2-95
Remove the idle gear.
Fig. 2-96
2 - 68
TRANSMISSION
W190
Remove both needle bearings and the axial bearing.
Fig. 2-97
Remove the retaining ring and extract the clutch pack.
Fig. 2-98
Press the cup spring using tool 380001280 and remove the circlip.
Remove the components that are free.
Fig. 2-99
Insert retaining ring 380001269 in the slot of the clutch
drum.
Place the puller with the legs holding the retaining
ring and pullout the clutch drum from the relevant
shaft.
Fig. 2-100
W190
TRANSMISSION
2 - 69
Disassembly of clutch K4
Remove the ring (arrow).
Fig. 2-101
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
2 - 70
TRANSMISSION
W190
Press the cup spring and remove the circlip.

Remove the components that are free.
Remove the piston.
Fig. 2-105
Use compressed air to push the piston out the cylinder.
Fig. 2-106
Remove the idle gear and remove the components
that are free.
Note It is not possible to separate the shaft from
the gear (hot pressed).
Fig. 2-107
W190
TRANSMISSION
2 - 71
Disassembly of the drive shaft

Remove the rectangular ring.
Extract the taper roller bearing.
In the same manner, remove the opposite taper roller
bearing.
Bush 380001294
Fig. 2-108
If required, use a press to pullout the turbine shaft
from the drive shaft.
Note The turbine shaft is secured axially by a retaining ring that is broken during the extraction operation.
Fig. 2-109
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.
Install suction pipe (1), pressure pipes (2) and lube

pressure pipe (3) in the hole of the transmission housing.
Secure the suction and pressure pipes using recessed

head hex screws.
Maximum torque (M8/8.8) ............................. 23 Nm
Fig. 2-110
Turn the housing 180.
Head the suction and pressure pipes (Arrows) in the
relevant holes of the housing, using special tools
380001287 - 380001286 - 380001289.
WARNING
The tips of the pipes must be perfectly flushed
with the face of the housing.
If required, correct the protrusion of the pipe to
make it flush.
Fig. 2-111
Install the O-Rings (2 x/pipe) in the slots of the two oil
pipes, lubricating them with clean oil.
Fig. 2-112
W190
TRANSMISSION
2 - 73
Install the two pipes (Arrows) until they bottom into

the housing.
Install e new O-Ring on the treaded plug and install it.
Tightening torque ........................................ 140 Nm
Fig. 2-113
Install the two oil pipes (Arrows) into the transmission
housing cover; turn the cover 180 and head the oil
pipes into the relevant holes.
WARNING
The tips of the pipes must be perfectly flushed
with the face of the housing.
If required, correct the protrusion of the pipe to
make it flush.
Fig. 2-114
Install the studs (M8 x 25).
Tightening torque (studs) .............................. 9.0 Nm
Note Apply Loctite (type No. 262) on the thread.
Install new O-Rings on the plugs (Arrows) and install
them into the relevant holes.
Tightening torque .......................................... 40 Nm
Fig. 2-115
Press the sealing covers with the concave face upward.
Note Apply Loctite (type No. 262) on the thread.
Fig. 2-116
2 - 74
TRANSMISSION
W190
Assembly of clutches KV and KR

Note The figures here below illustrate the reassembly
of clutch KV.
The disassembly of clutch K3 is similar.
Fig. 2-117
Preliminary reassembly of the clutch drum
Check the operation of the oil discharge centrifugal
valve.
Note The ball must be free. Clean it with compressed
air, as required.
Install the two O-Rings (arrows) without twisting them,
into the relevant slots of the piston, lubricating them
with clean oil.
Insert the piston until it bottoms in the clutch drum.
Fig. 2-118
Note Pay attention to the mounting position, see
the Figure.
Install the inner ring, the spring and the guide ring.
Fig. 2-119
Press the spring with tool 380001280 and secure it
with a retaining ring.
Fig. 2-120
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.
2 - 76
TRANSMISSION
W190
Setting the play between the discs = 2.7+ 0.2 mm

Note To set the play among the discs, retaining
rings with different thickness are available.
To ensure an error free measuring, install the discs
without oil at this stage.
Insert the clutch pack as indicated in the drawing at
page 72.
Fig. 2-122
Install the end spacer and insert the retaining ring
(ex. s = 2.55 mm).
Fig. 2-123
Press the end spacer with a force of 100 N (10 kg)
and place a dial gauge and zero it.
Then, push the end spacer with a screwdriver toward
the retaining ring until it contacts in (upward) and read
the play among the discs on the dial gauge
(Fig. 2-124).
Note In the event the reading gives a value different from the required one, correct it with a different
retaining ring (s = 2.1 . 4.2 mm).
Fig. 2-124
After completing the setting of the play among the
discs, remove the clutch pack, lubricate the discs
with clean oil and reinstall them.
WARNING
Use oil complying with the specifications of the
list of lubricants (section 0 of the Manual).
Fig. 2-125
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
2 - 78
TRANSMISSION
W190
Install the needle bearing.
Fig. 2-129
Move the idle gear until it bottoms against the stop.
Note Support it on the inner race of the bearing.
Fig. 2-130
Warm-up the inner part of the clutch drum (to about
120 C - 248 F).
Fig. 2-131
Install the clutch drum previously assembled until it
bottoms.
Fig. 2-132
W190
TRANSMISSION
2 - 79
Secure the clutch drum axially using the circlip.
Fig. 2-133
Check with compressed air the operation of the clutch.
Note If the components are installed correctly, the
opening and closing of the clutch can be heard distinctly.
Fig. 2-134
Press the taper roller bearing against the stop.
Install the opposite taper roller bearing in the same
manner.
Fig. 2-135
Install the rings (arrows).
Fig. 2-136
2 - 80
TRANSMISSION
W190
Reassembly of clutches K1, K2 and K3

Note The figures here below illustrate the assembly
of clutch K3.
The assembly of clutches K1 and K2 is similar.
Fig. 2-137
Warm-up the inner part of the clutch drum (fig. 2-135)
and install the drum until it bottoms (Fig. 2-136).
Fig. 2-138
Fig. 2-139
valve.
Note The ball must be free; clean with compressed
air as required.
with clean oil.
Fig. 2-140
W190
TRANSMISSION
2 - 81

the Figure.
Fig. 2-141
Install the cup spring pack and the guide ring.
Note Pay attention to the arrangement of the cup
spring elements; see the drawing at page 2-79.
Fig. 2-142
Press the cup spring and secure it with the retaining
ring.
Fig. 2-143
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)
7 = End spacer
3
7
4
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
face only (q.ty 1)
7 = End spacer
1
Note Install outer disc 3 with the unlined face directed toward the piston.
Fig. 2-145
W190
TRANSMISSION
2 - 83
Setting of the disc play

Disc play of clutch K1
Disc play of clutches K2 and K3
= 2.4+0.2 mm
= 1.8+0.2 mm

Insert the clutch pack as indicated in the drawing at
page 2-79.
Fig. 2-146
(ex. s = 3.1 mm).
Fig. 2-147
Press the end spacer with a force of 100 N (10 kg) and
place a dial gauge and zero it (Fig. 2-148).
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
WARNING
Fig. 2-149
2 - 84
TRANSMISSION
Install sliding disc (1) (55 x 78 x 5) needle axial cage

(2) and axial thrust ring (3) (55 x 78 x 1).
Note Install sliding disc 1 with the bevel directed
toward the needle axial cage.
W190
3
2
1
Fig. 2-150
Install both needle bearings.
Fig. 2-151
Insert the idle gear until all the inner discs are inserted into the splined hub.
Fig. 2-152
W190
TRANSMISSION
1
2
3
2 - 85
Install axial thrust ring (3) (55 x 78 x 1), needle axial

cage (2) and sliding disc (1) (55 x 78 x 5).
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
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
Fig. 2-159
valve.
Note The ball must be free; clean with compressed
air as required.
with clean oil.
Fig. 2-160
W190
TRANSMISSION
2 - 87

the Figure.
Fig. 2-161
Install the cup spring pack and the guide ring.
Note Pay attention to the arrangement of the cup
spring elements; see drawing.
Fig. 2-162
Press the cup spring with tool 380001280 and secure
it with the retaining ring.
Fig. 2-163
2 - 88
TRANSMISSION
W190
Clutch pack K4
The drawing here below illustrates the arrangement of
the components.
Drawing reference:
1 = Clutch drum
2 = Piston
face only (q.ty 1)
7 = End spacer
1,2+0,2 mm
5
6

4
WARNING
Install outer disc 3 with the unlined face directed
toward the piston.
Fig. 2-164
Setting of the disc play = 1.2+0.2 mm

Insert the clutch pack as indicated in the drawing.
Fig. 2-165
(ex. s = 3.4 mm).
Fig. 2-166
W190
TRANSMISSION
2 - 89
Press the end spacer with a force of 100 N (10 kg)

and place a dial gauge and zero it (Fig. 2-167).
the play among the discs on the dial gauge
(Fig. 2-168).
Note In the event the reading gives a value different
from the required one, correct it with a different retaining
ring (s = 2.1 . 4.2 mm).
Fig. 2-167
WARNING
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
2 - 90
TRANSMISSION
W190
Install the new needle bearings.
Fig. 2-171
Install the idle gear.
Fig. 2-172
Install axial thrust ring (3) (55 x 78 x 1), needle axial
cage (2) and sliding disc (1) (55 x 78 x 5).
1
2

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
W190
TRANSMISSION
2 - 91
Secure axially the clutch drum using the circlip.
Fig. 2-175
Check the operation of the clutch using compressed
air.
Note When the components are installed correctly,
the opening and closing of the clutch is perceived perfectly.
Fig. 2-176
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
2 - 92
TRANSMISSION
W190
Pre-assembly of the drive shaft

Cool-down the shaft (about - 80 C - 110 F), warmup the gear (about + 120 C 250 F) and install the
shaft until they contact.
Fig. 2-179
Secure the gear axially using the circlip.
Fig. 2-180
Press the circlip in the appropriate slot of the turbine
shaft.
Fig. 2-181
Insert the turbine shaft and insert the circlip in the
slot of the drive shaft - thus the turbine shaft is axially
secured.
Fig. 2-182
W190
TRANSMISSION
2 - 93

Then install the rectangular ring in the slot of the drive
shaft.
Press the opposite taper roller bearing.
Fig. 2-183
Pre-assembly and reinstallation of output shaft
Position the oil buffer plate.
Fig. 2-184
Warm-up the taper roller bearing and install it against
the shoulder.
Install the opposite taper roller bearing in the same
manner.
Insert the bearing outer races of all the bearings in

their seats on the transmission housing.
Install the O-Rings (arrows).
Fig. 2-185
KV
K2
K3
AN
Note When bearings that have many work hours are

reused, pay attention that the initial location of the outer
races are respected.
KR
K4
K1
AB
AN
KV
KR
K1
K2
K3
K4
AB
= Input
= Forward clutch
= Reverse clutch
= 1st speed clutch
= 2nd speed clutch
= 3rd speed clutch
= 4th speed clutch
= Output
Fig. 2-186
2 - 94
TRANSMISSION
W190
Position the oil buffer plate.
Fig. 2-187
Insert the output shaft previously assembled.
Secure the oil buffer plate with the recessed head
hex screws.
Tightening torque (M8/8.8) ............................ 23 Nm
Fig. 2-188
W190
TRANSMISSION
2 - 95
Reassembly of drive shaft and clutches

KR
Insert the bearing outer races of all the bearings in

their seats on the transmission housing.
AN
KV
Note When bearings that have many work hours are

reused, pay attention that the initial location of the outer
races are respected.
K4
K2
K1
K3
AB
AN
KV
KR
K1
K2
K3
K4
AB
= Input
= Forward clutch
= Reverse clutch
= 1st speed clutch
= 2nd speed clutch
= 3rd speed clutch
= 4th speed clutch
= Output
Fig. 2-189
WARNING
Prior to reinstalling the clutches and drive shaft,
smear grease on the rectangular rings and centre them on the relevant shafts.
Insert clutch KR, drive shaft and clutch KV together
in the transmission housing cover.
Fig. 2-190
Lift the drive gear and position clutch K4.
Fig. 2-191
2 - 96
TRANSMISSION
W190
Reinstall clutch K3.
Fig. 2-192
Position clutch K2.
Fig. 2-193
Lift clutch K4 and position clutch K1.
Fig. 2-194
The figure on the left illustrates the reinstallation position of the single clutches in the transmission housing cover.
Smear grease on the rectangular rings (arrows) and
centre them on the relevant shafts.
KR
KV
K2
K4
K3
K1
Fig. 2-195
W190
TRANSMISSION
2 - 97
Secure all the clutches using the appropriate tools

380001279.
Fig. 2-196
Turn the stand 180.
Install lifting hooks (arrows).
Fig. 2-197
Smear grease on the O-Rings of the two oil pipes.
Smear the mating faces with sealing compound
Loctite (type No. 574).
Position carefully, using an appropriate lifting rig, the
cover previously pre-assembled on the transmission
housing until they contact.
Note Make sure that the oil pipes coincide with the
relevant holes of the transmission housing cover.
Fig. 2-198
Remove the clutch locking tools 380001279.
Fig. 2-199
2 - 98
TRANSMISSION
W190
Insert the two dowels centrally on the front side of the

housing.
Fig. 2-200
Secure the transmission housing cover with the recessed head hex screws.
Tightening torque (M10/8.8) ......................... 46 Nm
Note Pay attention to the position of the lifting hook;
see the figure).
Fig. 2-201
Assembly of the pump shaft (P.T.O.)
Install the ball bearing.
Install the rectangular ring (arrow) in the relevant slot.
Fig. 2-202
Smear grease on the rectangular ring, centre it with
the shaft and insert the pump shaft until it shoulders.
Fig. 2-203
W190
TRANSMISSION
2 - 99
Secure the pump shaft using the circlip.
Fig. 2-204
Insert the O-Ring (arrow) in the ring slot of the oil
supply covers.
Fig. 2-205
Install the two covers (arrows) using hex nuts (use
flat washers).
Fig. 2-206
2 - 100
TRANSMISSION
W190
Reassembly of the output flanges

Install the seal with the lip directed toward the cavity
containing the oil.
Note Use the appropriate punch 380001271 to obtain the correct mounting position.
Wet the rubber lined outer diameter with alcohol.
Smear grease on the sealing lip.
Fig. 2-207
Install the output shaft.
Install the O-Ring (arrow) in the gap between flange
and shaft.
Fig. 2-208
Secure the output flange using the retaining plate and
the recessed head hex screws.
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
W190
TRANSMISSION
2 - 101
Torque converter pressure valve

The figure on the left illustrates the components of
the torque converter pressure valve.
4
1
2
3
Fig. 2-211
1 = Plunger
2 = Spring
3 = Resting plate
4 = Retaining plate
Note Install the resting plate with the point (6 mm
diam) directed toward the retaining plate.
Insert the components in the sequence illustrated in
Fig. 2-211, press the spring and secure the valve with
the retaining plate.
Tighten the plug (arrow) equipped with a new O-Ring.
Tightening torque (M14x1.5)......................25 Nm
Fig. 2-212
Oil supply housing - Transmission pump
Install setting screws 380001275 (arrows) and install
the seal.
Fig. 2-213
Position the oil supply housing and secure it temporarily using the recessed head hex screws.
Note Install only the screws required to obtain a
good contact do not tighten.
Fig. 2-214
2 - 102
TRANSMISSION
W190
Install the two setting screws 380001274 and insert

the stator shaft until it shoulders.
Note Pay attention that the holes coincide.
Fig. 2-215
Insert the O-Ring (arrow) in the slot and lubricate it
with oil.
Fig. 2-216
Install the transmission pump assembly and rest it
against the shoulder in a uniform manner, using the
recessed head hex screws (at this time without
O-rings).
Then remove the recessed head hex screws again.
Fig. 2-217
Install new O-Rings (figure) on the recessed head hex
screws.
Note Smear grease on the O-Rings.
Fig. 2-218
W190
TRANSMISSION
2 - 103
Secure the pump the transmission using the recessed

head hex screws.
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.
Fig. 2-221
Install the gasket and secure the cover with hex head
screws.
Tightening torque (M8/8.8) ........................... 23 Nm
Fig. 2-222
2 - 104
TRANSMISSION
W190
Insert the torque converter bringing it to contact.

Note The impulse generating disc on the torque
converter must be located in a central position with
respect to the hole of the induction sender; see arrow/
figure 2-221.
This is the only way to make sure that the torque
converter is perfectly inserted into the bell.
Fig. 2-223
Secure the flex disc on the torque converter tightening the hex head screws to the prescribed torque.
Tightening torque (M12/10.9) ....................... 115 Nm
Note Install the screws with Loctite (Type no. 262)
Fig. 2-224
Torque converter safety valve
Insert the safety valve (assembled) into the hole on
the transmission housing.
Fig. 2-225
W190
TRANSMISSION
2 - 105
Installation of the oil ducts plate and transmission control valve

Install the components as illustrated in the sketch
here below.
Tightening torque (M8) ................................. 23 Nm
(Hex nuts and recessed head hex screws)
Note Pay attention to the mounting position of
the various gaskets.
Drawing ref.
1=
2=
3=
4=
5=
Gasket
Oil ducts plate
Gasket
Intermediate plate
Gasket
Adapted Setting screws

Hex wrench 380001296
Fig. 2-226
Tighten the plug (arrow) with a new O-Ring.
Tightening torque (M16x1.5) ......................... 30 Nm
Fig. 2-227
Secure the transmission control valve with two
adapted setting screws then install the recessed head
hex screws with tool 380001295.
Tightening torque (M6) ................................ 9.5 Nm
Fig. 2-228
2 - 106
TRANSMISSION
W190
Installation of plugs and oil level pipe

Install the two plugs (arrows) with new O-Rings.
Tightening torque (M18 x 1.5) ....................... 50 Nm
Tightening torque (M26 x 1.5) ....................... 80 Nm
Fig. 2-229
Install the oil dipstick pipe (arrow)
Note Install a new gasket.
Fig. 2-230
Install the cover (arrow 1)
Note Install a new gasket.
Tightening torque (M8/8.8) ........................... 23 Nm
Install the plug (arrow 2) with a new O-Ring.
1
Tightening torque (M38x1.5) ....................... 140 Nm
2
Fig. 2-231
Speed sensor and induction senders
Figures 2-232 and 2-233 illustrate the mounting location of each induction sender and the speed sensor.
34 = Speed sensor
21 = Induction sender
n Tachometer output
n Turbine
n Central sender
n Engine
34
Fig. 2-232
W190
TRANSMISSION
Apply grease on the O-Rings and install on the speed

sensor and induction senders.
48
2 - 107
47
21

(Recessed head hex screw/Speed sensor)
(Induction sensor)
Fig. 2-233
Install the breather (arrow).
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
2 - 108
TRANSMISSION
W190
2.9 PROPELLER SHAFTS

GENERAL CHARACTERISTICS
DISTANCE BETWEEN
PINS (mm)
MAX TRANSMISSION
TORQUE (STALL) (Nm)
Front shaft
Universal joint
565.8
5855
Intermediate shaft
Universal joint
1037.3
5855
Rear shaft
Universal joint
105.6
5855
Front axle
Propeller
shaft
Intermediate
shaft
Rear axle
2
1
2
Fig. 2-233
Note -
Support
Rear shaft
Propeller shaft group

149 - 163 Nm
Threaded part: LOCTITE 262
88 - 102 Nm
W190
TRANSMISSION
2 - 109
6
1
2
10
1
2
4
2
5
9
Fig. 2-237
10
Front and intermediate prop-shafts
1. Spider - 2. Spider grease fitting - 3. Washer - 4. Front shaft - 5. Intermediate support - 6. Bearing 7. Seal - 8. Intermediate shaft - 9. Screw - 10. snap ring
2
1
Fig. 2-238
Rear prop-shaft
1. Screw 1/2"-20 - 2. Spring washer - 3. Spider - 4. Rear shaft - 5. Spider grease fitting
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
Reduction and differential

Type
Common, 2 stage reduction
Differential housing
Integral type
Differential limiter
Torque proportional
differential
Final drive
Type
Epicyclic
Weight
Rear
Front
926 Kg (2041 lbs)

900 Kg (1984 lbs)
2.10.1 GENERAL DESCRIPTION

The axle is composed of a differential, final reduction
units, oil-bath disc brakes and axle shafts connected
to the wheels.
The power output from the transmission is driven by
the prop shafts to the front and rear axles. Thus, the
power is driven to the differential that splits it to the
axle right and left shafts driving the final drives, reaching the wheels.
The oil bath disc brake is mounted in front of the final
drive and operates as service brake. As for the ope
"3 - BRAKES SYSTEM".
The front axle is mounted directly on the front axle by

screws.
The rear axle is mounted with a pivot pin, using supports on both sides of the axle, secured by screws to
the rear frame. Consequently, the rear axle can pivot
around the axle of the differential with an amplitude
depending upon the ground conditions travelled by the
loader. The drive axle mounted with a pivoting pin improves the driving conditions of the loader when travelling on rough terrain.
W190
TRANSMISSION
2 - 111
Fig. 2-239
Note -
Installation of axles on frame
788 Nm
Threaded parts: LOCTITE 262
1150 Nm
1. Front pivoting support - 2. Rear pivoting support - 3. Tyre - 4. Rim - 5. Front axle - 6. Rear axle
2 - 112
TRANSMISSION
Fig. 2-240
Note -
10
Assembly of rear axle and pivoting supports
227 Nm
Install with the groove toward plate (6)
Install with lip outwards
W190
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
W190
TRANSMISSION
4
2 - 113
7
1
10
11
12
13
Brake piping connection

ports, 2 points
Fig. 2-241
Note -
14
Front axle
230 Nm
230 Nm
Lip: Grease
Mating surfaces: LOCTITE 509
1. Oil seal - 2. Axle shaft - 3. Final drive - 4. Differential housing - 5. Differential - 6. Crown gear hub - 7. Pin - 8. Dowel 9. Axle shaft housing - 10. Dipstick - 11. Bleeding screw - 12. Bleeding screw - 13. Cover - 14. Draining plug
2 - 114
TRANSMISSION
Fig. 2-242
Brake piping connection

ports, 2 points
W190
10
11
13
14
12
15
5
2
Rear axle
Note - 1
230 Nm
230 Nm
Lip: Grease
Mating surfaces: LOCTITE 509

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
W190
TRANSMISSION
2 - 115
2.10.2 DIFFERENTIAL DESCRIPTION
Operation of the differential
The differential forms a single body with the reduction

unit.
The power is driven from the prop shafts to the differential gear housing through the pinion/bevel gear group.
Thus, it is driven through the right and left gears, to
the final drives. The reduction of r.p.m. is obtained by
the pinion/bevel gear ratio. The turn reduction is obtained by the bevel pinion/crown set.
When the loader is moving straight, the bevel ring

gear, the differential gear cage and the differential side
gears rotating together; the idle pinions inside the gear
cage do not rotate. Thus the right and left planetary
gears transfer the motion to the wheels at the same
speed, through the half-shafts. When the loader turns,
the right and left wheels turn at different speeds, the
planetary gears in the differential housing turn around
their pin proportionally with the speed difference between the right and left side gears.
While travelling straight

1
2
While making turns
High
speed
5
6
Fig. 2-243
Low
speed
Operation of differential
1. Idle gear - 2. Side gear - 3. Axle shaft - 4. Differential gear cage - 5. Idle pinion spider - 6. Bevel drive pinion - 7. Bevel
drive ring gear
Proportional torque differential

Wheel loaders often operate under severe terrain conditions, such as sandy or muddy grounds. Under such
unfavourable terrain conditions, a loader equipped with
a standard differential could experience a spinning of
the wheels, thus making difficult to exploit fully its
potential performance. Also, the tyres could wear
quickly. To avoid this, some models are equipped with
a proportional torque type differential, limiting its function.
A proportional torque differential design is almost identical to a normal differential, with the exception of the
idle pinions, having an odd number of teeth with a
special profile. When the tyres start slipping in soft
ground, the planetary gears continue transferring
power to both side gears, until the adhesion difference on the ground of the right and left tyre reach a
low value; thus the tyres are prevented from slipping.
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)
150 Nm (110.6 ft-lbs)
230 Nm (169.6 ft-lbs)
670 Nm (494.2 ft-lbs)
Outer diameter: LOCTITE 262
Threaded Part: LOCTITE 262
___
Lip: Grease
Bevel pinion/crown gear teeth backlash. 0.25 0.36 mm.
After reassembling the differential, set the spacer so that the rolling torque is
0.1 0.4 Nm, without seal.
1. Adjusting nut - 2. Bearing retainer - 3. Half-housing (B) - 4. Bevel crown gear - 5. Half-housing (A) - 6. Locking plate 7. Thrust washer - 8. Thrust washer - 9. Spider - 10. Drive pinion - 11. Bearing holder housing - 12. Idle gear - 13. Pin 14. Planet gear - 15. Shim - 16. Spacer - 17. Spacer - 18. Nut - 19. Flange - 20. Oil seal
W190
TRANSMISSION
2 - 117
2.10.3 "LSD" DIFFERENTIAL
2
10
11
1
1
Fig. 2-245
Limited Slip differential
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.
2 - 118
TRANSMISSION
W190
2.10.4 FINAL DRIVES DESCRIPTION

The final drive units are of a planetary type and create the final rpm reduction in the power train.
6
8
The power driven by the differential to the sun gear

shaft rotates the three planet gears inside the toothed
drum, thus driving the axle shaft through the planet
gear carrier.
1
Section A-A
(Operation of planet gears)
4
6
5
Power drive
Fig. 2-246
Drive of power
1. Pinion - 2. Differential - 3. Sun gear shaft - 4. Planet gear pin - 5. Planet gear - 6. Toothed drum - 7. Planet carrier - 8. Axle
shaft
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
Procedure for the setting of shims

1) Tighten screw (1) to a torque of 50 Nm and set inward the taper bearing, by rotating the axle shaft.
2) Loosen screw (1) without turning the shaft.
3) Measure the gap between thrust ring (3) and axle shaft. Value measured = Y.
4) Select the adjusting shims to form a stack no thicker than 0.03 to 0.10 mm than value Y.
5) Install the shim pack, the retaining ring and the screw.
1110 Nm
The rolling torque of the bearing must be included between 20 and 40 Nm
1. Screw - 2. Spacer - 3. Retaining plate - 4. Thrust ring - 5. Lock pin - 6. Brake disc (outer toothed) - 7. Brake disc (inner
toothed) - 8. Adapter - 9. O-ring - 10. Spring - 11. O-ring - 12. Piston - 13. Planet carrier - 14. Pin - 15. Ball - 16. Thrust ring 17. Needle bearing - 18. Planet gear - 19. Disc hub - 20. Sun gear
2 - 120
TRANSMISSION
W190
2.10.5 DISASSEMBLY OF THE AXLE

Precautions to be implemented during the disassembly
During the disassembly and reassembly of the axle, it is good practice to install it on an overhaul stand and to
Weight of unit:
front: ........................................ 950 kg (2094 lbs)
rear: ......................................... 930 kg (2050 lbs)
1)
Removal of the axle housing
1.
Remove the draining plug and drain the gear oil.

Quantity of oil:
front ..................................... 30 l (7.92 US/gal)
rear ...................................... 30 l (7.92 US/gal)
Fig. 2-248
2.
Remove the screws securing the axle housing.

Q.ty of screws: 20
Fig. 2-249
3.
Sling and hold the axle housing with a hoist and

support it on the opposite side to prevent that it
lowers.
Fig. 2-250
W190
TRANSMISSION
2 - 121
4.
Remove the axle tube from the differential body.

If they are joined, separate one from the other
using a screwdriver and soft mallet.
5.
Remove the sun gear and shaft from the differential.
6.
Remove the snap ring and disk hub from the

splines. Then, remove the snap ring.
Remove the axle tube and shaft at the opposite
side, using the same procedure as above.
Fig. 2-251
Fig. 2-252
7.
Fig. 2-253
2)
Disassembling axle tube
1.
Put the axle tube with the differential mounting

side upward. Using a nut runner (special tool),
loosen the retainer plate mounting bolt and remove it from the axle shaft.
Fig. 2-254
2 - 122
2.
TRANSMISSION
W190
Using a prying tool, separate the final reduction

gear assembly (planet carrier) from the shaft
splines, and remove it with a crane.
Remove any shim, if attached to the axle shaft.
Fig. 2-255
3.
Lay the axle tube on the bench. Using a screwdriver, remove the oil seal from the axle tube.
Fig. 2-256
4.
Remove the bearing cone from the differential

side of the axle tube.
Fig. 2-257
5.
Using a crane, lift the axle tube with its differential side upward to let the axle shaft drop from
opposite side.
Fig. 2-258
W190
TRANSMISSION
6.
2 - 123
Using a gas burner, heat up the bearing cone

attached to the shaft, and remove the bearing
come from the shaft.
Note Make sure to replace the bearings with a new

one.
7.
Remove the oil seal from the axle shaft.
8.
Remove the bearing cups from the differential

and wheel sides of the axle tube by tapping their
outer diameter evenly.
9.
Using a portal jig, remove the ring gear from the

axle tube.
3)
Disassembling final reduction gear assembly
1.
Remove the snap ring from the planet gear shaft.
Fig. 2-259
Fig. 2-260
Thrust bolt
Portal jig
Plate
Ring gear
Fig. 2-261
Fig. 2-262
2 - 124
2.
TRANSMISSION
W190
Drive the shaft from the gear.

Use caution not to lose the lock ball that the shaft
has.
Fig. 2-263
3.
Remove the planet gear and the (2) thrust washers.
Note Use caution not to lose the needle roller because they may come off with the planet gear.
Fig. 2-264
4.
Remove the needle rollers and the spacer from

inside the gear.
Number of needle rollers: 50
5.
Remove the (2) other planet gear shafts, using

the same procedure as above.
Fig. 2-265
6.
Remove the retainer plate from inside the planet

carrier. Keep any shim, if attached.
Fig. 2-266
W190
TRANSMISSION
2 - 125
4)
Removing brake unit
1.
Remove the end plate, brake ring, brake disk,

brake ring, brake disk and brake ring in this order
from the differential body. Then, remove the 8
pins.
2.
Remove the bolt (3), adapter (2) and spring (1)

from the brake piston.
Remove the bolts, adapters and springs from
other five positions in the same way.
3.
Then install three screws (3) previously removed

complete with adapter (2) on the mounting face
of the differential body housing to prevent the
piston from getting out accidentally.
Supply compressed air through the oil pressure
port to remove the piston from the differential
body.
Fig. 2-267
2 1
Fig. 2-268
2
4.
W190-2R004
Fig. 2-269
5.
6.
Remove the O-rings respectively from the larger

diameter and smaller diameter of the brake piston.
Remove the brake unit at the opposite side, using the same procedure.
Fig. 2-270
2 - 126
TRANSMISSION
5)
Removing drive pinion (bearing cage)
1.
Remove the bolts securing the cover from the

differential body, and remove the cover.
Number of bolts: 28
W190
Fig. 2-271
2.
3.
Check the ring gear for tooth surface contact pattern and backlash. Refer to steps (5) and (6) in
"2. Reassembly".
Remove the bolts securing the bearing cage.
Number of bolts:
8 for front axle
10 for rear axle
Fig. 2-272
4.
5.
Install two of the bolts removed at step (3), into

the puller screw holes in the bearing cage. Tighten
both evenly to separate the seating surface. Holding the bolts, remove the bearing cage and the
drive pinion as a unit.
Remove the half shim from between the differential body and bearing cage.
Fig. 2-273
6)
Disassembling drive pinion
1.
Put the drive pinion with the flange side upward.

Using a nut runner (special tool), loosen the flange
lock nut.
Fig. 2-274
W190
TRANSMISSION
2.
3.
2 - 127
Remove the nut and detach the washer ring and

O-ring.
Remove the flange from the drive pinion.
Fig. 2-275
4.
Using a press, push down the drive pinion and

remove it from the bearing cage.
5.
6.
Remove the two spacers from the pinion shaft.

Using a separator, remove the bearing cone from
the pinion shaft.
7.
Break the oil seal on the bearing cage with a screwdriver and remove it.
Fig. 2-276
Fig. 2-277
Fig. 2-278
2 - 128
8.
TRANSMISSION
W190
Remove the other bearing cone.
Fig. 2-279
9.
Remove the two bearing cups from inside the

bearing cage, tapping their outer diameter evenly.
10. Remove the O-ring from the outer diameter of
the bearing cage.
Fig. 2-280
7)
Removing differential case
1.
2.
Lift the differential case with a crane temporarily.

Remove the bolts securing the bearing retainer,
along with the lock plate.
Number of bolts: 10
Fig. 2-281
3.
Install two of the bolts removed at step 2, into

the puller screw holes in the bearing retainer and
tighten both evenly. Remove the bearing retainer,
holding the bolts.
Fig. 2-282
W190
TRANSMISSION
4.
5.
2 - 129
Remove the adjusting nut from the retainer. Then

turn the retainer upside down and remove the
bearing cup.
Remove the bearing retainer at the opposite side,
using the same procedure as above.
Fig. 2-283
6.
Remove the ring gear and differential case assembly from the differential body.
8)
Disassembling differential case
1.
Loosen the bolts securing the ring gear and remove the ring gear.
Number of bolts: 20
2.
Turn the differential case upside down and remove the 12 bolts securing the case from the
plane half case side.
Fig. 2-284
Fig. 2-285
Fig. 2-286
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.
Remove the 2 side gears, spider, 4 pinion gears

and 6 thrust washers from inside the differential
case.
Fig. 2-288
5.
Using the bearing puller, remove the bearing cone

from the plane half case and flange half case.
Fig. 2-289
W190
TRANSMISSION
2 - 131
9)
Disassembly of the "LSD" differential housing
1.
Mark the two differential half-housings and remove the 12 connecting screws.
To separate the two halves of the differential, tap
the centre of the spider using a soft metal bar.
2.
Extract five discs (A) four clutch discs (B) and

the relevant pack.
Remove side gear (C).
3.
Then extract the spider (D) complete with thrust

washers (E).
4.
Remove the other side gear and the relevant

clutch pack.
Fig. 2-290
A
B
C
Fig. 2-291
Fig. 2-292
If required, remove the bearings from the halfhousings with a double jaw puller.
Fig. 2-293
2 - 132
W190
TRANSMISSION
2.10.6 AXLE REASSEMBLY

Precautions to be implemented during the re-assembly
Wash disassembled parts with a clean washing oil and dry by blowing air.
Handle the washed parts, with care not to damage or contaminate them.
Check the disassembled parts for wear or damage and replace any worn or damaged part with a new one.
Refer to "2.13 VALUES OF REFERENCE FOR THE MAINTENANCE".
Replace all the seals with new ones.
1)
Reassembling differential case
1.
Place the flanged half case (differential case A)

on a work bench, and press the bearing cone
using a press or soft mallet.
Fig. 2-294
2.
Make sure the 2 dowel pins in the differential case.

Align the 2 holes in the thrust washer with the
dowel pins and install the thrust washer into the
case.
Fig. 2-295
3.
Install the side gear.
Fig. 2-296
W190
TRANSMISSION
2 - 133
4.
Install the 4 pinion gears and 4 thrust washers

onto the spider, and install them as a unit on the
side gear, engaging the gears.
5.
Use a rubber mallet to arrange the spider in the

housing.
6.
Place the half housing (differential housing B) on

a work bench and press the taper bearing with a
press or a rubber headed hammer.
7.
Turn the plane half case upside down and align

the thrust washer with the pins and paste it with
grease.
Fig. 2-297
Fig. 2-298
Fig. 2-299
Fig. 2-300
2 - 134
8.
TRANSMISSION
W190
Engage the other side gear with the pinion gears

and install the plane half case, matching the
marks. Tap the case with a soft mallet to make
sure that the two case halves are closely fitted
to each other.
Fig. 2-301
9.
Apply LOCTITE 262 to the threaded area of each

of 12 case bolts. Install the bolts and tighten them
in a diagonal order.
Fig. 2-302
10. Install the ring gear from upward. Using a soft
mallet, bring it into close contact with the flange
surface of the case. Tighten the mounting bolts
from downward temporarily.
Fig. 2-303
11. Turn the differential case upside down. Apply
LOCTITE 262 to the threaded area of each of the
ring gear mounting bolts and tighten them.
Number of bolts: 20
Fig. 2-304
W190
TRANSMISSION
2 - 135
3)
Reinstallation of "LSD" differential housing
1.
Place the flanged half housing on a workbench

and press the taper bearing with a press or a soft
metal mallet after warming-up the bearing inner
race.
Note Clean accurately all the parts before assembling them using non-flammable and non-toxic solvents.
Fig. 2-305
2.
Turn the flanged half-housing upside down and

insert, in sequence:
- an outer lobe counter-disc (A), a inner toothed
disc (B), an outer lobe counter-disc (A), and so
on, completing the clutch pack with spacer (C).
Fig. 2-306
A clutch pack complete with:
q.ty 4 clutch discs (inner toothed)
q.ty 5 reaction discs (outer lobes)
q.ty 1 spacer
plus possible shim discs.
C
A
Fig. 2-307
3.
Insert the shim/s on spacer (C) smearing a film

of grease between the contact faces before installing them.
Fig. 2-308
2 - 136
4.
TRANSMISSION
W190
Install side gear (P) making sure that the splines

engage the inner teeth of the discs.
Fig. 2-309
5.
Install the 4 planetary gears and the 4 thrust

washers on the spider and install them on the
side gear, engaging the teeth.
Use a soft material mallet to set the spider in the
mounting seats of the half-housing.
Fig. 2-310
6.
Engage the second side gear on the planetary

gears, then inset the second disc pack in a reversed sequence with respect to what described
in items "2" and "3". Insert shims, if any, smearing some grease on the contact faces. Continue
inserting the spacer, then an outer lobe disc, an
inner toothed disc etc.
Fig. 2-311
7.
Align carefully the lobes of the reaction discs.
8.
Install the two differential half housings matching the marks made before the disassembly and
tighten the screws indicated to a torque of 90
Nm.
Fig. 2-312
W190
TRANSMISSION
9.
0.05-0.15
2 - 137
Check using a feeler gauge on both sides of the

differential in two points at spaced 180 that each
clutch pack has a play 0.05 to 0.15 mm (condition required for a correct operation of the L.S.D.
differential)
Prior to measuring, make sure that the planetary
and side gears are well set.
Measure the tolerance through the holes on each
one of the two half-housing.
In the event the clutch pack play is different from
the prescribed value, disassemble the differential and rebuild the clutch packs using shims of
appropriate thickness.
Value of the shims available in mm:
0.1 - 0.2 - 0.25 - 0.5.
10. Close the differential and check again the correct operation.
Fig. 2-313
Fig. 2-314
2 - 138
TRANSMISSION
3)
Reassembling drive pinion (bearing cage)
1.
Press the smaller-diameter bearing cup into the

bearing cage. Turn the bearing cage upside down
and using a press the larger-diameter bearing cup.
W190
Fig. 2-315
2.
Apply grease to the O-ring and install into the

groove at the outer diameter of the bearing cage.
Fig. 2-316
3.
Press the bearing cone into the drive pinion.
4.
Install the longer spacer into the bearing cone

with the chamfered area at the inner periphery
pointed downward, and install the shorter spacer.
Fig. 2-317
Fig. 2-318
W190
TRANSMISSION
2 - 139
5.
Insert the pinion shaft into the support, then install the bearing race on the drive pinion.
6.
Press the bearing on the drive pinion using a

normal puncher.
7.
After pressing, give a load to the bearing cone

using a hydraulic press. Measure the rotational
resistance torque 0.20 - 0.30 Nm with a spring
balancer.
The capacity of the press should be high enough
to give a load of about 9500 kg (21000 lbs).
Fig. 2-319
Fig. 2-320
Reference - Instead of giving a load using a press,

the rotational torque may be measured after installing
the companion flange temporarily; putting the washer
on it and tightening the flange nut to the specified
torque value.
8.
If the rotational resistance torque is lower than

the standard value, remove the drive pinion and
grind the shorter spacer properly.
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
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)
Installing differential case
1.
Install the bearing cup to the 2 bearing retainers.
2.
Screw in the adjust nut until it comes in contact

with the cup.
Fig. 2-327
Fig. 2-328
2 - 142
3.
TRANSMISSION
W190
Lift the reassembled differential case with a crane

and put the case in the differential body, aligning
the ring gear with the notch in the differential body.
Fig. 2-329
4.
Install the bearing retainers at the right and left

sides of the differential body to hold the differential case. Tighten the mounting bolts.
Number of bolts (at one side): 10
Fig. 2-330
5)
Installing drive pinion (bearing cage)
1.
Putting shims between the bearing cage and the

differential body, install the drive pinion (bearing
cage) to the differential body.
Fig. 2-331
2.
Tighten the bearing cage with the mounting bolts.

Number of bolts: 8 for front axle
10 for rear axle
Fig. 2-332
W190
TRANSMISSION
2 - 143
3.
Use special tool 380002499 (1) and tighten the

right and left setting ring gears to 100 - 120 Nm
(72 to 87 Ft.lbs).
4.
Carry out steps "(5) Adjusting backlash of ring

gear" and "(6) Adjusting the tooth surface contact pattern of ring gear". After that, install the
lock plate and lock the adjusting nut.
6)
Adjusting backlash of ring gear
1.
Set a dial gauge on the tooth profile outer edge

of the ring gear.
Fix the drive pinion, and turn the ring gear back
and forth to measure the backlash.
Fig. 2-333
Fig. 2-334
2.
Fig. 2-335
3.
Ring gear backlash

Standard value: 0.25 - 0.36 mm
(0.0098 - 0.0142 in)
If the backlash is too large, loosen the adjusting

nut on the plane half case, tighten the adjusting
nut on the flange half case and bring the ring
gear closer to the drive pinion.
If the backlash is too small, adjust it in the opposite procedure as above.
2 - 144
W190
TRANSMISSION
7)
Adjusting the tooth surface contact pattern of

ring gear
1.
Apply a thin coat of red lead to several ring gear

teeth and turn the ring gear back and forth with a
hand to check the tooth surface contact pattern.
Fig. 2-336
2.
3.
Adjust the tooth surface contact pattern, referring to the following steps a. to e.
After acquiring the normal tooth surface contact
pattern, check the backlash again.
Toe (small end)

Heel (big end)
Face
Frank
Fig. 2-337
a.
Normal contact pattern (Fig. 2-338)

The normal contact pattern of the tooth surface
is from the toe to the heel and its length is approx.
80% of the total tooth length.
Note - The following adjustment items (b. to e.) show

the procedures for checking the convex surface side
of the tooth. Remember that the concave surface side
has opposite contact conditions.
Ring gear
Fig. 2-338
b.
Adjusting contact condition at toe (Fig. 2-339)

Loosen the adjusting nuts on the flange half case,
tighten the adjusting nuts on the plane half case
and shift the ring gear away from the drive pinion. Then, reduce the shim thickness of the bearing cage and bring the drive pinion closer to the
ring gear.
Ring gear
Drive pinion
Fig. 2-339
W190
TRANSMISSION
c.
2 - 145
Adjusting contact condition at heel (Fig. 2340)

Loosen the adjusting nuts on the plane half case
side, tighten the adjusting nuts on the flange half
case, bring the ring gear closer to the drive pinion. Then, increase the shim thickness of the
bearing cage and shift the drive pinion away from
the drive gear.
Ring gear
Drive pinion
Fig. 2-340
d.
Adjusting contact condition at face (Fig. 2-341)

Reduce the shim thickness of the bearing cage
and bring the drive pinion closer to the ring gear.
Then, loosen the adjusting nuts on the flange half
case, tighten the adjusting nuts on the plane half
case and shift the ring gear away from the drive
pinion.
Ring gear
Drive pinion
Fig. 2-341
e.
Adjusting contact condition at frank

(Fig. 2-342)
Increase the shim thickness of the bearing cage
and shift the drive pinion away from the ring gear.
Then, loosen the adjusting nuts on the plane half
case, tighten the adjusting nuts on the flange half
case and bring the ring gear closer to the drive
pinion.
Ring gear
Drive pinion
Fig. 2-342
8)
Installing brake unit
1.
Install O-rings at the 2 grooves at the outer diameter of the brake piston. After that, apply
grease.
Fig. 2-343
2 - 146
2.
W190
TRANSMISSION
Press the piston into the differential body, using

three screws (3) and adapter (2) previously removed (see illustration on the right).
3
W190-2R005
Fig. 2-344
3.
Install the spring (1), adapter (2) and bolt (3) of

the piston return mechanism onto the differential
body passing through each of the piston holes.
Then loosen the screws with the relevant adapter
used to press the piston into the differential body
and insert spring (1). Retighten the screws.
Fig. 2-345
4.
Install the snap ring, disk hub and snap ring onto
the sun gear and shaft.
Note Direct the stepped area of the disk hub upward.
Fig. 2-346
5.
6.
Install the sun gear and shaft which has the disk
hub, onto the side gear splines installed in the
differential case.
Install the 2 lock pins into the lower part of the
differential body. Install the brake ring aligning
them.
Fig. 2-347
W190
TRANSMISSION
2 - 147
7.
Install the brake disk onto the disk hub splines,

and then install the brake ring.
8.
Install the second brake disk, aligning with the

first disk.
Then, install the brake ring and end plate in this
order.
Fig. 2-348
9.
Fig. 2-349
10. Install the other 6 lock pins using a soft mallet.
11. Install the brake unit at the opposite side, using
Fig. 2-350
9)
Reassembling axle tube
1.
If the ring gear was replaced with a new one,

press the ring gear onto the axle tube using a
press or soft mallet and secure with 4 pins.
Fig. 2-351
2 - 148
2.
W190
TRANSMISSION
Turn the tube upside down, press the bearing cup

from the wheel side and install the bearing cone.
Fig. 2-352
3.
Then press the oil seal and apply grease to the

lip.
Note Install the inner sleeve to the oil seal.
Fig. 2-353
4.
Turn the tube upside down and lift it by the differential side with a crane. Lower it onto the standing axle shaft.
Fig. 2-354
5.
Place the tool (item 1 Fig. 2-354) on the axle shaft

and press the oil seal and the wheel bearing on
the shaft.
Fig. 2-355
W190
TRANSMISSION
2 - 149
6.
Install the bearing (cup and cone) onto the axle

tube.
7.
Use a normal puncher to install the bearing between the shaft and the differential body.
Fig. 2-356
W190-2R006
Fig. 2-357
10) Adjusting the preload of axle shaft bearing
(shim adjustment)
1.
Install the planet carrier without gear on the axle

shaft splines.
2.
Put the retainer plate in the planet carrier.

Turning the axle tube, tighten the retainer plate
mounting bolt to the torque of 50 Nm.
Fig. 2-358
Fig. 2-359
2 - 150
3.
W190
TRANSMISSION
Loosen the retainer plate mounting bolt and remove the retainer plate. Measure the difference
in height (Y in Fig. 2-361) between the axle shaft
end surface and the planet carrier.
Fig. 2-360
4.
Select a shim which is 0.03 to 0.10 mm (0.0012

to 0.0039 in) thicker than the height difference
(Y).
(Y)
Note - The measurement position of the height difference (Y) is shown in Fig. 2-361.
Fig. 2-361
5.
Install the selected shim on the axle shaft and

the retainer plate in this order. Tighten the bolt.
Fig. 2-362
6.
7.
Hook a spring balancer on the knock pin of the

axle tube, and measure the bearing's rotational
resistance torque by pulling it along the fitting
pitch circle.
If the measurement is not within the range 2 to 4
kg (4.4 to 8.8 lbs), readjust the shim. If the value
is smaller, reduce the shim thickness, and if it is
larger, increase the shim thickness.
Fig. 2-363
W190
TRANSMISSION
8.
2 - 151
After the shim thickness is determined, loosen

the bolt securing the retainer plate and remove
the planet carrier which was temporarily installed.
Fig. 2-364
11) Reassembling and installing final reduction
gear assembly
1.
Install the needle bearing on the planet gear. Needle rollers are arranged in two rows with (1) spacer
at the center. Apply grease properly to prevent
the rollers from dropping off.
Number of needle rollers: 50
2.
Install the 2 thrust washers in the planet carrier.
Fig. 2-365
Note - Set the washer's torque in the groove of the

carrier.
Fig. 2-366
3.
Insert the planet gear between the thrust washers.
Fig. 2-367
2 - 152
4.
TRANSMISSION
W190
Install the lock ball on the planet shaft and press

the planet shaft into the planet carrier.
Fig. 2-368
5.
Install the snap ring in the groove of the carrier to

lock the shaft.
Fig. 2-369
6.
7.
Put the retainer plate into the planet carrier.

Reassemble the other 2 planet gears and install
them in the planet carrier, using the same procedure as above.
Fig. 2-370
8.
Put the selected shim on the axle shaft and install the reassembled planet carrier on the shaft.
Fig. 2-371
W190
TRANSMISSION
2 - 153
9.
Apply LOCTITE 262 to the threaded area of the

retainer plate mounting bolt and tighten the bolt
to 1110 Nm torque to secure the planet carrier.
Fig. 2-374 shows the planet carrier being installed
with the nut runner.
10. Reassemble the other axle tube, using the same
procedure as above. Refer to the (8) to (9).
Fig. 2-372
12) Installing axle tube
1.
Apply LOCTITE 509 to the differential body surface which will mate with the axle tube.
Make sure that the beads of LOCTITE are applied, without a break, on the differential body
surface inside row of the bolt holes.
The bead width is 2 to 3 mm (0.08 to 0.12 in)
each.
2.
Lift axle tube horizontally and install it onto the

differential body, aligning with the sun gear and
mounting bolt holes. Apply LOCTITE 262 to the
threaded area of mounting bolts and tighten them.
Number of bolts: 20
Install the axle tube at the opposite side, using
Fig. 2-373
3.
Fig. 2-374
4.
Apply LOCTITE 509 to the cover mounting area

of the differential body. Make sure that the beads
of LOCTITE are applied, without a break, on the
body surface inside row of the bolt holes.
Fig. 2-375
2 - 154
5.
TRANSMISSION
W190
Fill the differential with gear oil before mounting

the cover.
Oil capacity
Unit: l (US/gal)
Axle (front):
31 (8.2)
Axle (rear):
31 (8.2)
Fig. 2-376
6.
Install the differential body cover and tighten the

securing screws to 100 Nm.
Q.ty of screws: 28
Fig. 2-377
W190
TRANSMISSION
2 - 155
2.10.7 INSTALLATION AND INSPECTION OF THE PINION BEARINGS PRE-LOAD

1. Measure the dimension between the inner and outer
race of the bearing.
a. Zero caliper A 380002600 after positioning over
measuring plane.
b. After positioning the bearing on the measuring table
as indicated in the figure, measure with caliper
A 380002600 dimension X of the pinion bearing
dimension after placing the outer race flat and
turning the bearing. Record dimension X.
W190-2R007
2. Measure the dimension between spacer and

bearing seat.
a. Insert the pinion head bearing on the pinion using
press.
b. Insert the outer race on the pinion support.
c. Install the outer support complete with pinion
bearing race, install the long spacer and turn to
settle the rollers (ten turns with a weigh equal to
10 kg).
d. Install temporary calibrated spacer (d) (d=13 mm)
and measure with caliper A 380002600 (after
zeroing it) dimension Y between spacer and bearing
seat (contact on pinion tail bearing support).
W190-2R008
3. Determine final spacer L to be installed, being

equal to calibrated spacer D minus dimension Y
measured plus dimension X measured at point 1b
plus theoretical bearing play Z (Z=2,20 mm);
thus L= (d-Y) + X + Z
example: x=2,60
y=2,83
L= (13-2,83)+2,60+0,20 L=10,17+2,60+0,20
L=12,97 spacer to be installed
4. Install the spacer measured at point (3), install the

bearing and turn the pinion support (4/5 turns) under
load. Install flange B without seal, install nut C
and tighten to torque: 67 da Nm.
5. Check that the rolling torque must be included

within 0,20-0,30 da Nm.
If required, repeat the operations of point (3)
increasing or decreasing the value of spacer L to
be installed.
W190-2R009
2 - 156
TRANSMISSION
W190
2.10.8 CORRECT MOUNTING POSITION OF THE PINION

1. Install the pinion assembly on the axle body and
secure it with four screws tightened to the
prescribed torque.
2. Install the calibrated tool on the body.
3. Define shims s to be installed between the axle
body and the pinion support:
- S = X dimension stamped on the pinion;
- dimension stamped on the pinion = 136,725
dimension obtained by supplier.
Example:
- dimension stamped on the pinion 152,7mm;
- Q = 153 - 152,7 = 0,3mm;
- X = 0,95mm (dimesnion measured with digital dial
gauge);
- S = 0,95 0,3 = 0,65mm shims to be installed.
W190-2R010
W190
2 - 157
TRANSMISSION
2.11 WHEELS/TYRES
Wheels
Tyres
The wheel is composed of rim and disc.

The wheel disc is bolted to the axle shaft. The tyre is
mounted on the rim forming a single body with it. Consequently, it is of the utmost importance that the correct rim is used, based upon the type of tyre to be
mounted. The use os a inappropriate rim could shorten
the life of the tyre and, in the worst cases, cause
serious accidents.
Also, the dimensions of the rim is provided in inches.
The first number indicates the width of the rim and
the second indicates the diameter.
In a standard configuration, the loader is equipped

with radial type tyres with tread type L3, having high
traction characteristics. It is recommended that the
most appropriate tyres are selected, since a large
variety of types is available, based upon the type of
operation and working requirements.
Example:
23.5
R
25
XHA
TL
=
=
=
=
=
23.5 R 25 XHA TL
Width of the tyre (~ 600 mm)
Radial
Diameter of rim (~ 635 mm)
Type of tread
Tubeless
Fig. 2-378
Rim for mod. W190 - Q.ty 5 pieces

Fig. 2-379
Thread of XHA tyre
Wheel securing screws tightening torque 788 nm

TYRE NORMAL INFLATING PRESSURE
WORK bar (psi)
TYRE
TRAVEL bar (psi)
FRONT
REAR
FRONT
REAR
Good Year
3.75 (54.3)
2.50 (36.2)
2.75 (39.8)
2.75 (39.8)
23.5 R25 XHA
Michelin
3.00 (43.5)
2.00 (29)
2.00 (29)
2.00 (29)
23.5 R25 XRD 1A
Michelin
3.25 (47)
2.00 (29)
2.00 (29)
2.00 (29)
23.5 R25 XLD-D2
Michelin
3.00 (43.5)
2.00 (29)
2.00 (29)
3.00 (43.5)
650/65 R25
Michelin
3.00 (43.5)
2.00 (29)
2.00 (29)
2.00 (29)
23.5 R25 XRD 1A
Michelin
3.25 (47)
2.00 (29)
2.00 (29)
2.00 (29)
23.5 R25 MINE D2

YELLOW COLOR
Michelin
3.25 (47)
2.00 (29)
2.00 (29)
2.00 (29)
23.5 R25 RL 5K (*)
Good Year
3.75 (54.3)
2.50 (36.2)
23.5 R25 RT 3B
Good Year
3.75 (54.3)
2.50 (36.2)
2.75 (39.8)
2.75 (39.8)
23.5 R25 RT 5C L5
Good Year
3.75 (54.3)
2.50 (36.2)
2.50 (36.2)
2.50 (36.2)
23.5 R25 GP 4B
Good Year
3.75 (54.3)
2.50 (36.2)
2.72 (34.9)
2.75 (39.8)
23.5 R25 20PR L3
Galaxy
2.50 (36.2)
2.25 (32.6)
23.5 R25 16PR L3
Alliance
2.50 (36.2)
1.50 (21.7)
23.5 R25 GP-2B
(*) It is suggested to load the machine on a trailer for road transit.

2 - 158
W190
TRANSMISSION
2.12 TROUBLESHOOTING
Trouble
Problem Cause
Noisy differential.
Remedy
Gear worn, damaged or broken.
Replace.
Excessive backlash of each gear.
Adjust or replace.
Bearing worn, damaged or broken.
Replace bearing.
Loose engagement of side gear and shaft splines.
Replace.
Loose bolts.
Retighten.
Low gear oil.
Add oil to specified level.
Gear (final reduction gear) worn, damaged or broken. Replace.
Noisy axle tube.
Oil leakage from

differential
Oil leakage from

axle shaft.
Excessive backlash of each gear.
Replace.
Bearing worn, damaged or broken.
Replace bearing.
Loose planet carrier holding bolt (retainer plate

mounting bolt).
Retighten (Adjust shims).
Improper preload of axle shaft bearing.
Adjust shims.
Low gear oil.
Add oil to specified level.
Broken liquid packing of differential cover.
Apply liquid packing.
Broken liquid packing of axle tube.
Apply liquid packing.
Worn or damaged O-ring of bearing cage.
Replace O-ring.
Oil seal worn or damaged.
Replace oil seal.
Loose bolt.
Retighten.
Oil seal worn or damaged.
Replace oil seal.
Oil seal installed improperly.
Repair or replace.
W190
2 - 159
TRANSMISSION
Trouble
Problem Cause
Remedy
Brake piston seal (O-ring) deteriorated or damaged.

Brake disk or brake ring worn or damaged.
Poor braking.
Overhaul and replace.
Brake piston rusted.

Foreign matter caught on brake disk.
Loose or damaged bleeder screw of disk brake.
Erratic braking.
Brake disk or brake ring run-out or worn unevenly.
Retighten or replace.
Wornparallel pin of disk brake.

Dragging brake.
Rusted brake piston.
Brake disk and brake ring seized.
2 - 160
W190
TRANSMISSION
2.13 VALUES OF REFERENCE FOR THE MAINTENANCE

Values in mm
Item
Thickness of bearing cage
Inner diameter of differential
pinion gear
Standard dimension
Allowable
limit
0.1 - 0.2 - 0.3
35.05 through 35.13

Tolerance
0.2
Diameter of differential spider pin

Thickness of differential pinion gear
thrust washer
Remarks
1.562 through 1.613
1.41
Thickness of differential side gear

thrust washer
2.31 through 2.36
2.24
Backlash between bevel pinion/crown gear teeth
0.25 through 0.36
Set by nut
Turning resistance torque of bevel pinion Nm
0.20 through 0.30
Set by spacer
Outer diameter of mating flange in the oil seal

rotation area
89.913 through 90.000
89.863
Turning resistance torque of axle shaft bearing

bearing (pitch line housing securing screws)
Nm
from 2.0 through 4.0
Value of shaft shims
0.1 - 0.2 - 0.25 - 0.5
Setting shims
W190
2 - 161
TRANSMISSION
Values in mm
Item
Standard Size
Useful limit
Brake disk thickness
5.9 to 6.5 mm
(0.232 to 0.256 inch)
5.58 mm
(0.220 inch)
Brake ring thickness
4.9 to 5.1 mm
(0.193 to 0.201 inch)
4.5 mm
(0.177 inch)
Free height
33 mm (1.30 inch)
31.7 mm
(1.25 inch)
Settings load
kg (lbs)
20.8 kg (45.9 lbs)
18.8 kg (41.4 lbs)
20.0 mm (0.787 inch)
Brake piston riturn spring
Setting
height
Remarks
2.13.1 TIGHTENING TORQUE VALUES FOR MAIN BOLTS

Item
Tightening torque
Nm (lbs.ft)
Remarks
Ring gear mounting bolt
230 (170)
Apply LOCTITE 262
Differential case mounting bolt
150 (110)
Apply LOCTITE 262
90 (66)
Apply LOCTITE 262
Bearing cage mounting bolt
230 (170)
Apply LOCTITE 262
Flange nut
670 (494)
Apply LOCTITE 262
50 (37)
Apply LOCTITE 262
Planet carrier holding bolt

(Retainer plate mounting bolt)
1110 (818)
Apply LOCTITE 262
Axle tube mounting bolt
230 (170)
Apply LOCTITE 262
Differential bearing retainer mounting bolt
Brake piston return spring mounting bolt
Differential cover mounting bolt
50 (37)
2 - 162
TRANSMISSION
2.14 LIST OF OVERHAUL SPECIAL TOOLS

TOOL NUMBER
DESIGNATION
380001274
Control valve screws (M10) adjusting tool
380001275
380001276
380001277
380001280
Clutch pack spring removal and assembly tool
380001281
Transmission overhaul rotary stand
380001288
Shaft bearing puller
W190
W190
TRANSMISSION
2 - 163
TOOLING
TOOL NUMBER
DESIGNATION
380001291
Shaft bearing puller
380001295
Control valve tightening screw wrench (TX27)
380001296
Control valve tightening screw wrench (TX40)
380001292
Primary shaft bearing mounting tool
380001269
Bearing half-ring holder tool
380001283
Bracket supporting the transmission on rotary stand to be used with

380001281
380001271
Primary shaft bearing mounting tool To be used with 380001278
2 - 164
TRANSMISSION
TOOLING
TOOL NUMBER
DESIGNATION
380001272
Bearing mounting tool on transmission housing
380001273
Bearing mounting tool on transmission housing
380001290
Adapter for bearing pulling
380001294
380001289
380001293
380001278
Handle for mounting tool
W190
W190
TRANSMISSION
2 - 165
TOOLING
TOOL NUMBER
DESIGNATION
380001279
Mounting tool for primary shaft oil seal To be used with 380001278
380001270
Bearing puller bridge
380001284
Hydraulic pipe rolling tool
380001285
380001286
380001287
380000818
AEB Starter
2 - 166
TRANSMISSION
TOOLING
TOOL NUMBER
DESIGNATION
380001217
Pag 2-161DPA 04 Testman kit assembly composed of:

380001224, 380001225, 380001226, 380001227
380001219
Diagnostic software English
380001221
Diagnostic software German
380001222
Diagnostic software French
380001224
DPA 04 interface
380001226
Testman basic software
380001225
Cable RS 232 connecting Sartor and DPA-04 interface
W190
W190
TRANSMISSION
TOOLING
TOOL NUMBER
DESIGNATION
380001227
Connecting cable DPA-04 Interface to transmission
380001297
Display assembly
380002499
Differential ring nut removal tool
380002600
Caliper inspection of the pinion bearings pre-load
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.
Engine diagnosis cable

Cable from multibrand interface
to ZF AEB starter.
Grader diagnosis cable
Cable motor
BB3 diagnosis cable
Special keyboard
I/O Stick
Excavator connecting cable
3,5 FDD
Printer
Printer cable
1850-2R520
W190
TRANSMISSION
380001594 PFT-8 HYDRAUIC TEST KIT
1850-2R521
A.
B.
C.
D.
D.
E.
F.
750L/M Flow block

700 bar pressure sensors
Temperature sensors 150 C
Sensor cables
Cable temperature sensors
Suitcase
Module PFT-8
2 - 169
2 - 170
W190
TRANSMISSION
380060209 CE - EST KIT COMPLETE KEYBOARD version
380060165 CE - EST KIT COMPLETE TABLET version
KIT Hydraulic PFT-8

380001594
CE - EST KIT DIAGNOSTIC

380060209
KIT Hydraulic PFT-8

380001594

380060165
W190-2R003
W190 EVOLUTION
BRAKE SYSTEM
3-1
SECTION 3
BRAKE SYSTEM
INDEX
PARAGRAPH
SUBJECT
3.1
3.2
3.2.1
3.2.2
OPERATION ........................................................................................................... 3-3

Generalities ............................................................................................................. 3-3
Operating conditions ............................................................................................... 3-3
3.3
3.3.1
DISC BRAKE .......................................................................................................... 3-5

Operation ................................................................................................................ 3-5
3.4
BRAKE PEDAL VALVE ........................................................................................... 3-6
3.5
BRAKES/POWER SYSTEM PUMP ....................................................................... 3-7
3.6
3.6.1
3.6.2
PARKING BRAKE CONTROL ................................................................................. 3-8

Checking the wear of the parking brake ................................................................... 3-9
Setting the parking brake ........................................................................................ 3-9
3.7
3.7.1
3.7.2
3.7.3
PARKING BRAKE ..................................................................................................

Releasing the parking brake ....................................................................................
Operation of the disc parking brake .........................................................................
Brake disengagement .............................................................................................
3.8
3.8.1
OTHER COMPONENTS ......................................................................................... 3-12

Service brakes accumulator .................................................................................... 3-12
3.9
BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS .......................................... 3-13
3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
3.10.6
DIAGNOSTICS AND TESTING ..............................................................................

Brake control pressure testing .................................................................................
Minimum and maximum accumulator recharge pressure adjustment .......................
Accumulator pre-charge test ...................................................................................
Instructions for the restoration of the service brakes accumulators pre-charge .......
Bleeding the brake system ......................................................................................
Brake disc wear check ............................................................................................
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 braking system includes:
The parking brake circuit is composed of:
- a two stage gear type powering pump (8) flanged on

the torque converter cover;
- solenoid valve (14) controlling the engagement and

disengagement of parking brake (6);
- filter (7) on the pump delivery;
- the parking brake group (6) is composed of a few

springs and a reaction hydraulic cylinder. The
springs provide the force locking the discs of the
parking brake when, through the solenoid valve,
pressurised oil in the cylinder is discharged. The
hydraulic cylinder, when activated by pressurised
oil, (by the solenoid valve) neutralises the action of
the springs, thus disengaging the brake;
- brake pedal valve (15) controlling simultaneously

front (1) and rear (9) brakes located inside the axles;
- two accumulators (4 and 13) that during normal
operation stabilise the pressure in the circuit and, in
case of emergency, with engine inoperative, allow
the actuation of the brakes for a certain number of
times;
- accumulator (11) installed on the parking brake power

line, during normal operation stabilises the pressure
in the circuit and, with engine inoperative, allows the
disengagement of the parking brake, a few times.
- the oil used by the circuit is the same of the equipment hydraulic system and it is taken from hydraulic tank (S).
4
R
13
R1
R2
15
T2
TO STEERING/EQUIPMENT
CIRCUIT
TO PILOTED SYSTEM CIRCUIT
M
T1
14
N
11
8
6
S
Fig. 3-1
3-2
BRAKE SYSTEM
W190
2
16
15
14
5
6
13
12
M
7
8
S
11
17
10
Fig. 3-2 Brake system

S. Tank - M. Pilot system circuit - 1. Front brakes - 2. Stop light pressure switch - 3. Accumulators control pressure switch 4 and 13. Brake system accumulators - 5 and 12. Quick release pressure pick-ups - 6. Parking brake - 7. Oil delivery filter 8. Brake oil pump - 9. Rear brakes - 10. Parking brake pressure switch - 11. Parking brake accumulator - 14. Parking brake
control solenoid switch - 15. Brake pedal valve - 16. Transmission cut-off pressure switch - 17. Quick release pressure
pick-up point.

BRAKE SYSTEM
W190
3-3
3.2 OPERATION
3.2.1 GENERALITIES
3.2.2 OPERATING CONDITIONS
Brake system
Conditions of:
The brake system is powered by pump (8) sucking oil

from oil tank (S) and forwards it to flow regulation valve
(18), filtered by filter (7).
Two hydraulic accumulators (4 and 13) and two check
valves provide the accumulation of a quantity of oil
under pressure sufficient to actuate the brakes a limited amount of times, even with the engine inoperative, thus when the flow of pump (8) is nil.
Parking brake
Parking brake (6) is composed of a disc brake operating on the output shaft of the transmission.
The equipment receives oil under pressure from the
regulation valve.
Pressure switch (10) closes the "parking brake engaged" signal electric circuit when the pressure drops
below the value of 15 bar, with the consequent engagement of the parking brake.
Service brakes
Of an oil-bath, disc type, they are located inside the
final drives of the axles (1 and 9). When pressing the
brake pedal, valve (15) supplies the braking circuit
with a controlling pressure (thus a braking force) proportional to the stroke of the brake pedal (Pf Max =
45 bar).
When releasing the pedal, valve (15) discharges the
brake circuit oil zeroing the braking action on discs
(1 and 9).
During the braking phase pressure switch (2) activates
the electric circuit of the stoplights. Pressure switch
(16) controls the transmission cut-off device.
13
12
5
R1
R2
15
22
engine running
service brakes disengaged
parking brake engaged
accumulators during recharging phase
19
The delivery of pump (8) reaches flow regulation valve

(18). The oil flow opens and passes main check valve
(19) then opens and passes check valves (22 and 23)
charging the accumulators of service brakes (4 and
14) and parking brake accumulator (11).
Controlling spools (20 and 21) when brake pedal (P)
is released, block the flow of the oil coming from the
pump and keep the brake disc actuating pistons
(1 and 9) in discharge. Thus the service brakes are
disengaged.
Solenoid valve (14) controlling parking brake (6) is
positioned so that the oil flowing from the parking brake
chamber is discharged thus parking brake (6) is actuated by the action of the springs.
21
18
T2
16
T1
20
2
7
23
14
N
Conditions of:
-
10
engine running
service brakes engaged
parking brake disengaged
accumulators charged.
This condition occurs when braking while the machine

is operating.
The parking brake is disengaged since solenoid valve
(14) forwarding oil under pressure to the brake piston
neutralises the action of the springs.
Brake pedal (P), when pressed, presses the springs
actuating controlling spools (20 and 21) determining
the opening of the delivery gaps to the brakes (1 and
9).
In the lower part of controlling spool (21) the barking
pressure starts operating, pushing the disc pack of
brakes (1 and 9). In this manner, while the pressure
on the discs increases, controlling spools (20 and 21)
are pushed upward and close the delivery gaps. In
this manner a pressure is obtained on brake discs
(1 and 9) thus a braking force proportional to the pressure on pedal (P).
The presence of two accumulators (4 and 13) and two
controlling spools (20 and 21) allow the operation of
two separate circuits for the front and rear brakes.
The failure of one circuit does not influence the operation of the other one.
17
V = 0,71
Po = 19 bar
11
TO ENGINE
HYDRAULIC FAN
V = 1,41
Po = 70 bar
T
30 bar
PV
Fig. 3-3 Brakes hydraulic system circuit

Steering/Equipment
Q=162 l/min
Brakes/Pilot valves
Q=32 l/min
8
63 cc/rev.
13 cc/rev.
P. Brakes pedal - S. Tank - M. Pilot system circuit - 1. Front

brakes - 2. Stop light pressure switch - 3. Accumulators
control pressure switch - 4. and 13. Brake system accumulators - 5. and 12. Quick release pressure pick-ups 6. Parking brake - 7. Oil delivery filter - 8. Brake oil pump 9. Rear brakes - 10. Parking brake pressure switch 11. Parking brake accumulator - 14. Parking brake control solenoid switch - 15. Brake pedal valve - 16. Transmission cut-off pressure switch - 17. Quick release pressure pick-up point - 18. Flow regulation valve - 19. Main
check valve - 20. Front axle brakes control spool 21. Rear brake control spool - 22. and 23. Check valves.
3-4
BRAKE SYSTEM
W190
W190
BRAKE SYSTEM
3-5
3.3 DISC BRAKE

The disc brake is composed of two oil-bath, discs
and it is mounted inside the axle housing. On this
loader, four brake groups are mounted in the axles,
one on each axle shaft.
The structure of the disc brake is described in the
TRANSMISSION section.
The inner circumference of the discs is splined

and it is keyed to the axle shaft. The outer circumferences of the pressure plate and reaction plate
are secured to the axle housing by dowels, so that,
the locking of the brake discs causes the stopping of the axle, thus braking.
2) Releasing the brakes

When oil pressure is relieved from the brake piston, this moves slightly rearwards to release the
brake disc and the the braking action stops.
3.3.1 OPERATION
1) Actuation of the brake
The pressure of the brake oil acts on the rear face
of the brake piston and locks the brake discs between the disc pressure plate and the reaction plate.
8
Brake
pressure oil
11
9
10
3
2
1
12
13
14
Fig. 3-4 Operation of disc brake

1. Axle shaft - 2. Planetary carrier - 3. Solar shaft - 4. Disc hub - 5. Reaction plate - 6. Pin - 7. Disc brake - 8. Disc pressure
plate - 9. Piston - 10 and 11. Sealing ring - 12. Spring - 13. Piston guide - 14. Screw.
3-6
BRAKE SYSTEM
W190
3.4 BRAKE PEDAL VALVE
max 19
To dump
To other users
or dump
T1
Rear brake feed
port (45 bar)
T2
Front brake feed port
(45 bar)
Accumulator pressure
adjustment
Fig. 3-5 Brake pedal valve
Angle adjustment with pedal

released 40 to 60
Min. angle from released position
to start sending pressure oil to
the brakes
Max working angle 16
Pedal angle adjust

screw
Backlash
take-up screw
Brake oil delivery

spools
Brake feed ports

Brake pressure adjustment stop
screw = Pf Max.
Fig. 3-6 Section view of oil delivery spools to users
W190
BRAKE SYSTEM
3-7
3.5 BRAKES/POWER SYSTEM PUMP

The brakes circuit is powered by the hydraulic oil delivered by the pump keyed on the transmission housing, together with the steering pump. The same pump
powers the power system.
BRAKES PUMP (AND POWER SYSTEM)

Designation: ........................................................................................................... Kajaba KP1013ABGH
Type: ........................................................................................................................................ Gear type
Drive: .............................................................................................................. mounted on steering pump
Delivery ............................................................................................................ 32 lt/min (7.03 USG/min.)
Maximum pressure: ..................................................................................................... 170 bar (2465 psi)
10
Item "C"
13
12
11
Fig. 3-7 Brakes/power steering pump sections
1. Driven gear - 2. Mounting flange - 3. Gear plate - 4. Centering dowel - 5. Closing plate - 6. Oil seal - 7. Driving gear 8. Side plate - 9. Side plate - 10. O-Ring - 11. Sealing device - 12. Gasket B - 13. Gasket A
3-8
BRAKE SYSTEM
W190
3.6 PARKING BRAKE CONTROL

WARNING
To prevent possible damages to mechanical
components, do not engage the parking brake
while the machine is moving.
The parking brake (button B) operates on the
transmission output shaft blocking the machine when
parking.
Every time the machine is parked, move the gearshift
lever into neutral and engage the parking brake.
Brake engaged
= ON
Brake disengaged = OFF
W190-3R001
Fig. 3-8
ON
OFF
Note When the engine is cut-off the parking brake is

automatically engaged.
If during a stoppage the engine has been cut-off and

the switch was left in position "OFF", it is necessary
to move the switch into position "ON" first and then into
"OFF" to re-start the machine.
P
Fig. 3-9
Hazard light switch

In the event of a failure or a forced stoppage, actuate
hazard light switch "C" as well as the parking brake.
W190
BRAKE SYSTEM
3-9
3.6.1 CHECKING THE WEAR OF THE

PARKING BRAKE
Check that the minimum thickness of the friction
material is not less than 2 mm (0.07 in) for each braking
element F.
If not, replace the braking elements following this
procedure:
1. Block the wheels of the loader with wedges;
2. After cleaning the surrounding area, remove piping
T;
3. Remove cover C and unlock locknut D;
4. Turn screw E anticlockwise until pressure
cylinder P is fully retracted. Under this condition,
the brakes can be replaced;
5. Install the oil piping previously disconnected and
apply the pressure required to pre-charge spring
M (about 85 bar - 1232 psi);
6. Turn screw E clockwise until the braking
elements touch disc G then unscrew screw E
4/5 turn. Under this condition, the play between
disc and braking elements is 2 mm (0.07 in).
7. Tighten locknut D holding screw E in its position.
8. Reinstall cover C tightening manually with a
filter wrench as much as possible;
9. If required, bleed the air through valve S.
B
T
Fig. 3-10
P
S
M
3.6.2 SETTING THE PARKING BRAKE

To set the parking brake, follow points 1 through 3 and
6 through 8 of the procedure described here above.
F
G
Fig. 3-11
3 - 10
BRAKE SYSTEM
W190
3.7 PARKING BRAKE

Parking brake manual disengagement (in case of
emergency).
B
WARNING
Disengage the parking brake manually only if it is

absolutely necessary. Namely, this should be done
only when towing a failed loader to traffic-free areas. If the loader is on an incline, check that the
wheels are securely blocked with wedges or
stones prior to releasing the parking brake.
Fig. 3-12
3.7.1 RELEASING THE PARKING BRAKE

P
F
G
Fig. 3-13
D C
E
Parking brake "A" operates on disc "B" keyed on the

transmission output shaft.
In the event the engine fails to start or the hydraulic
pumps fail, or other troubles occur blocking the machine,
proceed as follows:
Block the wheels of the loader with wedges.
After cleaning the surrounding area, loosen cover
"C".
Unlock locknut "D" and loosen setting screw "E"
anticlockwise, until the brake is released.
Reinstall nut "D" and cover "C" tightening manually
as far as possible with a filter tool.
The parking brake is of an oil-bath, multiple disc type
and it is mounted on the intermediate shaft of the
transmission.
The brake is actuated by a series of inner springs and
it is disengaged by the oil pressure controlled by the
parking brake valve.
Its structure is described in the section 2 TORQUE
CONVERTER - TRANSMISSION.
Fig. 3-14
W190
BRAKE SYSTEM
3 - 11
3.7.2 OPERATION OF THE DISC PARKING

BRAKE
When the oil under pressure actuating brake piston
(1) is discharged, this is pushed by the force of spring
(2) closing the brake rotary discs against transmission output disc (4).
5
4
Fig. 3-15
Parking brake
1. Brake piston - 2. Springs - 3. Support plate - 4. Transmission output shaft disc - 5. Brake discs.
3.7.3 BRAKE DISENGAGEMENT

1. When pressure oil is sent to the rear surface of
the brake piston, this overcomes the spring action
and moves.
2. A clearance is established between each brake
disc and fixed plate, the brake discs are released
and the brake is disengaged.
3 - 12
BRAKE SYSTEM
W190
3.8 OTHER COMPONENTS

3.8.1 SERVICE BRAKES ACCUMULATOR
The membrane accumulator is used to store pressure oil to release the parking brake.
Oil from the charge pump is diverted by the check
valve to the accumulator which maintains the pressure at a certain value.
CAPACITY ...................................................................... 1.4 l (0.36 gal)

MAX. WORKING PRESSURE FOR
ACCUMULATOR .................................................... 210 bar (3045 psi)
Fig. 3-16
GAS TO BE USED ............................................................ NITROGEN

GAS PRE-CHARGE PRESSURE .............................. 45 bar (652 psi)
WEIGHT ............................................................. 5.4 kg abt (11.90 lbs)
Accumulator
1. Gas filling plug - 2. Accumulator body - 3. Oil inlet connection.
W190
BRAKE SYSTEM
3 - 13
3.9 BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS
max 19
N
M
T1
F
R2
R1
T2
R3
TI2
P
T1
R1
R2
B
T2
TI1
X
Fig. 3-17
Brake pedal valve hydraulic connections
F. Accumulator control pressure switch - M. Other users or to dump - N. Dump - P. Inlet - R1-2. Accumulator - T1-2. To the
brakes - TI1-2. Brake control pressure switch.
3 - 14
BRAKE SYSTEM
W190
3.10 DIAGNOSTICS AND TESTING

3.10.1 BRAKE CONTROL PRESSURE TESTING
Connect two pressure gauges (end of scale 100 bar
(1450 psi)) to the pressure ports shown in Fig. 3-18.
Release the lock-nut (E, Fig. 3-18) and turn the screw
in or out if pressure values are not within the rated
range.
Apply the parking brake.

Start machine engine and wait until it settles to maximum torque speed.
Such a pressure must be measured after a pedal stroke

of about 70 mm (2.79 in).
Seal the screw after adjustment.
With the engine idling, press the brake pedal and check
that pressure reading on the gauges is approximately
45 bar (652 psi).
Rear axle
pressure port
Front axle
pressure port
Fig. 3-18
Braking pressure adjustment
W190
BRAKE SYSTEM
3 - 15
3.10.2 MINIMUM AND MAXIMUM ACCUMULATOR RECHARGE PRESSURE ADJUSTMENT

Connect two pressure gauges (end of scale 200 bar
(2900 psi)) to the quick coupling pressure ports
(7 and 8, Fig. 3-19) on the accumulators.
Start machine engine and bring oil temperature to
approximately 40 to 50 C (104 to 122 F) by means
of the attachment control lever. Cycle the brake pedal
several times to make oil temperature even.
different from the rated value, remove the plug (1),

release the lock-nut (5) and turn the screw (4) with
micrometric variations until obtaining correct value.
Check pressure again before tightening the lock-nut
(5).
Maximum recharge value
With the engine idling and the parking brake applied,
observe maximum recharge pressure on pressure
gauges M1 and M2.
Pressure should be 130 5 bar (188 72 psi).
If maximum recharge pressure is different from the
rated value, remove the plug (1), release the lock-nut
(3) and turn the screw (2) out to increase the accumulator maximum recharge pressure.
Minimum recharge value

With the engine idling and machine at a standstill,
brake slowly 4 or 5 times.
Observe minimum pressure values on pressure
gauges M1 and M2 before recharge starts.
The pressure gauges should momentarily read 80 5
bars (1160 72 psi). If minimum recharge pressure is
M1
M2
7
8
Fig. 3-19
34
Minimum and maximum accumulator recharge pressure adjustment
M1 & M2. Pressure gauges - 1. Plug - 2. Maximum pressure adjust screw - 3. Lock-nut - 4. Minimum pressure adjust screw 5. Lock-nut - 6. Accumulators - 7 & 8. Pressure ports.
3 - 16
BRAKE SYSTEM
W190
3.10.3 ACCUMULATOR PRE-CHARGE TEST

Accumulators fitted to the braking system are membrane type, pre-charged using nitrogen.
Normal minimum membrane porosity and continued
use reduce pre-charge pressure in time and limit accumulator efficiency.
It is advised to check the nitrogen pre-charge every
six months and restore it, if necessary.
Pre-charge pressure should never drop below approximately 90% of the rated value.
Check is to be carried out with the accumulators
drained of hydraulic oil. This condition is obtained as
follows:
- as regards accumulators (4 and 13, Fig. 3-3) by
pressing the brake pedal slowly several times;
- as regards the parking brake release accumulator
(11, Fig. 3-2) by operating repeatedly the diverter
valve (14) with the engine stopped.
Check the pre-charge as follows:

1. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake
circuit.
2. Close valves (B) and (C) on the nitrogen charging
kit, refer to the illustration 3-20.
3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumulator.
5. Remove the cap from the accumulator valve stem.
6. Connect valve (F) to the accumulator valve stem.
Fig. 3-20 Nitrogen charging kit 380001737
7. Make sure that valve (D) is open.

8. Turn the stem into valve (F) and read the pressure
gauge (E).
9. The pressure must result 45 bar (652.6 psi). If the
pressure is too low, charge the accumulator with
dry nitrogen.
94L95
W190
BRAKE SYSTEM
3.10.4 INSTRUCTIONS FOR THE

RESTORATION OF THE SERVICE
BRAKES ACCUMULATORS PRECHARGE
Note Check the pressure of the accumulator ion accordance with the instructions listed in "Check the accumulator
pre-load". Keep the nitrogen charging kit connected to the
accumulator.
3 - 17
1. Close (turn counterclockwise) valve (A) and open

valve (B). Close valves (C) and (D).
2. Turn the stem out of valve (F) until the stem stops
moving. Disconnect valve (F) from the accumulator valve stem.
3. Connect the nitrogen charging kit to a dry nitrogen

tank.
4. Slowly turn valve (A) clockwise and read gauge (E)
until the pressure is 45 bar (652.6 psi). Stop turning
valve (A).
5. If the pressure increases above 45 bar
(652.6 psi), quickly open and close valve (D) and
read gauge (E). If the pressure is still too high, close
valve (A) (turn counterclockwise) a small amount
and quickly open and close valve (D). The pressure shown on gauge (E) is the charge pressure.
Turn the stem into valve (F) until the stem stops
moving and open valve (D) to charge the accumulator.
7. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
8. Close valve (B) and disconnect the nitrogen charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem. Install the guard and cap screws on the accumulator.
94L95
3 - 18
BRAKE SYSTEM
W190
3.10.5 BLEEDING THE BRAKE SYSTEM

It is necessary to bleed the brake system when anyone of the conditions here below occurs:
- after replacing hydraulic oil in the attachment oil
reservoir;
- when air has entered the system because of poor
sealing of hoses or charge pump;
- after disconnecting or replacing any of the system
parts.
Bleed the system as detailed below (this is a twoman operation):

- position the machine on a level surface and start
the engine;
- with the engine idling, one operator should release
the bleed screw (two on each axle) while the other
is pressing the brake valve pedal. Tighten the bleed
screw before releasing the brake pedal;
- repeat this operation until bleeding all air from the
system (fluid should come out of the bleed screw
free of bubbles);
- repeat for the other axle.
Fig. 3-22
Brake oil bleed screw (S) locations on the axle (1 per brake)
W190
BRAKE SYSTEM
3 - 19
3.10.6 BRAKE DISC WEAR CHECK
Fig. 3-23
Brake disc wear check hole locations
Threads: LOCTITE 572
The control of the wear on the 4 brake discs (for each

axle) is carried out after draining the oil from the group.
Remove inspection plugs (A) and (B);
The brake discs are to be replaced if a thickness gauge
blade of the 5.3 mm can be made to pass through the
steel discs.
Note The check of the operation play must be performed using air pistols.
3 - 20
BRAKE SYSTEM
W190
SECTION 4
STEERING SYSTEM
INDEX
PAGE
PARAGRAPH
SUBJECT
4.1
4.1.1

Description of the steering system operation ........................................................... 4-2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
MAIN AND SECONDARY PRIORITY VALVES ......................................................

Description of operation of main priority valve .........................................................
Main priority valve diagram .....................................................................................
Steering emergency circuit ......................................................................................
Secondary priority valve ..........................................................................................
4-6
4-6
4-8
4-9
4-9
4.3
4.3.1
4.3.2
4.3.3
4.3.4
POWER STEERING ...............................................................................................

Power steering (removal) .........................................................................................
Disassembly of power steering ...............................................................................
Assembly of the power steering ..............................................................................
Disassembly of the valve block ..............................................................................
4-10
4-11
4-12
4-14
4-16
4.4
TEST OF THE STEERING SYSTEM ..................................................................... 4-17
4.5
EMERGENCY STEERING PUMP .......................................................................... 4-20
4.6
4.6.1
4.6.2
4.6.3
STEERING CYLINDERS ........................................................................................

Removal .................................................................................................................
Disassembly and reassembly .................................................................................
Installation ..............................................................................................................
4-21
4-21
4-22
4-22
W190
4-1
STEERING SYSTEM

Type: ............................................................. hydraulically controlled by orbitrol actuated by the steering wheel
Angle of articulation of the frames .............................................................................. 40 rightward and leftward
Number of turns of steering wheel: ................................................................................................................ 3.7
Setting of pressure relief valve ............................................................................................... 210 bar (3045 psi)
Setting of safety valve pressure ............................................................................................. 280 bar (4061 psi)
Steering pump: ..................................................................................................................................... gear type
Steering cylinder:
Type: ................................................................................................................ Stantuffo a doppia azione
Q.ty: ...................................................................................................................................................... 2
Cylinder stroke: ...................................................................................................................... 422 mm (16.61 in)
Weight (each): ............................................................................................................................ 31 kg (68.4 lbs)
The loader is of an articulated frame type. The steering
force is applied between the front and rear modules by
a couple of double stroke cylinders actuated by an
orbitrol, directly connected to the steering column. The
loader is also equipped with an emergency steering system.
The steering system uses the same oil of the equipment system. The two systems are combined, since
the oil in excess of the steering pump is forwarded to
the equipment system. The system is made of hydraulic tank (S) pump (1) main priority valve (2) steering unit
(orbitrol 5) complete with check valves and steering

cylinders (4).
The emergency steering system is composed of the
following components:
- emergency pump (14);
- secondary priority pump (12);
- two check valves on main and secondary priority
valve;
- one check valve (8) with pressure switch (7) installed
on the oil return pipe to the tank.
4
5
4
To equipment control
valve
12
To brakes
circuit
14
Hydraulic tank (S)
Fig. 4-1 Steering system

1. Main pump - 2. Main priority valve - 4. Steering cylinders - 5. Orbitrol - 12. Secondary priority valve - 14. Emergency pump.
4-2
STEERING SYSTEM
W190
4.1.1 DESCRIPTION OF THE STEERING

SYSTEM OPERATION
The oil in tank (S) is sucked by pump (1) composed
of two sections: one section powers the steering/
equipment system, the other powers the brake system.
The oil is directed toward priority valve (2) containing a spool that, in case of steering, sends the oil
directly to orbitrol (5).
The hydraulic oil pressure at input (P) of orbitrol (5)
is controlled by pressure relief valve (6) set at 210
bar (3045 psi), that discharges the oil in case the
said value is exceeded.
When required, the oil is directed to the steering
system and the equipment system. With the steering at rest, the oil at the end of the priority spool
upward, thus allowing the oil of the pump to flow to
the equipment system. The steering system has
priority and gets oil first. The priority valve together
with the orbitrol make the LOAD SENSING system.
Operation of the LOAD SENSING system

The load sensing system provides the powering of
the orbitrol with a quantity of oil (taken from the main
pump delivery) required by the steering action, letting
the residual flow of the pump into the equipment hydraulic system (equipment control valve).
As an example, when the steering wheel is in neutral
position, the majority of the pump oil flow is forwarded
to the hydraulic control valve operating the equipment
hydraulic system, so that the oil delivered by the main
pump is used in an efficient manner to achieve the
maximum saving of energy.
When the operator actuates the steering wheel, the
oil is directed to the steering control cylinders through
the orbitrol. Two safety and anti-cavitation valves (1)
located inside valve block (10) operate in the event of
shocks on the wheels, absorbing their effects.
The valve have also an anti cavitation function, ensuring that with the orbitrol in neutral, the cylinder
chambers are always filled with oil, thus preventing
oil vacuums in the circuit in case of intervention of
the safety (shockless) valves protecting against hard
shocks on the wheels.
Under normal operation conditions of supply pump (1)
the oil delivered by emergency steering pump (14)
flows through secondary priority valve (12) to hydraulic tank (S) with a pressure exceeding 1.5 bar (21.75
psi).
On the tank check valve (8) set at 1.5 bar (21.75 psi)
and pressure switch (7) are installed, that under normal conditions keep the emergency steering indicator light in the cab OFF.
In the event, while the wheels are moving, a sudden
cut-off of the engine or supply pump (1) (steering section) occur, orbitrol (5) sends a signal (LS) to secondary priority valve (12) that positions itself so that the
oil flow delivered by steering emergency pump (14) to
the orbitrol circuit.
The oil directed to the orbitrol is sufficient to ensure
the steering, even with engine inoperative.
Under these conditions, since the oil is diverted to
the orbitrol, pressure switch (7) monitors a pressure
drop (lower than 1.5 bar (21.75 psi)) and signals to the
operator the intervention of the emergency steering
pump (14) activating the relevant indicator light in the
cab.
W190
4-3
STEERING SYSTEM
7
8
L
R
T LS
5-6
10
11
4
D
F
12
13
14
Fig. 4-2 Emergency steering circuit

D. To equipment control valve - F. To brake pedal valve - L. To left cylinder (bottom side) - LS. Load Sensing signal P. Supply form pump - R. To right cylinder (bottom side) - T. Discharge to tank - 1. Dual supply pump (steering/brakes) 2. Main priority valve - 3. Check valves - 4. Steering cylinders - 5. Orbitrol - 6. Pressure relief valve - 7. Pressure switch for
emergency steering pump low pressure - 8. Check valve on tank (from emergency steering pump) - 9. Check valve (from
orbitrol) - 10. Valve block - 11. Safety and anti-cavitation valve - 12. Secondary priority valve - 13. Check valves on LS (load
sensing) circuit - 14. Emergency steering pump
4-4
W190
STEERING SYSTEM
11
10
T
5 bar
5
LS
D
13
3
3
CF
PP
EF
EF
0.8
CF
PP
0.8
2
0.8
1.0
LS
12
0.8
1.0
7
14
1,5 bar
Fig. 4-3 Steering hydraulic system
W190
STEERING SYSTEM
LEGENDA OF STEERING HYDRAULIC SYSTEM

D - To control valve
F - To brake pedal valve
L - To left cylinder (bottom side)
LS - Load-Sensing signal
P - Supply from pump
R - To right cylinder (bottom side)
T - Discharge to tank
1 - Dual supply pump
- Steering/equipment section
(max flow Q = 162 lt/min) (35.63 USG/min)
- Brakes/pilot system section
(max flow Q = 32 lt/min) (7.03 USG/min)
2 - Main priority valve (stand-by setting 12 bar)
(174 psi)
3 - Check valves
4 - Steering cylinders
5 - Orbitrol
6 - Pressure relief valve (setting 210 bar) (3045 psi)
7 - Pressure switch for emergency steering pump
low pressure
8 - Check valve on tank (emergency steering circuit
- setting 1.5 bar) (21.75 psi)
9 - Check valve (orbitrol circuit - setting 5 bar)
(21.75 psi)
10 - Valve block
11 - Safety and anti-cavitation valve (setting 280 bar)
(4061 psi)
12 - Secondary priority valve (setting stand by 4 bar)
(58.01 psi)
13 - Check valves on LS (Load Sensing) circuit
4-5
4-6
W190
STEERING SYSTEM
4.2 MAIN AND SECONDARY PRIORITY VALVES

4.2.1 DESCRIPTION OF OPERATION OF
MAIN PRIORITY VALVE
Item (g) represents the position of the spool under
the conditions of equipment (booms and bucket) operation only without intervention by the steering. Check
valve (1) is closed due to the lack of flow toward the
orbitrol, keeping the latter under pressure. This condition is maintained for a few instants, due to the dynamic leakage inside the orbitrol, from which an alternate closing and opening movement of supply duct
(CF) occurs.
If the steering is continued to stroke-end and the circuit pressure increases, the pressure relief valve inside the orbitrol opens discharging excess pressure
directly to the hydraulic oil tank.
Two orifices (S1 and S2) creating a pressure gradient
downstream, provide a gradual movement of spool
(2) during the various phases of operation.
Oil is sucked by the pump and forwarded directly to

the main priority valve. The oil powers the valve from
duct (P).
In the event the steering of the machine is required,
spool (2) is positioned as in detail a. This position is
maintained by the return spring and by the oil coming
from duct (LS).
Duct (LS) is connected to the orbitrol and the pressure is directly proportional to the steering speed. If
the steering is gradually zeroed (item b) the pressure
in the orbitrol decreases thus it decreases in duct (LS)
as well.
Being the delivery pressure to the orbitrol (duct CF)
higher, under these conditions, spool (2) moves and
presses the return spring gradually uncovering the
delivery to control valve (EF).
S2
EF
123456
123456
123456 Static oil
Oil to discharge
Oil under pressure
CF
EF
LS
CF
EF
CF
LS
LS
PP
PP
PP
S1
P
Fig. 4-4 Main priority valve operation phases

a. Full flow delivery phase to orbitrol - b. Simultaneous flow delivery to orbitrol and equipment control valve - c. Full cutting
-off to orbitrol and full delivery to control valve - S1 and S2. Orifices - 1. Check valve - LS. From orbitrol - CF. To orbitrol and
(upon request) to secondary priority valve - P. From hydraulic pump - 2. Spool.
W190
4-7
STEERING SYSTEM
Removal
Disassembly
The valve is installed on the frame on the left side of

the machine, under the cab.
To disassemble the priority valve proceed as follows:
Drain the hydraulic oil from the tank, tagging and disconnecting the oil hoses. Remove the securing screws
and remove the valve.
1) remove plug (1) and relevant O-Ring (2) from port

(PP);
2) remove plug (6) and relevant O-Ring (2) from port
(LS) and extract spring (5);
3) extract spool (3) using a nylon rod pushing from
the opposite side of the valve.
1
2
3
5
2
6
4
Fig. 4-5 Main priority valve

1. Plug - 2. O-Ring - 3. Spool - 4. Valve body - 5. Spring - 6. Orifice plug
60 Nm
Reassembly and installation

The reassembly and installation are performed reversing the operations above.
Tighten the components to the prescribed torque indicated in Fig. 4-5.
4-8
W190
STEERING SYSTEM
4.2.2 MAIN PRIORITY VALVE DIAGRAM

The priority valve is combined with the orbitrol to make
the "load sensing" system that distributes the flow of
the main pump to the steering and equipment hydraulic systems.
EF
CF
EF
CF
PP
PP
LS
LS
P
P
Fig. 4-6 Priority valve diagram

P:
LS:
EF:
CF:
PP:
PUMP (from main pump)

LOAD SENSING (from Orbitrol)
MAIN CIRCUIT (to equipment control valve)
STEERING CIRCUIT (to orbitrol)
PILOTING CIRCUIT (by-passed inside the valve)
Setting = 12 bar (174.04 psi)
W190
4-9
STEERING SYSTEM
4.2.3 STEERING EMERGENCY CIRCUIT

General description
The configuration of the device includes a gear pipe
directly keyed on the transmission to ensure, when
the machine is moving (forward or reverse) the flow of
oil to the emergency system. Oil sucked by the emergency pump reaches the secondary priority valve that,
in case of operating failure of the steering pump, is
positioned in a manner to ensure the flow of oil toward
the orbitrol and the cylinders.
The emergency steering circuit has the purpose of

allowing the steering of the machine, in the event of
accidental cutting-off of the engine or in case of failure of the main steering pump.
Its intervention is signalled by the activation of an
indicator light located on the right of the dashboard.
TO ORBITROL
TO EQUIPMENT
CONTROL VALVE
TO ORBITROL
EF
TO MAIN
PRIORITY
VALVE
EF
0.8
0.8
CF
0.8
1.0
LS
1.0
PP
0.8
EMERGENCY
STEERING
PUMP
STEERING/
BRAKES POWER
PUMP
1.5 bar
CF
PP
TO SECONDARY
PRIORITY VALVE
TANK
CAB DASHBOARD
C
STEERING
EMERGENCY
INDICATOR LIGHT
Fig. 4-7 Emergency steering diagram
4.2.4 SECONDARY PRIORITY VALVE

The secondary priority valve is equal to the main priority valve, being the "stand-by" pressure different at
4 bar 58 psi, is installed on the frame, on the right
side, under the cab.
The removal/disassembly/reassembly and installation

are the same of the main priority valve.
4 - 10
W190
STEERING SYSTEM
4.3 POWER STEERING

Its normal function is the one of a hydraulic motor to
perform dosing operations. In case of emergency, it
is made to operate as a manual pump for manual
steering (without hydraulic power).
The power steering is composed of the controlling valve

and rotor group. The controlling valve is a rotary valve
that, with its rotation changes the oil passages, thus
actuating the steering cylinders. The rotor group is
located under the controlling valve.
4
T
LS
DANFOSS
1
2
Fig. 4-8 Power steering

1. Valve block - 2. Power steering - 3. To main and secondary priority valves (unit with emergency steering) - 4. To tank - 5.
From pump - 6. To left steering cylinder - 7. To right steering cylinder.
PT L
R
OVPL 28
OSPL 1000 LS
LS
Fig. 4-9 Hydraulic diagram
W190
4 - 11
STEERING SYSTEM
4.3.1 POWER STEERING

Removal
The power steering is complete with valve block (2)
that is flanged on the steering.
It is suggested to mark the sections of the steering,
so that the same position is ensured when reassembling.
Remove the securing screws and remove valve block
(2) and power steering (1).
Drain the hydraulic oil from the tank, steer fully rightward or leftward to reach the zone under the cab. Tag
and disconnect the oil pipes from valve block (2). From
the inside of the cab, remove the steering column
guard, until the steering securing screws are reached,
then remove the four screws (5).
Remove the steering complete with valve block.
3
5
Fig. 4-10
Steering column complete
1. Power steering - 2. Valve block - 3. Steering column - 4. Steering wheel - 5. Power steering securing screws - 6. Valve
block securing screws.
Note -
65 Nm
20 Nm
35 - 45 Nm
65 Nm 0.5
4 - 12
STEERING SYSTEM
4.3.2 DISASSEMBLY OF POWER STEERING

Remove securing screws (22) and remove cover (19).
Remove fixed ring (17) complete with inner rotor (15).
Pullout spacer (14) and O-Ring (13).
Extract the rotor drive shaft (12).
Remove threaded bush (4) and extract ball (3) from
the check valve.
To remove the springs, it is necessary to pullout
slightly the rotary valve from the sleeve, remove blade
springs (9), extract the valve pushing it out from the
sleeve, paying attention to rotate it slowly to facilitate
the operation.
Check carefully all the components.
Check that the sliding surfaces are free from scratches
and are not deformed.
Replace all damaged parts.
Replace all seals and possibly the blade springs as
well.
It is important that the assembly of the parts making
the power steering done with the maximum cleanliness.
Lubricate freely the parts with hydraulic oil.
Check that all oil ducts are unclogged.
Extract sleeve (11) complete with rotary valve (8).
Extract thrust bearing (6) and the sleeve return spring
retaining ring.
Disassemble the rotary valve from the sleeve, removing drive pin (10).
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
Power steering parts
1. Seal - 2. Power steering body - 3. Check valve ball - 4. Treaded bush - 5. Seal - 6. Thrust bearing parts - 7. Ring
8. Rotary valve - 9. Sleeve (11) return springs - 10. Sleeve (11) and shaft (12) drive pin - 11. Valve (8) seat sleeve
12. Rotor (17) drive shaft - 13. O-Ring - 14. Ring - 15. Rotor - 16. O-Ring
17. Rotor (15) fixed ring - 18. O-Ring - 19. Cover - 20. Washers - 21. Screw with pin - 22. Cover (19) securing screws
23. Pressure relief valve - 24. Pressure relief valve seat.
4 - 14
W190
STEERING SYSTEM
4.3.3 ASSEMBLY OF POWER STEERING

Install the seal in the power steering body.
Reinstall rotary valve (8) into sleeve (11) turning it
slowly while installing it.
Align the spring passage cuts and insert the springs
inside the sleeve and rotary valve.
Note In the event a tool is required to install the
springs, make it from a recessed head screw wrench
of appropriate size.
The long part of the wrench must be splined for a depth
of about 13 mm and a width of 3.2 mm.
Centre correctly the springs installed so that they result flush with the outer diameter of the sleeve.
Insert ring (7) retaining the springs.
Install pin (10) driving the sleeve/rotary valve.
Insert ball (3, Fig. 4-12) into its seat on the body and
install threaded bush (4).
To facilitate the operations to follow, before installing
the drive shaft, mark it with a sign parallel to the pin
cutting.
Install drive shaft (12) checking that the slot is inserted on the pin.
Note Mark (B) on the shaft must be parallel (C) to
the drive pin and surface (D) securing the valves block.
Arrange shoulder ring (14) with the relevant O-ring
seals.
Install fixed ring (17) complete with rotor (15).
Note Make sure that the two vanes of the rotor indicated
in the figure are parallel (A) to mark (B) made previously
on the shaft, thus to drive pin (C) and surface (D) securing
the valve block.
Install thrust bearing (6).

Insert the sleeve assembly into the orbitrol body,
making sure that all parts are free to turn.
Note During the installation of sleeve ( 11 ) in
the orbitrol body, make sure that the drive pin
remains horizontal.
Install the cover checking that the marks made prior

to the disassembly coincide.
Assemble the group tightening the screws to the torque
of 35 Nm. following the sequence indicated in
Fig. 4-12.
Note Screw w/ pin (21) must be inserted in the hole
where threaded bush (4) is.
B
C
A
B
C
7
5
Fig. 4-12
Timing of power steering
A - B - C - D. Surfaces that must result parallel among them at the reassembly.
W190
4 - 15
STEERING SYSTEM
23
24
7
3
10
11
12
9
13
14
15
16
17
19
18
20
21
22
W190-4R001
Fig. 4-13
Power steering parts
4 - 16
W190
STEERING SYSTEM
4.3.4 DISASSEMBLY OF THE VALVE

BLOCK
Remove plugs (8) from the valve block as well as the
multiple safety, shockless and anti-cavitation valves
(5).
Replace the O-Rings.
Extract from the block check valves (9).
Reassemble the component parts reversing the disassembly sequence.
Lubricate all parts.
Clean accurately all the components and check that

the sliding surfaces are free from scratches.
Install the valve block assembly on the orbitrol tightening the screws to a torque of 65 Nm.
1
C1
3
8
10
6
5
6
7
8
1
Fig. 4-14 Exploded view of the valve block

1 and 2. O-Rings - 3. Dowel - 4. Securing screws - 5. Multiple safety valves - 6. Springs - 7. O-Ring - 8. Plugs - 9. Check
valves - 10. Valve body.
Note -
37 - 43 Nm
W190
4 - 17
STEERING SYSTEM
4.4 TEST OF THE STEERING SYSTEM

The steering cylinder control circuit is powered by a
hydraulic pump in two sections.
One section of the pump powers, through a priority
valve, the steering system.
The other section powers the brakes system and the
pilot valve.
The pump sucks oil from the hydraulic tank and forwards it, with the steering inoperative, to the equipment control valve. The oil flow in the delivery circuit
is proportional to the performance required.
A main pressure relief valve set at 210 bar (3045 psi)
regulates the maximum pressure of the system, discharging the excess pressure.
Fig. 4-15 Installation of the steering pump on the transmission-torque converter group
1. Steering pump - 2. Brakes/pilot system pump - 3. Torque converter.
Note:
Mating surfaces:
LOCTITE 509
Steering section
Designation:
Type:
Drive:
Maximum delivery:
Maximum pressure:
Engine/pump speed ratio:
Kayaba KFP5163
gear
gear
162 lt/min (35.63 US/gal)
210 bar, 2300 rpm (3045 psi)
0.894 : 1
4 - 18
W190
STEERING SYSTEM
Delivery side
Suction side
Delivery
IN
Suction
Rotation direction
Fig. 4-16 Steering and brakes/pilot valve pump
1. Front pump (steering) - 2. Rear pump (brakes-power system)
W190
12
15
Section B-B
Fig. 4-17
4 - 19
STEERING SYSTEM
14
A
10 11
13
13
10
14
15
Section A-A
Steering pump section
1. Mounting flange - 2. Driven gear - 3. Intermediate plate - 4. Centering dowel - 5. Covering plate - 6. Adapter - 7. Brakes/
power system pump (see fig. 4.11) - 8. Seals - 9. Washer- 10. Plate - 11. Driving gear - 12. Coupling sleeve - 13. Plate 14. Back-up ring - 15. Seal.
4 - 20
STEERING SYSTEM
W190
4.5 EMERGENCY STEERING PUMP

Designation: ......................................................................................................... ZF driven by the transmission
Type: ............................................................................................................................. bi-directional, gear type
Drive: .......................................................................................................................................................... gear
Delivery: ...................................................................................................................................... 32 cu cm /turn
2
1
Fig. 4-18
Removal
Reinstallation
Disconnect the hydraulic pipes from emergency steering pump (2) remove securing screws (1) and remove
the pump.
Recover spacer (4) and O-Ring (3).
Position correctly spacer (4) and O-Ring (3) then install steering emergency pump (2).
Tighten securing screws (1) and connect the hydraulic pipes.
W190
4 - 21
STEERING SYSTEM
4.6 STEERING CYLINDERS

The two, double acting, steering cylinders, with rod
and cylinder sleeve mounted, respectively, to the front
and rear module of the frame.
The loader is steered by extracting or retracting the
rod.
Specifications:
Cylinder bore ................................... 80 mm (3.14 in)
Rod diameter ................................... 45 mm (1.77 in)
Piston stroke ............... 422 2 mm (1661 0.07 in)
Weight ............................................... 31 kg (68 lbs)
4.6.1 REMOVAL
Proceed as follows:
- drain the oil from the equipment reservoir;
- disconnect the oil pipes;
- from the rod side, loosen the retaining plate securing screw and extract the pin;
- disconnect the greasing pipe of the pivot pin from
the left cylinder;
- from the bottom side, loosen the retaining plate securing screw and extract the pin;
- remove the cylinder assembly.
10
11
12
13
17
14
Section
15
16
Fig. 4-19 Steering cylinder components

Notes - 1
451 Nm (333 ft-lbs)
1030 Nm (760 ft-lbs)
16 Nm (11.8 ft-lbs)
Pressure pick-up (PT 1/8)

Threaded area: LOCTITE 767
1. Cylinder head - 2. O-Ring - 3. Back-up ring - 4. O-Ring - 5. Mud scraper - 6. Bushing - 7. Seal - 8. Cylinder rod 9. Cylinder sleeve - 10. Piston seal - 11. O-Ring - 12. Piston - 13. Stop screw - 14. Steel ball - 15. Ball bushing - 16. Snap
ring - 17. Pressure pick-up plug.
4 - 22
STEERING SYSTEM
W190
4.6.2 DISASSEMBLY AND REASSEMBLY
4.6.3 INSTALLATION
Loosen cylinder head (1) and extract rod (8) complete

with piston (12).
Reinstall the cylinder on the machine, reversing the

removal sequence.
Loosen the piston securing screw (13), then loosen it

from the cylinder rod (8).
After starting the engine, check, with repeated movements of the steering, that the cylinder rod does not
show signs of leakages.
In the event the ball bushing has an excessive play,

replace it as follows:
- remove retaining snap rings (16);
- using a punch or a press, extract bushing (15) from
its seat, taking care to push on the outer side of the
bushing only.
Handle all components with great care.

Do not place hands and fingers between parts. Wear
glasses, gloves and safety shoes.
Check that the rod is free from signs of denting, burring or wear.
Check, using a ruler or placing it on a flat surface,
that the rod is not bent.
Inspect the inside of the cylinder; in the case of
scratches or wear, it must be replaced.
Replace all damaged components.
Reassemble the cylinders, reversing the disassembly phases considering the following:
- lubricate all parts appropriately;
- install new seals, ensuring the correct position and
direction;
- tighten the piston to torque 2 ;
- tighten screw (13) to torque 3 and stake;
- tighten front head (1) to torque 1 .
SECTION 5
BUCKET BOOMS AND FRAME

INDEX
PARAGRAPH
SUBJECT
PAGE
5.1
5.1.1
5.1.2
5.1.3
GENERAL DESCRIPTION ......................................................................................

Bucket ....................................................................................................................
Bucket automatic positioner ....................................................................................
Setting the boom maximum height ..........................................................................
5-1
5-5
5-6
5-7
5.2
5.2.1
5.2.2
FRAME ................................................................................................................... 5-8

Frame central pivot ................................................................................................. 5-9
Removal-installation of frame central pivot ............................................................. 5-11
5.3
BUCKET STOPS .................................................................................................... 5-20
5.4
LIST OF OVERHAUL SPECIAL TOOLS ................................................................. 5-22
W190
5-1

The load handling system is composed of:
- booms
- strut
- link
- bucket
- bucket cylinder
- boom cylinders
- pins
Linkage
Bucket shape
Bucket capacity:
Heaped
Struck
Bucket positioner
Boom kick-out
Weight:
Booms
Strut
Link
DEB bucket (without cutting edge)
The bucket positioner device and the boom kick-out

ensure an optimised efficiency of the equipment.
All pivot pins of the handling system have dust seals
to prevent the entry of debris.
The three bucket pivot pins and the lower strut hinging pin are equipped with O-rings. All pivot pins are
mounted with securing screws.
For the part relative to bucket and boom cylinders,
please refer to Section 6 (Hydraulic system).
Zed
DEB, general purpose
3.4 cum
3.1 cum
Mounted (proximity type)
Mounted (proximity type)
1100 kg (2420 lbs)
275 kg (606 lbs)
58 kg (128 lbs)
1275 kg (2810 lbs)
5-2
W190
6
5
11
7
7
12
12
11
9
10
10
Detail of typical pin
Bucket pins
Fig. 5-1 Booms, strut and bucket
Note Apply grease to the inner surfaces of the bushings and dust seals, prior to inserting the pins. Apply rust
preventing oil to the inner surfaces of the bosses.
1. Bucket - 2. Strut - 3. Boom - 4. Bucket cylinder - 5. Link - 6. Boom cylinder - 7. Locking screw - 8. Dust seal - 9. Bushing 10. Pin - 11. Grease fitting - 12. O-Ring.
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
Fig. 5-2 Booms, Strut and Bucket
Note -
Set a maximum play at 1.5 mm (0.059 in) or less.
5-4
W190
The 5 mm. diam. hole of the bush

must be aligned with centre line
of the link and cylinder ringes.
Section D-D
Duter lube
groove
Bush installation diagram
8 mm
Immer lube
groove
Fig. 5-3 Installation of equipment central hinging bushes

Note In the central hinging of the link (section D-D), the bushes must be oriented with the outer grooves directed
inword.
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.
The choice of the type of bucket, as a function of the

material and the work conditions, is essential, to ensure an efficient performance
(Multiple purpose bucket with reversible cutting

edge, DEB)
Note -
1070 Nm (788 ft-lbs)
(Multiple purpose bucket with bolted teeth)

Note -
1940 Nm (1430 ft-lbs)
1070 Nm (788 ft-lbs)

2
1
Fig. 5-4 Bucket
5-6
W190
Removal of the bucket

Rest the bucket on the ground on a flat surface.
Position some wooden shims under the booms so
that, when the booms are separated, the position
remains unchanged, facilitating the reinstallation.
Remove the screws securing the link and boom pins,
pullout pins (1 and 2) paying attention that the grease
fittings are not damaged, recovering eventual shims in
place.
Sling a hoist to the bucket, using the two existing eyes,

then disconnect it from the booms and lift it carefully.
Reverse the operations to re-install the bucket.
1
Fig. 5-5
5.1.2 BUCKET AUTOMATIC POSITIONER

WARNING
Mark
Fig. 5-6
Fig. 5-7
Before setting the bucket automatic positioner,

engage the parking brake. Do not allow any bystander to linger near the loader.
The tilt circuit is equipped with a bucket automatic
positioner.
This device has the purpose of returning automatically
the bucket to a horizontal position, every time, after
dumping the material, the machine is going to return to
a new work cycle.
For this purpose, when the bucket is dumped forward,
move the bucket tilt lever backward, beyond strokeend (to the left in case of a single lever control). The
lever is held by an appropriate detent and returns by
itself into neutral position once the bucket reaches the
pre-established position, being when the two red mark
overlap (horizontal bucket). The horizontal positioning
of the bucket is set as follows:
start the engine and position the bucket parallel to
the ground;
cut-off the engine;
loosen nut A;
slide the device in the slot until the final end of rod
B is aligned with sensor C.
tighten nut A.
The maximum actuating distance of device C indicated
with respect to rod B is 5 mm (0.20 in). Comply with this
tolerance, using nut A as required.
W190
5-7
5.1.3 SETTING THE BOOM MAXIMUM

HEIGHT
Sensor "A" provides the automatic detent of the boom
raise control lever, with the subsequent return to
neutral of the same lever each time the booms reach
maximum height.
The maximum raise of the booms is set proceeding as
follows:
Start the engine and raise the booms to the highest
position desired;
Cut-off the engine;
Loosen securing screws "B" and move plate "C" as
required;
Fasten the securing screws;
Start the engine and operate the boom raising a few
times to verify the correct positioning.
The maximum actuating distance of the device with
respect to plate "E" is 5 mm (0.20 in). Comply with this
tolerance, positioning sensor "A" using the securing
nuts.
A
C
Fig. 5-8
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
Fig. 5-9 Frame
1. Bearing - 2. Plug - 3. Cover - 4. Seal - 5. Shim - 6. Valve - 7. Split pin - 8. Bearing - 9. Plug - 10. Plug - 11. Seal - 12. Shim13. Screw 16x120 - 14. Grease fitting - 15. Front frame - 16. Pin - 17. Shim - 18. Shim - 19. Pin - 20. Screw 16x25 - 21. Flat
washer - 22. Bush - 23. Pin - 24. Bush - 25. Bush - 26. Flat washer 16x30x3 - 27. Screw 16x55 - 28. Screw 16x100 - 29. Shim 30. Flat washer - 31. Shim - 32. Rear frame
W190
5-9
Fig. 5-10 Rear ballast installation
Note -
1510 Nm
Ballast weight: 1965 kg (4332 lbs)
5.2.1 FRAME CENTRAL PIVOT

The loader is of an articulated frames type: the front
frame is connected to the rear frame by two hinging
pins around which the loader is pivoting, when steering.
WARNING
The steering action could crush the body between
the two modules (front and rear) of the frame.
Block the articulation with the safety bar, prior to
transporting the machine or performing repair
interventions. On the other hand, relocate the
safety bar in its original position, prior to starting
operating the machine.
(With loader under repairs)
Fig. 5-11
Safety bar
5 - 10
W190
(Upper hinging)
6
7
1
2
13
(Lower hinging)
14
15
6
16
10
17
11
18
12
2
Fig. 5-12 Central hinging
Note -
88 Nm
Threaded area: LOCTITE 262
215 Nm
Ring outer area: LOCTITE 262
1. Cover - 2. Dust seal - 3. Bushing - 4. Cover - 5. Shim - 6. Grease fitting - 7. Bearing - 8. Pin - 9. Bushing - 10. Cover 11. Shim - 12. Washer - 13. Pin - 14. Cover - 15. Shim - 16. Bearing - 17. Dust seal - 18. Bushing
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
Do not work under or near attachments of the

machine or any part of them that are not adequately
supported or blocked.
Insert under the front and rear frame adequate resting
supports providing conditions of stability and safety
during the disassembly phase.
W190-5R001
Fig. 5-13
ATTENTION
Do not allow unauthorised personnel to repair or
to maintain this machine. Read and head carefully
the Operation andMaintenance InstructionManual
prior to starting, operating, maintaining, refuelling
or repairing this machine.
DISASSEMBLY
2
Remove spacer (1) of the central pivot lower pin by

removing securing screws (2).
W190-5R002
Fig. 5-14
ATTENTION
Handle all parts with great care. Do not place hands
or fingers between pieces.Wear authorised
protective clothing/devices such as glasses, gloves
and safety shoes.
Recover shims (3).
3
W190-5R003
Fig. 5-15
5 - 12
W190
Then extract frame central pivot lover pin (1) using a

punch and a mallet.
1
W190-5R004
Fig. 5-16
Remove locking screw (2) complete with washer (3)
from flange (4) of the upper pin.
W190-5R005
Fig. 5-17
Extract frame central pivot upper pin (5).
W190-5R006
ATTENTION
Fig. 5-18

Lift and handle all heavymaterials witha
liftingdevice with appropriate capacity. Make sure
that all items are properly secured by appropriate
slings and hooks. Use the lifting eyes provided
for this purpose. Beware of persons standing near
the load to be lifted.
Use a hoist and lifting chains to sling and extract the
front frame to separate it from the rear frame.
W190-5R007
Fig. 5-19
W190
5 - 13
Remove positioning bush (1) of the pivot pin from the

front frame lower support.
W190-5R008
Fig. 5-20
Remove covers (2) by removing screws (3).
3
2
W190-5R009
Fig. 5-21
Remove shims (4).
W190-5R010
Fig. 5-22
Extract the two seals (5) from lower pivot covers (2)
and proceed in the same manner for the upper pivot
seals.
2
5
W190-5R011
Fig. 5-23
5 - 14
W190
Use a punch of adequate dimensions to extract the

bearings pack assembly from the lower pin pivot seat.
Proceed in the same manner for the removal of the
bearing pack from the upper pivot.
W190-5R012
Fig. 5-24
REASSEMBLY
LOWER HINGING
Prior to re-assembly, clean thoroughly all parts. Check
the wear conditions of the bearings and replace them
if required.
2
1
Lubricate adequately the seats of front frame bearing

support (1) and the seats of the rear frame pins seats.
Install outer race (2) of the lower bearing.
W190-5R013
Fig. 5-25
ATTENTION
protective clothing/devices such as glasses, gloves
and safety shoes.
Lubricate lower bearing (3).
W190-5R014
Fig. 5-26
ATTENTION
Do not allow unauthorised personnel to repair or
to maintain this machine. Read and head carefully
the Operation andMaintenance InstructionManual
prior to starting, operating, maintaining, refuelling
or repairing this machine.
Install bearing (3) and spacer (4).

W190-5R015
Fig. 5-27
W190
5 - 15
Install upper bearing (1).

1
W190-5R016
Fig. 5-28
Install outer race (2) of the upper bearing.
2
W190-5R017
Fig. 5-29
Apply LOCTITE 262 in the dust seal seat of lower
cover (3).
W190-5R018
Fig. 5-30
Place dust seal (4) on cover (3).
3
4
W190-5R019
Fig. 5-31
5 - 16
W190
Use punch (1) 380002594 to press dust seal (2) into

the relevant mounting seat of cover (3).
1
3
2
W190-5R020
Fig. 5-32
Proceed in the same manner for the installation of
dust seal (4) on upper cover (5).
4
W190-5R021
Fig. 5-33
Install the two covers and close the bearing pack
tightening the two screws to a torque of 88 Nm.
Measure the gap existing between upper cover (5)
and frame (6). The shim pack must be equivalent to
the gap measured + 0.2 mm, where 0.2 mm represents
the right tolerance for the correct rolling of the bearings.
6
W190-5R022
Fig. 5-34
Insert shims (7) corresponding to the value identified.
W190-5R023
Fig. 5-35
W190
5 - 17
Reinstall the covers using six securing screws (1) after

previously applying LOCTITE 262 on the threaded part.
Use a torque wrench to tighten the screws o a torque
of 88 Nm.
W190-5R024
Fig. 5-36
Install grease nipple (2).
Proceed in the same manner for the installation
of the bearings on the upper pivot.
W190-5R025
Fig. 5-37
Insert positioning bush (3) on the front frame lower
support.
ATTENTION
W190-5R026
Fig. 5-38

Lift and handle all heavymaterials witha
liftingdevice with appropriate capacity. Make sure
that all items are properly secured by appropriate
slings and hooks. Use the lifting eyes provided
for this purpose. Beware of persons standing near
the load to be lifted.
Using a host and lifting chains, hook and assemble
the front frame to the rear frame.
W190-5R007
Fig. 5-39
5 - 18
W190
Insert frame central pivot upper pin (1) using a mallet.
ATTENTION
1

protective clothing/devices such as glasses,
gloves and safety shoes.
W190-5R027
Fig. 5-40
Insert lower pin (2).
W190-5R028
Fig. 5-41
Lock upper pivot pin (1) using screw (3) complete with
washer (4).
W190-5R029
Fig. 5-42
Use a wrench drive to install two screws, lower pivot
pin locking plate (5) and measure the gap present
between plate (5) and the face of lower frame (6).
5
W190-5R030
Fig. 5-43
W190
5 - 19
Insert shims (1) corresponding to the value identified.
W190-5R031
Fig. 5-44
Reinstall plate (2) complete with shims using six
screws (3) tightened by a torque wrench to a torque of
88 Nm. Tighten the three screws (4) to a torque of
215 Nm.
4
3
W190-5R032
Fig. 5-45
5 - 20
W190
5.3 BUCKET STOPS
580
30
MAX LENGHTH -5 mm
Fig. 5-46
Set lower bucket hinging pin axis at 580 mm (22.82 in) from ground.
Extend bucket cylinder to its max. position and then retract it by 5 mm.
Weld the two upper abutting end plugs "A" to the bucket. Plug thickness shall be equal to the span between boom
and bucket.
W190
5 - 21
20
C
B
Fig. 5-47
Set booms to max. height.

Weld the two lower abutting end plugs "B" to the bucket so that with completely tilted bucket, "C" span is equal
to 2 mm (0.07 in) max.
5 - 22
5.4 LIST OF OVERHAUL SPECIAL TOOLS

TOOL NUMBER
DESIGNATION
380002594
Punch dust seal
W190
SECTION 6

INDEX
PARAGRAPH
SUBJECT
PAGE
6.1
6.1.1

Hydraulic system diagram ....................................................................................... 6-3
6.2
6.2.1
HYDRAULIC SYSTEM PUMP ................................................................................ 6-5

Inspection and repair of equipment pump ................................................................ 6-7
6.3
6.3.1
6.3.2
6.3.3
EQUIPMENT CONTROL VALVE ............................................................................

General description .................................................................................................
Main pressure relief valve .......................................................................................
Safety and anti-cavitation valves ............................................................................
6.4
6.4.1
6.4.2
CONTROL VALVE CONTROLS .............................................................................. 6-13

Control valve hydraulic control ................................................................................ 6-15
Supplementary hydraulic function (variant) .............................................................. 6-18
6.5
HYDRAULIC OIL RESERVOIR ............................................................................... 6-20
6.6
6.6.1
6.6.2
CYLINDERS ........................................................................................................... 6-21

Booms cylinders ..................................................................................................... 6-21
Bucket tilt cylinder .................................................................................................. 6-22
6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
L.T.S. ANTI-PITCHING SYSTEM (Variant) .............................................................

Description ..............................................................................................................
Discharge of the accumulators ................................................................................
L.T.S. hydraulic diagram ..........................................................................................
Functional tests of L.T.S. system ............................................................................
Test of L.T.S. accumulator precharge .....................................................................
Instruction for the resetting of accumulator precharge .............................................
6.8
6.8.1
TROUBLESHOOTING ............................................................................................ 6-30

Troubleshooting using the "ELECTRONIC SERVICE TOOL" device. ...................... 6-30
6.9
TOOLING ................................................................................................................ 6-31
6-9
6-9
6-11
6-12
6-23
6-23
6-23
6-25
6-26
6-27
6-28
W190
6-1
Equipment pump
Hydraulic oil
tank
Main hydraulic
circuit
Bucket dumping
cylinder
Equipment
control valve
Right boom
cylinder
Left boom cylinder
Fig. 6-1 Equipment hydraulic system
6-2
W190

The configuration of the hydraulic system is as follows: A hydraulic oil tank with a 97 lt (25.62 US gal)
capacity (capacity of system 135 lt (35.6 US gal))
mounted centrally on the right of the loader, complete
with filter and by-pass valve set at 1 bar (14.50 psi),
located on the return circuit from the actuators.
A hydraulic pump with discharge valve mounted on
the transmission housing driven by the gear mounted
on the torque converter pump wheel.
An equipment monobloc control valve with two sections receiving the oil from the pump, with a main
pressure relief valve set at 210 bar (3045 psi).
The control valve has two sections in series, controlling two circuits respectively: bucket rollback/dumping and boom raising/lowering.
Each one of the two circuits is equipped with safety
and anti-cavitation valves preventing dangerous pressure peaks that could overload pipes and cylinders.
Each section has a spool hydraulically piloted by a
power assisted pilot valve. The control valve piloting
system operates at a pressure of about 30 bar
(435 psi) and it is connected to the brakes system.
The pilot valve can by hydraulically cut-off by a threeway stop valve so that accidental movements of the
levers are not causing undesired movements of the
equipment.
The equipment control valve is connected the steering circuit. The oil in excess coming from the steering
pump is directed, when the steering is inoperative, to
the equipment circuit by the main priority valve. Also,
the circuit includes, upon request, a system reducing
the stress caused by the travelling of the machine on
rough terrain with a loaded bucket, designated as
L.T.S. (Load Travel Stabiliser).
I fact it is known that when travelling on rough ground,
the bucket load causes a disturbing pitching of the
machine, influencing the stability of the load and of
the loader besides the discomfort of the operator.
In this instance, a large hydraulic accumulator
preloaded with nitrogen, is capable of absorbing the
dynamic loads, is connected to the boom cylinders
through a valve block.
Once the speed of 7 kph (4.35 mph) is exceeded, a
solenoid valve automatically actuates the circuit, connecting the cylinder chambers with the accumulator,
providing the damping action.
A sequence valve set at 120 bar (1740 psi) protects
the accumulator from pressure peaks.

W190
ATTACHMENT

BUCKET CYLINDER
BOOM CYLINDERS
6-3
6.1.1 HYDRAULIC SYSTEM DIAGRAM
7
4
B
A
T
6
Y
A1
X2
B2
A
A2
274 bar
Pb3
MX MA
Pa3
B3
A3
X1
B1
230 bar
B2
186 bar
A2
Pb2
Pa2
A3
P1
T1
210 bar
B1
B3
175 bar
V = 0,71
Po = 19 bar
175 bar
A1
Pa1
Pb1
30 bar
PV
P2
T2
10
Implement
Q = 162 1/ min
Brake / Manipulator / Orbitrol

Q = 32l / min.
Q = 162 1/ min
Steering / implement
VPP
12
Engine rated speed : 2175 rpm

Engine / Pump ratio : 0,894
Pump rated speed : 2300 rpm
63cc/rev. 13cc/rev.
172
bar
63cc/rev.
1 bar
11
Fig. 6-2
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
W190
W190
6-5
6.2 HYDRAULIC SYSTEM PUMP

The hydraulic cylinder control is powered by a hydraulic pump sucking oil from the hydraulic tank and
forwarding it to the equipment control valve.
The pressure to be established in the delivery system is proportional to the performance required and it
is in any case, limited by the pressure relief valve.
This valve set at 210 bar (3045 psi) regulates the maximum pressure in the system, discharging the pressure in excess through a quick discharge valve installed at the output of the equipment pump.
Specifications of equipment pump

Designation: ................................................................................................... KayabaKFP5163AY-APNH
Type: ................................................................................................................ gear with discharge valve
Drive: ................................................................................................................................................ gear
Delivery at 2300 rpm: .................................................... 162 lt/min (35.62 USG/min) at 170 bar (2465 psi)
Maximum pressure at nominal speed: .......................................................................... 210 bar (3045 psi)
Engine/pump speed ratio: ...........................................................................................................0.894 : 1
Pump rotation ranges: ...................................................................................................... 600 2500 rpm
Weight ........................................................................................................................ 28.7 kg (63.27 lbs)
5
4
A
1
2
3
B
Fig. 6-3 Installation of pump on transmission-torque converter group
A. From hydraulic oil tank (suction) - B. To equipment control valve (delivery) - 1. Equipment pump - 2. Quick discharge
pump - 3. Transmission - 4. Steering - brakes pump - 5. O-Ring.
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
Fig. 6-4 Equipment pump
1. Gear plate - 2. Drive gear - 3. Driven gear - 4. Mounting flange - 5. Plate - 6. Seal - 7. Retainer - 8. Plate - 9. Dowel 10. O-Ring (high temperature) - 11. Seal (high temperature) - 12. Circlip - 13. Washer - 14. Pump cover - 15. Plunger 16. Check valve - 17. Plug - 18. Circlip - 19. Spring - 20. Plug - 21. O-Ring - 22. O-Ring - 23. Nut - 24. Setting screw 25. Nut - 26. Plug - 27. Spring guide - 28. Spring - 29. Push rod - 30. O-Ring - 31. Plug - 32. O-Ring - 33. Plug - 34. O-Ring 35. Screw (L=85.8 mm (3.37 in)) - 36. Screw (L=132 mm (5.19)) - 37. Screw (L=188.5 mm (7.42 in)) - 38. Washer.
W190
6.2.1 INSPECTION AND REPAIR OF EQUIPMENT PUMP
Suction
chamber
When disassembling, mark all components so that

they can be re-installed in the correct position.
After cleaning each individual item, inspect all the parts
of the pump.
1) Gear plate
One of the methods to obtain a better volumetric
efficiency of a gear pump is the design allowing
the end of the teeth to stay in contact with the
inner wall of the chamber containing the gear itself.
Consequently, once the pump starts running, marks
left by the gear teeth are shown around the suction port (fig. 6-5).
The contact mark is normal as long as it is less
than 1/2 the inner circumference of the gear cavity.
Dimension a of the mark depth (fig. 6-6) is normal
if it as about 0.05 mm (0.00196 in). When dimension a exceeds 0.15 mm (0.00589 in) also the shaft
and bearings can wear out. Thus, these items as
well, must be thoroughly checked.
If a is 0.15 mm (0.00589 in), replace the pump
with a new one.
Contact
mark
Fig. 6-6 Dimension of mark depth
2) Driving and driven gear

In case the shaft or the gear surface shows roughness felt by running a finger nail, or in case the
surface of the teeth shows excessive wear zones,
it is necessary to replace the item.
Suction
chamber
6-7
Contact
mark
Fig. 6-5 Gear intermediate plate
Fig. 6-7
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
In case the level of roughness found shows

several scratches that can be felt by a finger
nail.
Suction side
Irregularities
Discharge
side
Fig. 6-9 Irregularities on the bearings

Suction side
Irregularities
Fig. 6-8 Irregularities on the plate
4) Mounting flange (1) and covering plate (8)

(fig. 6-7)
Regarding the mounting flange and the cover plate,
check to find out it there is an eventual wear in the
bearing zone (fig. 6-9).
If the teflon film is worn-out and the red surface of
the copper base metal is showing for an arc larger
than 150 along the inner circumference of the
bearings, change the part.
W190
6-9
6.3 EQUIPMENT CONTROL VALVE

6.3.1 GENERAL DESCRIPTION
The oil ducts inside it are of a series type, so that the
bucket function has priority over the booms function.
Thus, pressurised oil reaches the booms port only
when the bucket spool is in neutral.
The control valve is hydraulically actuated by the pilot valve located in the cab; it is equipped with a main
pressure relief valve and three safety and anti-cavitation valves.
When the pressure in the system exceeds the value

of 210 bar (3045 psi), the main pressure relief valve
discharges oil to protect cylinders and pipes.
The safety and anti-cavitation valves protect the relevant circuits from sudden preassure peaks due to
mechanical loads on the equipment capable of causing a pressure increase beyond the pre-set value, and
they are mounted on the single spools of the control
valve.
SPECIFICATIONS OF EQUIPMENT 2-SPOOL CONTROL VALVE

Model
Type
Spool sequence
Setting of main valve
Setting of secondary valve (A1)
Setting of secondary valve (B1)
Setting of secondary valve (A2)
Delivery
Weight
Kayaba KVML-270-2
series, hydraulically piloted
P BUCKET BOOMS T
210 bar 5 (3045 psi 72)
230 bar 5 (3336 psi 72)
186 bar 5 (2698 psi 72)
274 bar 5 (3974 psi 72)
270 l/min (59.39 USG/min)
54 kg (119 lbs)
6 - 10
1
2
View from C
Fig. 6-10
1.
2.
3.
4.
Equipment 2 spool control valve
SAFETY AND ANTI-CAVITATION VALVE

(186 bar 5) (2698 psi 72)
MAIN PRESSURE RELIEF VALVE
(210 bar 5) (3045 psi 72)
(274 bar 5) (3974 psi 72)
(230 bar 5) (3336 psi 72)
A1 - B1 BUCKET SPOOL SECTION

A2 - B2 BOOMS SPOOL SECTION
P1.
OIL INLET (FROM PUMP)
OIL INLET (FROM STEERING VALVE)
P2.
T1.
DISCHARGE
DISCHARGE (FROM STEERING VALVE)
T2.
W190
W190
6 - 11
6.3.2 MAIN PRESSURE RELIEF VALVE

The main pressure relief valve is located in the inlet
section, between the neutral duct and the low pressure duct (discharge duct).
Operation
b) Operation (A)
When the pressure in neutral duct (HP) increases
and exceeds the pressure setting of the main relief valve piloted valve (5) opens. Pressurised oil,
discharged by the pilot valve, enters low pressure
duct (LP), flowing through sleeve (4) and valve
seat (6).
a) At rest
Oil at the delivery pressure in neutral duct (HP)
flows through orifice (2) of main valve (1) filling
inner cavity (3). Because of the surface difference
on which the pressure actuates, main valve (1)
stays closed in its seat in sleeve (4).
4
6
LP
HP
4
LP
5
LP
HP
Fig. 6-12
Operation (A)
LP
Fig. 6-11
At rest
6 - 12
c) Operation (B)
W190
Operation
When pilot valve (5) opens, the pressure in inner

cavity (3) decreases, moving main valve (1), so
that pressurized oil in neutral duct (HP) can discharge directly into low pressure duct (LP).
a) At rest
Pressurized oil, in the port connected to cylinder
(HP), flows through the orifice in piston valve (1)
and acts on the opposite surfaces of make-up valve
(2) and safety valve (3). Due to the surface difference on which the pressure works, the two valves
are kept closed, one against the other.
LP
LP
HP
HP
LP
1
Fig. 6-14
Fig. 6-13
LP
At rest
Operation (B)
b) Operation (A)
6.3.3 SAFETY AND ANTI-CAVITATION

VALVES
The safety and anti-cavitation valves are mounted in
the bucket and booms sections.
In the bucket section, a valve is located between port
(A1) connected with the cylinder (bottom side) and the
discharge duct, and a valve between port (B1) connected with the cylinder (rod side) and the discharge
duct.
The booms section is equipped with a single safety
valve, located between port (A2) connected with the
cylinders (bottom side) and the discharge duct.
The eventual auxiliary section is also equipped with
two valves configurated, respectively, between the
ports connected with the cylinder chambers and the
discharge.
When the pressure in the port connected to cylinder (HP) increases and exceeds the setting of the
safety pressure, pilot valve (4) opens.
Pressurized oil, discharged by the pilot valve, enters low pressure duct (LP) flowing through makeup valve (2) and valve seat (5).
5
LP
HP
LP
Fig. 6-15
Operation (A)
W190
c) Operation (B)
6 - 13
e) Operation in make-up
When pilot valve (4) opens, the pressure on the

raer side of piston valve (1) decreases, moving
piston valve (1). Consequently, the orifice of piston valve (1) closes so that the pressure on the
rear side of safety valve (3) decreases further.
If the pressure at port (HP) connected to the cylinder is lower than the value in low pressure duct
(LP), being a condition for potential cavitation,
make-up valve (2) moves proportionally to the
surface difference on which a negative pressure
intervenes. Consequently, to avoid cavitations, oil
can flow from low pressure duct (LP) to port (HP)
connected to the cylinder.
LP
LP
HP
HP
1
Fig. 6-16
LP
4
LP
Operation (B)
Fig. 6-18
Operation in make-up
6.4 CONTROL VALVE CONTROLS

d) Operation (C)
The pressure acting on the opposite surfaces of
safety valve (3) are unbalanced. Due to this pressure difference, the safety valve opens so that
pressurized oil can be discharged directly from port
(HP) connected to the cylinder, to low pressure
duct (LP).
LP
The control system of the control valve is of a power

assited type with different levers for the functions:
booms lowering/raising and bucket roll-back/dumping.
The control valve spools are actuated by hydraulic
connections. The circuit pressure (30 bar) (435 psi) is
ensured by a pressure relief valve equipped with an
hydraulic accumulator.
It is possible to install, upon request, a third lever
controlling a third spool of the control valve, in case it
becomes necessary to mount a special type of equipment requiring a third hydraulic function. For this purpose, the support in the cab is arranged for receiving
a third control spool.
HP
WARNING
LP
Fig. 6-17
Operation (C)
The piloting system of the control valve is

equipped with a safety device allowing its cuttingoff. Actuate the cut-off device to lock the control
levers in neutral position when the equipment is
not in use.
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)
Equipment control valve assembly
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.
The plungers of the booms valve body and the bucket

roll-in plunger are equipped with solenoid type detents
that hold them respectively in booms max. raise, float
and bucket roll-in positions. The detent occurs when
the relevant control levers are forced full stroke. The
levers can be, in any case, disengaged at any moment.
20.5
20.5
Valve body
assembly
(for booms)
Valve body
assembly
(for bucket)
Connecting
screw
(Code)
1: Port A1 - coil side (boom raise)
2: Port A2 - coil side (bucket rollin)
3: Port B1 - coil side (float)
[3]
A2
A1
B2
B1
P
[1]
[3]
Booms
[1]
A1
B1
[2]
[2]
A2
B2
Bucket
Booms
Fig. 6-20 Pilot valve
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
Bucket control valve body
1. Nut - 2. Rocker arm - 3. Adjusting screw - 4. Support flange - 5. Piston - 6. Spring - 7. Cup - 8. Split pin - 9. Spring 10. Plunger - 11. Valve body - 12. Solenoid - 13. Plate - 14. Piston - 15. Guide - 16. Screw connecting upper and lower
bodies - 17. Dust boot - 18. O-Ring - 19. Electrical connection.
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
Booms control valve body
1. Nut - 2. Rocker arm - 3. Adjusting screw - 4. Support flange - 5. Piston - 6. Spring guide - 7. Spring - 8. Cup - 9. Spring
support ring - 10. Split pin - 11. Spring - 12. Plunger - 13. Valve body - 14. Solenoid - 15. Plate - 16. Piston - 17. Guide 18. Screw connec. Upper and lower bodies - 19. Dust boot - 20. O-ring - 21. Electrical connections
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.
A three spool equipment control valve is arranged, a

third control lever in the cab besides the hydraulic
piping.
Supplementary hydraulic
function lever
Fig. 6-23
Configuration of supplementary hydraulic function
W190
B1
B3
Safety and pressure relief valve set

at 230 10 bar (3336 145 psi)
B2
Auxiliary section
A3
6 - 19
A2
A1
Safety and pressure relief valve set

at 230 10 bar (3336 145 psi)
Fig. 6-24
Arrangement of three section control valve for third hydraulic function
A3
A2
(3)
A1
B3
B2
(1)
B1
T
(2)
Aux. valve section

BUCKET
Fig. 6-25
BOOMS
AUX.
Three levers pilot valve
6 - 20
W190
6.5 HYDRAULIC OIL RESERVOIR

Type ................................................................................................................................................. Pressurised
Capacity of reservoir ................................................................................................................. 130 l (34.34 gal)
Setting of by-pass valve on oil filter .......................................................................................... 1 bar (14.50 psi)
Filters on return .................................................................................................................. filtering capacity 15
The reservoir contains the hydraulic oil for the main
hydraulic system, the steering system and the brakes
system.
Inside the reservoir a filter is mounted, on the oil return line, equipped with a by-pass valve that, in case
of clogging of the filtering element, discharges the oil
directly into the reservoir.
1
2
3
4
5
6
7
8
9
A
G
B
C
D
13
12
11
Fig. 6-26
Hydraulic oil reservoir
1. Oil filter cover - 2. O-ring - 3. Spring - 4. Filter holder - 5. Oil return filter - 6. Plug - 7. Introduction filter- 8. Breather pipe 9. Reservoir - 10. Oil level indicator - 11. Cover - 12. O-ring - 13. Inspection passage - A. From heat exchanger - B. From
equipment control valve - C. To steering pump - D. To equipment pump - E. To diverter valve (em.st.) - F. To emer. St. Pump
W190
6 - 21
6.6 CYLINDERS
6.6.1 BOOMS CYLINDERS
Boom cylinder:
The two boom cylinders are double stroke type. The

cylinders are extended and retracted, respectively to
raise or lower the booms. The boom cylinder is composed of: cylinder sleeve, bottom, rod, piston and seal
pack.
Kayaba
double stroke
2
140 mm (5.5 in)
75 mm (2.9 in)
960 mm (37.79 in)
130 kg (286 lbs)
Type
Q.ty
Inner diameter of cylinder
Diameter of rod
Stroke of cylinder rod
Weight (single)
12
1
7
2
11
9-10
Fig. 6-27
Note
Boom cylinders
451 Nm
3450 Nm
57 Nm
1. Rod - 2. Sleeve - 3. Rod seal - 4. Front sleeve - 5. O-Ring - 6. Screw M20x2.5x55 - 7. Piston seals - 8. Piston - 9. Nut 10. Washer - 11. Threaded dowel - 12. Ball
6 - 22
6.6.2 BUCKET TILT CYLINDER
W190
Boom cylinder:
The bucket tilt cylinder is double stroke. Depending

upon the extension or retraction of the cylinder, the
bucket rolls-back or is dumped by the linkage made
of a strut and rod. The bucket cylinder is composed
of: cylinder sleeve, bottom, rod, piston and seal pack.
Type
Q.ty
Inner diameter of cylinder
Diameter of rod
Stroke of cylinder rod
Weight (single)
Kayaba
double stroke
1
190 mm (7.48 in)
95 mm (3.74 in)
505 mm (19.98 in)
190 kg (419 lbs)
1
2
1
7
2
11
12
9-10
Fig. 6-28
Note
Bucket cylinder
1140 Nm
13900 Nm
57 Nm
1. Rod - 2. Sleeve - 3. Rod seal - 4. Front sleeve - 5. O-Ring - 6. Screw M27x3x70 - 7. Piston seals - 8. Piston - 9. Nut 10. Washer - 11. Threaded dowel - 12. Ball
W190
6 - 23
6.7 L.T.S. ANTI-PITCHING SYSTEM (VARIANT)

6.7.1 DESCRIPTION
Positon 0 (L.T.S. OFF)
The L.T.S. (Load Travel Stabilizer) system, supplied

as an optional, ensures a better driving comfort and a
reduction of dynamic loads on the components of the
machine (frame, axles etc.) when the unit travels with
or without load.
Without the L.T.S. system, the machine is subject,
as a result of irregular terrains, to unwanted pitching,
increasing with the travel speed.
With the L.T.S. system ON, the terrain irregularities
are absorbed by the equipment. In this manner, it is
possible to exploit completely the potential of the
machine, especially on uneven terrains, without
stressing mechanical components and providing max.
comfort for the operator.
Position 1 (L.T.S. ON)

Automatic gearbox
The transmission control unit automatically engages
the L.T.S. system whenever the speed of the machine
exceeds 7 km/h (4.34 mph) and disengages it when
the speed drops, thus allowing the loading and dumping of the bucket without unwanted movements of the
boom. The indicator comes on when the system is
ON and stays out when the system is OFF.
This position is recommended for normal use of the
system.
The system includes, essentially:

- A switch (incorporating the indicator) located on the
dashboard, to activate or disactivate the system;
- A piston type accumulator (oil capacity = 5.5 Liters
(1.45 gal); gas capacity = 6 Liters (1.58 gal)
preloaded with nitrogen and connected to the boom
raise/lowering cylinders;
- A valve block controlled by a solenoid valve.
Manual gearshifting
The L.T.S. is OFF when the gearshift lever is in first
speed.
Position 2 (L.T.S. constantly ON)
This position is useful only to allow the discharge of
the accumulator in view of maintenance or repair interventions (for this purpose, it is necessary to place
the equipment control valve in float position).
This position can be used for occasional operation
only, to obtain the cushion effect at speeds below
7 km/h (4.34 mph).
WARNING
L.T.S. system ON
The system is activated by a switch (with built-indicator) located on the switch panel.
For an efficient performance of the L.T.S. system,

the boom must be free to move.
Do not use the L.T.S. system when travelling on
open roads requires the locking of the boom.
WARNING - DANGER
Prior to any maintenance intervention on the
equipment and the L.T.S. system it is required that
the accumulator is discharged to avoid the exit of
pressurised fluid.
The L.T.S. switch has three positions:
6.7.2 DISCHARGE OF THE ACCUMULATORS
Fig. 6-29
L.T.S. three position switch.
To discharge the accumulator, proceed as follows:

- start the engine at idle speed;
- place the L.T.S. switch on position 2 (the indicator
must come ON);
- position the bucket flat on the ground;
- lock the equipment control lever in "Float" position;
- waiting a few seconds in this position the accumulator is discharged.
6 - 24
W190
To L.T.S. powering relay (cab)
"Brown box"
controller
Transmission pilot valve
Transmission "Est-37"
controller
L.T.S. control switch
To transmission
"Est-37" controller
Steering valve
L.T.S. valve
Hydraulic accumulator
Fig. 6-30
Components of L.T.S. system
W190
6 - 25
6.7.3 L.T.S. HYDRAULIC DIAGRAM
1
2
X2
B
7
X1
MX MA A
EQUIPMENT
CONTROL VALVE
T
X2
LTS VALVE
TYPE MHRSM 25 B2X/EG26C 4 M
X1
MA
MX
Fig. 6-31
L.T.S. hydraulic system diagram
1. Accumulator - 2. Solenoid valve "1" - 3. Discharge - 4. Cylinder bottom side valve - 5. Cylinder rod side valve 6. Sequence valve - 7. Pressure relief valve
6 - 26
W190
6.7.4 FUNCTIONAL TESTS OF L.T.S. SYSTEM

Testing of electrical system
Start the engine.
Raise the boom to max. height and insist in this position (valve activation) for about five seconds.
Place the L.T.S. switch on position 2; the indicator

must come ON.
Lower the bucket to the ground.
Bring the engine to medium/high speed and raise the

boom to max. height.
Engage the L.T.S. system placing the L.T.S. switch

into position 2 (the indicator must come ON).
Lower quickly the boom and stop it suddenly at

midlevel.
The bucket should raise about 200 mm (7.87 in).
The boom must oscillate before stopping and no waving movements must be felt in the cab.
Bring the engine speed back to idle and move the
L.T.S. switch to position 1.
Test of hydraulic circuit between boom cylinders,

bottom side, and accumulator
Start the engine and run it at idle speed.
The indicator must remain OFF.

Engage second speed and start the machine.
When the speed of the machine reaches 5 km/h
(3.1 mph), the indicator in the switch must come ON.
Slow down the machine and stop it; the indicator must
go OFF.
With flat bucket, raise it about 30 cm (11.81 in) from

the ground.
Lift the machine from the ground by tilting the bucket.
Move the equipment pilot valve to "Float" position so
that the machine drops to the ground.
Engage the system positioning the L.T.S. switch on
position 2 (the indicator comes ON) so as to discharge
the accumulator.
Move the pilot valve back to neutral.
Valve opening test

The scope of the test is to check the opening of valves
(4 and 5, fig. 6-48).
Roll-back the bucket: the boom should drop until touching the ground.
Start the engine and run it at idle speed.

Move the L.T.S. switch to position 2; the indicator
must come ON.
With bucket flat on the ground, move the equipment
pilot valve to "Float" position to discharge accumulator (1).
Move the pilot valve to neutral.
Switch OFF the L.T.S. system moving the switch to
position 0.
W190
6.7.5 TEST OF L.T.S. ACCUMULATOR

PRECHARGE
6 - 27
The accumulator installed on the L.T.S. anti-pitching

system is of a piston type preloaded with nitrogen.
The nominal precharge pressure is 18 bar (261 psi) at
15 C (59 F) with a 6 Ltr (1.6 gal) capacity.
Accumulator
Important A precharge of the accumulator lower

than the nominal value, can cause a defective operation of the L.T.S. anti-pitching system.
If could be useful to check yearly and when required
the nitrogen precharge. The checking operation must
be performed with the accumulator emptied of hydraulic oil.
2
Fig. 6-32
1. Protection cap - 2. Threaded plug.
WARNING
Prior to any maintenance intervention on the
equipment and the L.T.S. systems it is required
that the accumulator is discharged to avoid
pressurised fluid from escaping.
For the accumulator discharge procedure, please refer to point 6.7.2.
Check the pre-load, proceeding as follows:

1. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake
circuit.
2. Close valves (B) and (C) on the nitrogen charging
kit, refer to the illustration 6-33.
3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumulator.
5. Remove the cap from the accumulator valve stem.

7. Make sure that valve (D) is open.
8. Turn the stem into valve (F) and read the pressure
gauge (E).
9. The pressure must result 18 bar (261 psi). If the
pressure is too low, charge the accumulator with
dry nitrogen.
94L95
6 - 28
W190
6.7.6 INSTRUCTIONS FOR THE RESETTING

OF ACCUMULATOR PRE-CHARGE
With tool applied to the accumulator connection proceed as explained below:
GS98N801

1. To nitrogen tank - 2. Valve A - 3. Valve B - 4. Valve D - 5. To accumulator - 6. Valve C.
WARNING
Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
WARNING
Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 18 bar
(261 psi). If the charging valve breaks away from
the accumulator, the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
WARNING
Do not expose the accumulator to temperatures
above 49 C (120 F). A charged accumulator contains nitrogen compressed to 18 bar (261 psi). High
heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
Important The four valves must be in the positions
noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer
to the above illustration.
Important To help prevent equipment damage, the low
pressure gauge valve C MUST BE SHUT OFF during high
pressure (10 bar/145 psi and above) applications.
W190
6 - 29
1. Close the shutoff valve A by turning it all the way

to the left (counterclockwise), refer to the illustration on page 6-28.
10. Install the charging hose fitting onto the accumulator pressure valve (2), refer to the illustration on
page 6-27.
2. Open valve B by turning it out all the way to the left

(counterclockwise).
11. Tighten the needle valve by turning it clockwise.

Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the nitrogen
pressure level inside the accumulator, refer to illustration on page 6-28.
3. Close valve C by turning it all the way to the right

(clockwise).
4. Close the gauge valve D by turning it all the way to
the right (clockwise).
5. Connect the charging hose to the nitrogen supply
tank.
6. SLOWLY turn valve A clockwise while watching
the high pressure gauge. Stop turning valve A when
the needle on the gauge reaches 18 bar (261 psi).
Note If the needle goes over the needed pressure, quickly
open and close valve D and check the pressure setting
again.
The charging kit is now ready to be installed on the
accumulator.
7. Remove the two screws and the protection bracket
from the accumulator body.
8. Remove the valve cap from the pressure valve (1)
on the accumulator; refer to the illustration on page
6-28.
9. Back off the needle valve on the accumulator end
of the charging hose by turning it counterclockwise
to the maximum amount. This prevents nitrogen
from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve, refer to the illustration on page 6-28.
12. Open the shutoff valve A on the nitrogen supply

tank. While observing the pressure on the gauge,
slightly open the needle valve on the accumulator charge hose. By regulating the needle valve,
fill the accumulator to 18 bar (261 psi). Close the
needle valve. Close the shutoff valve A on the
nitrogen supply tank.
13. Close valve B by turning to the right (clockwise).
After a few minutes, check the accumulator for
leakage.
14. Back off the needle valve on the accumulator end
of the charging hose by turning it counterclockwise
the maximum amount. This will prevent nitrogen
from escaping from the accumulator as the hose
is removed. Remove the charging hose from the
accumulator pressure valve (2), refer to the illustration on page 6-27.
15. Install the valve cap onto the pressure valve (1)
on the accumulator.
16. Install the protection bracket on the pressure relief
valve using the two screws.
17. Remove the charging hose from the nitrogen supply tank, refer to the illustration on page 6-28.
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
Note For the pressure values, please refer to the

single sections of this Manual
BRAKES
HYDR.
REAR
6.8.1 USE OF THE ELECTRONIC

SERVICE TOOL
EST is a specific and indispensable instrument to
perform diagnoses on the product.
The new instrument designated as Electronic Service
Tool, is essentially made of a portable PC with peculiar
design features (STHPX) and a technologically
advanced flow meter measuring flows, pressures and
temperatures.
The components equipping the EST system are instruments
designed and developed for specific filed usage.
In fact, the PC is able to withstand shocks, contact with
liquids and substances dangerous for normal PCs on the
market.
The EST system provides the diagnosis of the main
groups of the machine through the measuring of
operational parameters of the electronic control
components (controllers, sensors etc.) and the
measure of flows, pressures and temperature.
MAIN
MAIN
TRANSM.
PILOT
FWD
TRANSM.
T. CONV.
-1-
TRANSM.
REV
-3-
TRANSM.
-2-
-4-
The EST system provides the diagnosis on

Excavators, wheeled Loaders Dumpers, Graders
and Dozers.
The EST system is a data bank.
It makes possible saving and forwarding the diagnoses
performed, directly from the operation site, loading all
the technical information required for service activities
(CDs, Manuals, parts Catalogues etc.).
The software starts automatically once the STHPX is
switched ON. It can provide a report of the tests
performed, indicating , besides the i.d. data of the
vehicle being tested, the references to the Customer
and the Dealer's representative performing the
intervention as well.
The technical report, in an electronic format, can be
forwarded by E-mail or recorded for future inspections
and comparison, useful in the implementation of the
PTF-8. The software is protected by an access key
(SMS key) assuring a protected usage.
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
Bag
PC to vehicle interface
Cable PC to vehicle
Cable PC to vehicle interface
Cable PC to vehicle
M.
N.
O.
P.
Q.
R.
S.
T.
T.
U.
V.
Engine diagnosis cable

Cable from multibrand interface
to ZF AEB starter.
Grader diagnosis cable
Cable motor
BB3 diagnosis cable
Special keyboard
I/O Stick
Excavator connecting cable
3,5 FDD
Printer
Printer cable
1850-2R520
6 - 32
380001594 PFT-8 HYDRAUIC TEST KIT
1850-2R521
A.
B.
C.
D.
D.
E.
F.
750L/M Flow block

700 bar pressure sensors
Temperature sensors 150 C
Sensor cables
Cable temperature sensors
Suitcase
Module PFT-8
W190
W190
6 - 33
380060209 CE - EST KIT COMPLETE KEYBOARD version

380060165 CE - EST KIT COMPLETE TABLET version
KIT Hydraulic PFT-8

380001594

380060209
KIT Hydraulic PFT-8

380001594

380060165
W190-2R003
6 - 34
W190
SECTION 7
ELECTRICAL SYSTEM
INDEX
PARAGRAPH
SUBJECT
PAGE
SAFETY RULES ...................................................................................................
7-1
7.1
GENERAL LAYOUT OF THE ELECTRICAL SYSTEM ..........................................
7-2
7.2
MAIN CONNECTORS ............................................................................................
7-3
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
MAIN COMPONENT CONNECTIONS (CAB) ........................................................

Fuses ....................................................................................................................
Cab instrument board .............................................................................................
Indicators on instrument board ...............................................................................
Switch board ..........................................................................................................
Automatic transmission .........................................................................................
7-8
7-9
7-13
7-16
7-16
7-17
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
LOCATION OF MAIN COMPONENTS ON ENGINE ..............................................

Main switch ...........................................................................................................
Starter switch ........................................................................................................
Solenoid switches and diodes ................................................................................
Pressure switches - sensors - switches .................................................................
Alternator ...............................................................................................................
7-21
7-23
7-23
7-24
7-35
7-58
7.5
ACOUSTIC TRANSDUCERS .................................................................................
7-60
7.6
CLIMATISATION SYSTEM ...................................................................................
7-61
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.
7-2
ELECTRICAL SYSTEM
W190
7.1 GENERAL LAYOUT OF THE ELECTRICAL SYSTEM

The electric wires are divided into five main groups:
1. Cab wires
2. Front frame wires
3. Rear frame wires
4. Engine wires
5. Transmission wires.
WARNING
Always disconnect the battery cable prior to cleaning, repairing, connecting or disconnecting any
cable of the electrical system to prevent the possibility of personal injuries.
Always keep all the lights equipping the machine
efficient. Replace at once any burnt-out bulb.
The above mentioned groups are connected among them by five multiple connectors located under the cab, near
the front frame fixtures.
1
B
Fig. 7-1
A. Left side connectors - B. Right side connectors - 1. Cab wires - 2. Front frame cable - 3. Rear frame cable 4. Transmission cable - 5. Engine cables.
W190
ELECTRICAL SYSTEM
7-3
7.2 MAIN CONNECTORS

CABLE CONNECTION ENGINE - CAB
24-31
31
20
30
18
29
2
7
1
8
22
11
16
LEFT SIDE VIEW

OF CAB
10
3
17
28
21
9
19
6
15
23
12
13
27
14
26
24
25
X18
GROUND CABLE (PLAIT)
W190-7R003
Fig. 7-2
MACHINE - CAB INTERFACE
CONTACT
NUMBER
WIRE NUMBER
(MACHINE)
(X18) 24-31 WAY CONNECTOR

WIRE SECTION
(MACHINE)
LAYOUT
EMPTY
EMPTY
WIRE NUMBER
(CAB)
WIRE SECTION
(CAB)
EMPTY
72
0.5
60
0.5
SWITCH
60
0.5
19
0.5
ACCELERAROR PEDAL SWITCH
19
0.5
81
0.5
ACCEL. PEDAL POTENTIOMETER -
81
0.5
83
0.5
ACCEL. PEDAL POTENTIOMETER OUT
83
0.5
10
55
0.5
ACCEL. PEDAL POTENTIOMETER +
55
0.5
11
28
0.5
EDC FAILURE INDICATOR (ENGINE CONTROLLER)
28
0.5
12
43
0.5
AXLE ARRANGEMENT
43
0.5
13
64
0.5
EDC FAILURE INDICATOR (ENGINE CONTROLLER)
64
0.5
14
0.5
EMPTY
15
EMPTY
16
EMPTY
17
EMPTY
18
EMPTY
19
27
0.5
27
0.5
20
21
49
0.5
EMPTY
ACCELERAROR PEDAL SWITCH.
TROUBLESHOOTING BUTTON
EMPTY
72
0.5
TROUBLESHOOTING CONNECTOR
49
0.5
22
22
0.5
ENGINE COOLANT TEMP. INDICATOR CONTROL RELAY (87)
22
0.5
23
23
0.5
ENGINE OIL PRESSURE INDICATOR CONTROL RELAY (87)
23
0.5
24
25
46
0.5
26
59
27
28
0.5
29
836
WATER IN FUEL SENSOR
30
19
GROUND
19
31
31
0.5
LINC K31
31
0.5
EMPTY
COLD STARTING ENGAGED INDIC. CONTROL
46
0.5
0.5
NEUTRAL RELAY CONTACT ARRANGEMENT
59
0.5
0.5
EMPTY
EMPTY
836
7-4
ELECTRICAL SYSTEM
W190
TRANSMISSION - CAB CABLE CONNECTION
24-23
W
V
X
K
L
J
H
M
A
N
F
LEFT SIDE VIEW

OF CAB
D
E
S
R
O
P
X21
GROUND CABLE (PLAIT)
W190-7R004
Fig. 7-3
(X21) 24 - 23 WAY COONECTOR
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
WIRE NUMBER
CAB
WIRE SECTION
CAB
430
434
SOLENOID Y1
56
SOLENOID Y2
10
438
SOLENOID Y3
32
442
SOLENOID Y4
55
446
SOLENOID Y5
LAYOUT
450
SOLENOID Y6
51
454
VPSI (+) (TRANSM. HYDRAULIC CONTROLLER)
12
458
K
L
EMPTY
TEMP.
39
574
TEMPERATURE SENSOR
49
462
TEMP.
46
GE 2
SPEED SENSOR B1
19
BL2
SPEED SENSOR B1
GN3
SPEED SENSOR B2
41
SW3
SPEED SENSOR B2
RT4
SPEED SENSOR B3
42
BL4
SPEED SENSOR B3
500
SPEED SENSOR B4
504
SPEED SENSOR B4
62
508
SPEED SENSOR B4
45
EMPTY
EMPTY
570
TEMPERATURE SENSOR
46
W190
ELECTRICAL SYSTEM
7-5
FRONT CABLE - CAB CONNECTION
24-31
20
31
19
15
13
24
14
27
RIGHT VIEW OF CAB
23
12
16
22
11
17
28
10
18
29
21
30
26
25
X20
W190-7R005
Fig. 7-4
(X20) 24 - 31 WAY CONNECTOR
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
169
LTS SOL. VALVE
EMPTY
613
LAYOUT
WIRE NUMBER
CAB
WIRE SECTION
CAB
169
BRAKES ACCUMULATOR PRESS. SW
613
116
HORN PEDAL BUTTON
116
138
HORN
138
103
RIGHT FRONT TURNING LIGHT
103
109
LEFT FRONT TURNING LIGHT
109
EMPTY
EMPTY
10
330
RIGHT FRONT HEAD LIGHT
330
11
339
LEFT FRONT HEAD LIGHT
339
12
EMPTY
13
EMPTY
14
231
LEFT LOW BEAM LIGHT
231
15
223
RIGHT LOW BEAM LIGHT
223
16
219
LEFT HIGH BEAM LIGHT
219
17
221
RIGHT HIGH BEAM LIGHT
221
18
EMPTY
945
19
975
TRANS. CUT-OFF PRESSURE SW (+)
975
20
974
21
995 (M)
0.3
BOOM PROXIMITY SENSOR (+)
TRANS. CUT-OFF PRESSURE SW (OUT)
974
995 (980)
0.3
22
980 (N)
0.3
BOOM PROXIMITY SENSOR (OUT)
980
0.3
23
994 (M)
0.3
BUCKET PROXIMITY SENSOR (+)
994 (981)
0.3
24
981 (N)
0.3
BUCKET PROXIMITY SENSOR (OUT)
981
0.3
25
EMPTY
26
859
27
956
28
954
29
LTS BLOCK SOL. VALVE
859
LTS (+)SOL. VALVE (+)
956
LTS SOL. VALVE (-)
954
EMPTY
30
EMPTY
31
EMPTY
7-6
ELECTRICAL SYSTEM
W190
REAR CABLE - CAB CONNECTION
24-21
H
K
G
L
F
RIGHT VIEW OF CAB
M
D
E
T
N
S
R
X22
W190-7R006
Fig. 7-5
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
978
PARKING BRAKE PRESS. SWITCH (+)
EMPTY
996
PARKING BRAKE PRESS. SW. (OUT)
331
RIGHT TAIL LIGHT + PLATE
LAYOUT
WIRE NUMBER
CAB
WIRE SECTION
CAB
978
996
EMPTY
EMPTY
331
EMPTY
332
LEFT TAIL LIGHT
332
1
1
120
LEFT REAR TURNING LIGHT
120
125
RIGHT REAR TURNING LIGHT
125
802
START. SAFETY (REAR RELAY BOX 87)
802
556
ALARM RELAY B (REAR RELAY BOX 85)
556
558
ALARM RELAY B (REAR RELAY BOX 85)
558
876
FDS FAN INVERSION (REAR RELAY BOX 86)
876
895
LINE "M" FROM 15 Amp FUSE (REAR RELAY)
895
1.5
801
LINE "ACC" FROM 15 Amp FUSE (REAR RELAY)
804
1.5
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
W190
ELECTRICAL SYSTEM
7-7
REAR CABLE - CAB CONNECTION
24-18
6
7
8
18
9
1
17
10
5
RIGHT VIEW OF CAB
16
4
11
15
12
14
13
X23
W190-7R007
Fig. 7-6
CONTACT
NUMBER
WIRE NUMBER
MACHINE
WIRE SECTION
MACHINE
772
10
DIVERTER BOX (30)
809
AIR CONDITIONER PRESSURE SWITCH
LAYOUT
WIRE NUMBER
CAB
WIRE SECTION
CAB
10
809
EMPTY
EMPTY
844
EMERG. STEERING PUMP PRESS. SW.
844
000
2.5
GROUND
2.5
000
2.5
GROUND
2.5
225
2.5
RIGHT REAR WORK LIGHT
225
2.5
835
DIVIDER VALVE (STEERING OIL LOW PRESSURE)
835
10
637
ALTYERNATOR "L" (BATTERY CHARGE INDICATOR)
637
11
EMPTY
12
663
AIR CLEANER CLOGGING (SENSOR)
13
557
FUEL LEVEL SENSOR
14
555
INDICATOR
15
824
16
886
17
885
FRONT WASHER PUMP
18
EMPTY
663
557
555
AIR CONDITIONER PRESSURE SWITCH
824
REAR WASHER PUMP
886
885
"
"
7-8
ELECTRICAL SYSTEM
W190
7.3 MAIN COMPONENT CONNECTIONS (CAB)
23
14
15
22
24
20
12
19
2
3
34
18
9
10
5
1
28
30
21
29
23
16
32
11
31
24
27
33
17
26
7
25
13
W190-7R009
1. Cable electric - 2. Electronic unit control - 3. Collar - 4. Electronic unit control - 5. Cable - 6. Printed circuit board 7. Printed circuit board - 8. Switch remote control - 9. Washer - 10. Screw - 11. Cable electric-plate - 12. Gasket - 13. Relay
-14. Cable electric - 15. Cable electric - 16. Electronic unit control - 17. Cable electric-switch - 18. Plate - 19. Gasket 20. Spacer - 21. Plaque data - 22. Grommet - 23. Screw - 24. Washer - 25. Flasher unit - 26. Fuse - 27. Plate 28. Electronic unit control - 29. Gasket - 30. Printed circuit board - 31. Printed circuit board - 32. Cable electric 33. Flasher unit - 34. Cable.
The main connections in the cab can be reached after removing the rear and right side plastic material panels.
W190
ELECTRICAL SYSTEM
7-9
7.3.1 FUSES
WARNING
Always disconnect the battery cable prior to

cleaning, repairing, connecting or disconnecting
any cable of the electrical system to prevent the
possibility of personal injuries.
Always keep all the lights equipping the machine
efficient. Replace at once any burnt-out bulb.
2
1
Note In the event a fuse is burnt out, it is necessary

to replace it at once. Search for the cause of the failure.
If the trouble persists, have the system inspected by
competent personnel.
The fuses in the cab can be reached by removing the
panel located behind the operator's seat on the left
side. The burning of a fuse is signalled by the activation
of the relevant indicator light.
Fig. 7-8
TABLE OF CAB FUSES

FUSE
DESCRIPTION
VALUE
F1A
F1B
F1C
CEIL. LIGHT/CLIMATE CONTR.

+ 30 EMERGENCY LIGHTS
+ 15 LIGHTS/FLASHING SW
7.5Amp
7.5Amp
7.5Amp
F2A
F2B
F2C
ROTARY BEACON
CUMMINS ENG. INDIC. LIGHTS CONTROLLER ACTIVATION
FRONT WIPER7PUMP/TIMER
7.5Amp
5Amp
7.5Amp
F3A
F3B
F3C
HEATER (FAN)
LIGHTING SW
BUCKET/FAN INVERT. S.V. BOOM AND RAISE SINGLE LEV.
15Amp
5Amp
5Amp
F4A
F4B
F4C
TURNING LIGHTS
VOLT. REDUCT./RADIO/12V JACK/CB (OPT)
SEAT HEATER
5Amp
7.5Amp
5Amp
F5A
F5B
F5C
ACC REAR RELAY BOX

REAR WORK LIGHT
FRONT WORK LIGHTS
15Amp
10Amp
10Amp
F6A
F6B
F6C
COND. COMP./AUT.LOAD. (OPT)

REAR WIPER/PUMP
LTS/BLOCK S. V.
7.5Amp
5Amp
5Amp
F7A
F7B
"M" REAR RELAY BOX

RH TAILIGHT/LH HEADLIGHT /TUV + CSI/INSTR/CIGAR
LIGHTER LIGHT
RH TAILLIGHT/LH HEAD/TUV + CSI/LHTAIL/LOW
BEAM/LICENCE LIGHT
15Amp
SEAT COMPRESSOR
EMPTY
AUX. INV./ATC FILTERS/ ACC. PEDAL SENS./REVERSE
RELAY/TRANSM. SOL./BUZZER/MULTIPLE INSTR.
5Amp
5Amp
7.5Amp
F9A
F9B
F9C
EMPTY
EMPTY
CENTRALISED LUBE (OPT)
3Amp
3Amp
7.5Amp
F10A
F10B
F10C
CIGARETTE LIGHTER
B CUMMINS CONTROLLER
HIGH BEAM
7.5Amp
10Amp
10Amp
F11A
F11B
F11C
HORN/HORN RELAY
STARTER BOARD
TROUBLESHOOTING SOCKET
7.5Amp
30Amp
3Amp
F12A
F12B
F12C
"B" CUMMINS CONTROLLER

HEAD/TAIL LIGHT POWERING
LOW BEAMS
10Amp
7.5Amp
10Amp
F7C
F8A
F8B
F8C
Fig. 7-9 Fuse group 1

Indicator light
F1A
F1B
F1C
F2A
F2B
F2C
F3A
F3B
F3C
F4A
F4B
F4C
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
F8A
F8B
F8C
F9A
F9B
F9C
F10A
F10B
F10C
F11A
F11B
F11C
F12A
F12B
F12C
3Amp
3Amp
7 - 10
ELECTRICAL SYSTEM
W190
A couple of "link" fuses respectively for the machine

services (50 Amp) and alternator (80 Amp) are located
in the left side of the engine compartment.
50A
80A
Fig. 7-10
Fuse group "2"
Fig. 7-11
Fuse group "3"
The following fuses are located inside the relay box

accessible from the right side of the engine
compartment:
F1 E Stop lights (4A)
F2 E Moisture in fuel sensor (4A)
F3 E Back-up alarm (7.5A)
F4 E Alternator "S" (4A)
F5 E Alternator "15" (4A)
F6 E EDC controller (4A)
F1 D EDC engine controller (20A)
F2 D Fuel pre-heater resistor (20A)
F3 D Amplifier + FDS solenoid valve (4A)
M
"MEGA" fuse 150 Amp engine cold starting
D
E
Fig. 7-12

W190
ELECTRICAL SYSTEM
7 - 11
PROTECTION TREE ELECTRIC DIAGRAM

+
FUSE 150A
FUSE 80A
LINK
FUSE 50A
"ACC"
ACCRALAY
ALTERNATOR
MEGA
STARTER
GRID HEATER
F1A - 7.5A
CAB. LIGHTS
LINK
F1D - 20A
EDC CONTROL UNIT
CLIMATE CONTROL UNIT

F1B - 7.5A
F11 B - 20A
EMERGENCY LIGHTS
F2D - 20A
START
ON
ACC
OFF
H
KEY IGNITION
M REAR RELAY BOX

F6E - 4A
F5E - 4A
F8B - 5A
BACK-UP ALARM
F10B - 7.5A
BACK-UP LAMPS
F9B - 3A
15 ALTERNATOR
F8A - 5A
PARKING BRAKE SWITCH
F6C - 5A
ZF CONTROL UNIT
F10C - 10A
HEAD LIGHTS
F11A - 7.5A
F4E - 4A
EDC CONTROL UNIT
S ALTERNATOR
HORN
HORN RELAY SOLENOID
EMPTY
F11C - 3A
SEAT COMPRESSOR - OPTIONAL
F12A - 3A
LTS SOLENOID VALVES
F8C - 7.5A
CONTROL UNIT ZF
F6B - 5A
EDC DIAGNOSTIC CONNECTOR

B. BOX CONTROL UNIT
F12B - 7.5A
SIDE AND TAIL LIGHTS 24 V

F7B-3A
CUT-OFF SAFETY VALVE
BACK-UP ALARM RELAY SOLENOID

SPEED SENSOR
F10A - 7.5A
LIGHTER
F3E - 7.5A
ST M ACC G2 G1 B
F7A - 15A
FUEL PREHEATER RESISTANCE
LTS RELAY SOLENOID
LEFT SIDE LIGHT
REAR WINDSCREEN WIPER MOTOR
LEFT SIDE LIGHT T.U.V. - OPTIONAL
REAR WINDSHIELD MOTOR PUMP
LEFT SIDE LIGHT I.R.T.C. - OPTIONAL
AUXILIARY SELECTOR SW.

RANGE SELECTOR
INSTRUMENT LIGHT
F6A - 7.5A
ELECTROMAGNETIC CLUTCH - OPTIONAL
F9A - 3A
EMPTY
LIGHTER LAMP
F7C-3A
AUTOMATIC LOADING CONTROL - OPTIONAL
F9C - 7.5A
RIGHT SIDE LIGHT
CLUSTER METER
F5C - 10A
F5B - 10A
RIGHT SIDE LIGHT T.U.V. - OPTIONAL
REAR FLOOD LIGHTS
RIGHT SIDE LIGHT I.R.T.C. - OPTIONAL
F5A - 15A
ACC REAR RELAY BOX
ACC RELAY SOLENOID

F1C - 7.5A
PLATE LIGHT
F1E-4A
LIGHTS EXCHANGE SWITCH
STOP LIGHTS
F2A - 7.5A
F12C - 10A
LOWER BEAMS
F2E-4A
BEACONS
F2B - 7.5A
LEFT TAIL LIGHT
FRONT FLOOD LIGHTS
BUZZER + DIGITAL DISPLAY

B. BOX
RIGHT TAIL LIGHT
W.I.F.
CENTRAL GRASE LUBRIFICAT. -
F2C - 7.5A
OPTIONAL
FRONT WINDSCREEN WIPER MOTOR
F4C - 5A
SEAT HEATER
FRONT WINDSCHIELD MOTOR PUMP

F4B - 7.5A
F3A - 15A
TIMER K4 FRONT WINDSCREEN
POT. DIVIDER
CAB ELECTROFAN - OPTIONAL
RADIO - OPTIONAL
F3B - 5A
F3C - 5A
JACK 12 V
LAMPS SWITCH
CB - OPTIONAL
BOOM, BUCKET PROXIMITY SW.

BOOM FLOAT/MAX LIFT DETENT SOLEN.
F4A - 5A
TURN LIGHTS
Fig. 7-13
SINGLE LEVER RELAY SOLENOID - OPT.
X5
895
804
711
949
724
MPC 2.8 6 VIE 90
1
2
3
4
5
6
5mm
D5
5mm
D4
5mm
D12
5mm
D13
5mm
D11
5mm
D8
5mm
D7
5mm
D17
5mm
D16
5mm
D3
5mm
D6
5mm
D10
5mm
5mm
5mm
5mm
110
922
188
921
921
889
809
809
149
112
889
879
171
995
994
168
168
167
M6
SEAT HEATER
REDUCTION
N.C.
LAMP SW
LIGHT SW
+ WIPER + PUMP
CONDITIONER
N.C.
N.C.
X1-20
X1-21
X1-19 + ROT.BEACON SW
X1-18
X1-17
X1-16
X1-14
X1-15
X1-13
X1-12
CLIMATE PRESSURE SW
+15 FLASHING
X1-11
+15 LIGHTS SW
X1-10
+ FRONT WIPER + PUMP
+15 EMERGENCY LIGHTS
X1-9
X1-8
X1-7
BOOM SV
+ PROXIMITY
X1-6
BUCKET LEVEL SV
X1-5
+ LTS SV SW
REAR WORK
FRONT WORK
ON HARNESS
X1-4
X1-3
X1-2
X1-1
X27
X 4 = M A R K I I 1 1 WAY 9 0 N E U T R A L
X 1 = M A R K I I 2 1 WAY 9 0 G R E E N
N.C.
ACC. REAR CENTR.

+ HEATING
M FROM KEY
B+ FROM KEY
M REAR CENTR
2.2K L/4W
R5
F2B 7.5A
2.2K L/4W
R4
F2A 7.5A
2.2K L/4W
R12
F4C 5A
2.2K L/4W
R13
F5A 15A
2.2K L/4W
R11
F4B 7.5A
2.2K L/4W
R8
F3B 15A
2.2K L/4W
R7
F3A 15A
2.2K L/4W
R17
F6B 5A
D9
D18
D14
D15
R6
2.2K L/4W
R20
F7B 3A
2.2K L/4W
R21
F7C 3A
2.2K L/4W
R26
F9B 3A
2.2K L/4W
R27
F9C 7.5A
2.2K L/4W
R26
F9A 3A
2.2K L/4W
R24
F8C 7.5A
2.2K L/4W
R22
F8C 5A
2.2K L/4W
R23
F8B 5A
2.2K L/4W
R19
F7A 15A
5mm
D20
5mm
D21
5mm
D26
5mm
D27
5mm
D26
5mm
D24
5mm
D22
5mm
D23
5mm
D19
166
450
450
333
330
331
339
334
332
858
852
858
B.BOX+15
ZF 45
ZF 45
ZF 45
ZF 45
ZF 45
ZF 45
ZF 45
983
587
+ 15 B. BOX
N.C.
+ F2
+ GEARSHIFT
+ REAR. START.
+ SPEED SENSOR
+ ZF + 2 CO. SW
+ ACC.
+ 15
+ HEATED SEAT
N.C.
X3-10
N.C.
N.C.
N.C.
N.C.
X3-20
X3-21
X3-19
+LIGHT FUSE FROM SW
CIG.LIGHTER LIGHT
X3-17
X3-18
INSTR. BACK LIGHT
N.C.
X3-16
X3-15
LH HEADLIGHT
X3-14
RH HEADLIGHT
X3-13
X3-12
RH TAIL LIGHT
N.C.
N.C.
X3-8
X3-9
X3-11
N.C.
LH TAILLIGHT
RH TAIL LIGHT
RH TAIL LIGHT
N.C.
N.C.
X3-7
X3-5
X3-6
X3-4
X3-3
X2-3
+ BUZZER
X2-8
FRONT INSTR. POWER
X2-9
X2-10 + LCD
X3-2
X3-1
X2-13
X2-12
X2-4
X2-5
X2-6
X2-7
X2-11
X2-2
X2-1 + PARK. BRAKE SW
R1
F1A 7.5A
2.2K L/4W
R30
F10C 10A
2.2K L/4W
R36
F12C 3A
2.2K L/4W
R32
F11B 20A
2.2K L/4W
R33
F11C 3A
2.2K L/4W
R34
F12A 3A
2.2K L/4W
R29
F10B 7.5A
2.2K L/4W
R28
F10A 7.5A
2.2K L/4W
R35
F12B 7.5A
2.2K L/4W
R31
F11A 7.5A
2.2K L/4W
R2
F1B 7.5A
2.2K L/4W
+B
R6
EDC +30
5mm
D30
5mm
D36
5mm
D32
5mm
D33
5mm
D34
708
441
721
153
925
X27
923
924
ZF23-ZF68
B.BOX+30
5mm
D29
5mm
D28
5mm
D35
5mm
D31
5mm
D2
5mm
D1
M5
X8
N.C.
DIAGNOSTIC SOCKET
+30 B. BOX
F1 EST37 +30
EST37 +30
+ CIG. LIGHTER
B+ LIGHTS SW
HORN RELAY
B+ EMERG. LIGHTS
+ CEILING LIGHT
X4-10 + HIGH BEAM RELAY
X4-10 + LOW BEAM RELAY
X4-9
X4-8
X4-7
X4-6
X4-5
X4-4
X4-3
X4-2
X4-1
ON HARNESS
7 - 12
2.2K L/4W
R16
F6A 7.5A
2.2K L/4W
R3
F1C 7,5A
2.2K L/4W
R6
F2C 7.5A
2.2K L/4W
R10
F4A 5A
2.2K L/4W
R9
F3C 5A
2.2K L/4W
R18
F6C 5A
2.2K L/4W
R14
F5B 10A
2.2K L/4W
R15
F5C 10A
+ACC
X7
ELECTRICAL SYSTEM
W190
FUSE BOX DIAGRAM
Fig. 7-14
W190
ELECTRICAL SYSTEM
7 - 13
7.3.2 CAB INSTRUMENT BOARD

The monitoring system monitors the operating conditions of the loader through sensors and switches installed on the machine and provides information to
the instrument board located in the operator's compartment indicating the current operational conditions
of the loader.
13
22
12 25
10
4-68-15
The instrument board is composed of instruments including the tachometer, control indicator lights signalling that all systems are operating correctly or not
(alarm indicators) and signalling indicators.
5 7 16
21
26
17
27-28
CN1
CN3
23
11 18-19
CN2
Fig. 7-15
CONNECTION
CN1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Acc. oil low press. Indic. light

Eng. coolant high temp. indic. light
Eng. coolant temp. indicator
Instrument board light
Left turning light
High beam lights
Ground
Fuel level
Parking brake indic. light
Battery failure indic. light
Fuel reserve indic. light
Not connected
Right turning light
Tachometer
CONNECTION
CN2
CONNECTION
CN3
18
19
20
21
22
23
24
25
26
27
28
Buzzer
General signal
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)
7 - 14
ELECTRICAL SYSTEM
Connection CN1
1
9 10 11 12 13 14 15 16 17
Connection CN2
18 19
20 21
22 23 24 25 26
Connection CN3
28
27
Fig. 7-16
Instrument board electric diagram
FM
WTM
OTM
EHM
SM
L1-L13
L14 - L21
:
:
:
:
:
:
:
FUEL LEVEL INDICATOR

ENGINE COOLANT TEMPERATURE GAUGE
TRANSMISSION/TORQUE CONVERTER OIL TMPERATURE GAUGE
HOURMETER
TACHOMETER
INDICATOR LIGHTS
INTRUMENT LIGHTS
W190
W190
ELECTRICAL SYSTEM
7 - 15
BUTTON - 0
BUTTON - 1
BUTTON - 2
BUTTON - 3
Fig. 7-17
Electric diagram of digital display
7 - 16
ELECTRICAL SYSTEM
W190
7.3.3 INDICATORS ON INSTRUMENT BOARD

Engine coolant
temperature indicator
Engine coolant
temperat. indicator
150 C
50 C
67 C00
102 C00
50 C00
120 C00
Nominal value
of resistance
1st point of measurement
Scale
50 C
120 C
102 C
135 C
67 C
Fuel level
indicator
Instrument
E00
F00
49.8
16.8
91.7
10.4
80
10
Fig. 7-18
7.3.4 SWITCH BOARD
e
n
m
f
l
W190-7R010
Fig. 7-19
a. Seat heater (opt.) - b. Transmission cut-off when braking - c. Transmission auto engagement - d. Boom raising detent
(3 pos.) - e. Pre-heater indicator light + fuel filter with moisture - f. Radiator fan inverter - g. LTS (opt.) - h. Block valve cutoff (opt.) - i. Auxiliary direction reverser safety - l, m, n. Free.
W190
ELECTRICAL SYSTEM
7 - 17
7.3.5 AUTOMATIC TRANSMISSION
T\M OIL TEMP
20
F
COOLANT TEMP
55
30
10
40
50
FUEL
1\10h
44
66
HOURMETER
km\h
88
A
11
99
12
12
77
10
10
11
11
Fig. 7-20
Configuration of automatic transmission
1. Automatic transmission controller ATC - 2. Forward-Reverse control unit - 3. Monitoring board - 4. Gearshift pilot valve 5. Kick-down/shift-down functions button - 6. Forward-reverse diverter - 7. Forward-Reverse diverter safety switch 8. Automatic transmission engagement switch - 9. LTS device switch (opt.) - 10. Transmission - 11. Transmission sensors 12. LTS accumulator control group (opt.).
7 - 18
ELECTRICAL SYSTEM
W190
GEARSHIFT SELECTOR
2
3
4
ND
X2
X2
X1
X1
A
B
C
D
A
B
C
D
Fig. 7-21
SPEED SELECTION
1 = 1st speed
2 = 2nd speed
3 = 3rd speed
4 = 4th speed
SPEED SELECTION
F = FORWARD
R = REVERSE
N = NEUTRAL
Fig. 7-22 Gearshift selector electric diagram
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
Display connector
Display connector
Diagnostic connector
Speed sensor B1
Parking brake relay
Fuse 10B (7.5 Amp)
Line CAN H
Line CAN L
Line CAN l
Man./Auto SW
-
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
Speed sensor B2
Speed sensor B3
Fuse 6C (7.5 Amp)
Temperature sensor B15
Speed sensor B4
Gearshift selector
Gearshift selector
Gearshift selector
Clutch cut-off sw
Gearshift selector
Fuse 10B (7.5 Amp)
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
FUSE 7.5A (BOX 8C)
LTS
X19-5
ZF30
ZF2
KICK-DOWN SW.
ZF45
ZF45
GND
ZF45
ZF45
TRANSM. CONTROL
AUXILIARY CONNECTION
F-N-R
ZF31
ZF31
ZF44
ZF44
ZF20
ZF20
ZF45
ZF45
ZF45
X19-31
X19-44
X19-23
X19-20
X19-68
ZF23
FUSE 7.5A (BOX 10B)
ZF68
K2
X19-45
BATT
B3
772
CU 2.5
(A)
ZF65
B2
X6
(B)
B
Z
HORN
ZF63
ZF7
X19-65
197
30
87
85
86
556
FUSE 7.5A (BOX 8C)

558
X19-7
(21/M)
163
CU 2.5
ZF45
(21/N)
X19-63
(C)
(D)
ZF67
BACK-UP
ALARM RELAY
X19-67
(D)
ZF43
ZF56
X19-43
ZF45
ZF64
ZF
X19-32
ZF67
EST 37
ZF15
ZF15
ZF18
ZF18
X19
X19-15
X19-18
B4
500
ZF45
508
504
(23/U)
GND
438
Y3
(23/C)
442
Y4
ZF4
(23/S)
ZF62
Y5
ZF51
450
Y6
(23/F)
TRANSMISSION
CONTROL
TRANSMISSION
HYDRAULIC
BLOCK
446
(23/E)
X19-51
454
ZF12
(23/G)
X19-13
X19-39
ZF13
ZF39
458
TEMP.
(23/J)
X19-4
X19-62
(23/D)
ZF9
X19-9
X19-46
ZF46
462
TEMP.
(23/L)
(23/T)
SPEED SENSORS
OUTPUT
ZF45
DISPLAY
CONNECTOR
ZF32
X19-55
595
X19-12
A5
Y2
(23/B)
ZF55
ZF45
434
X19-10
ZF45
TRANSMISSION
SELECTOR
Y
(23/A)
ZF10
X19-64
(C)
DIAGNOSTIC-INTERFACE
(CONNECTOR)
430
X19-56
(B)
X7
570
X19-49
A6
ZF14
ZF14
(23/X)
ZF49
B15
574
ZF19
X19-19
GE2
(23/M)
ZF3
X19-3
ZF21
BL2
(23/N)
X19-21
GN3
ZF41
X19-41
(23/O)
ZF3
B2
SW3
SPEED SENSORS
PICK-UP
(23/P)
ZF45
ZF29
ZF29
ZF3
X19-29
BL4
(5/4)
(23/R)
ZF42
X19-42
921
921
P.B.
CONVERTER OUTPUT
TEMP. SENSOR
(23/K)
X19-14
B3
RT4
(23/Q)
1
S12
ZF21
MAN./AUT. SW.
S2
X19-66
DIODE
ZF30
30
ZF30
975
ZF45
(31/19)
CLUTCH CUT OFF

PRESSURE SW.
ZF45
87
975
974
ZF66
(31/20)
87
ZF45
943
CN1-25
B.B.
X19-30
86
921
85
921
ZF45
AUXILIARY SELECTOR
ENABLE SW.
PARKING BRAKE
RELAY
S13
ZF45
567
996
ZF45
996
21/C
Fig. 7-24
CLUTCH CUT OFF SW.
S17
PARKING BRAKE SW.
978
ZF45
996
ZF45
978
21/A
ZF transmission electric diagram
ZF45

W190
ELECTRICAL SYSTEM
7 - 21
7.4 LOCATION OF MAIN COMPONENTS ON ENGINE

VIEW FROM B
RIGHT SIDE SECTION VIEW
Engine coolant temperature

sensor
Common rail pressure sensor
Fuel heater
Camshaft sensor
Crankshaft sensor
BOSCH
EDC7 controller
BOSCH
BOSCH
Alternator
Temperature sensor
Fuse 80 Amp
Fuse 50 Amp
79102142
Engine rpm sensor
Depression switch
Central gear rpm sensor
Converter turbine rpm sensor

Detail Y
Connector x 21
Level indicator sender
A.C. electric compressor
Alternator
Pressure switch
82 bar (1189 psi)
A
Starter motor
Temperature sensor
7-22
TRANSMISSION
VIEW FROM A
SIDE VIEW
LEFT SIDE
Fig. 7-25

7 - 22
ELECTRICAL SYSTEM
W190
LOCATION OF MAIN COMPONENTS ON THE MACHINE

Batteries (2)
Switch 1 bar (14.50 psi)
L
Proximity sensors
Accelerator pedal
Battery cable
Battery starter
motor cable
Potentiometer
Switch 1 bar (14.50 psi)
DETAIL L
Brake
solenoid valve
cable
Ground cable
DETAIL Z
Z
Battery cable
General switch key
DETAIL K
Switch
Electric
timer
Switch 15 bar
(26.10 psi)
Main switch
ELASIS
DETAIL R
SECT. A-A
VIEW FROM A
Switch 1.8 bar
Proportional amplifier
SECT. B-B
Ground cable
VIEW FROM B
DETAIL W
Washer tank
Relay
Diode
Plaid assembly
Pressure switch 73 bar

(1059 psi)
Washer pump
Solenoid switch
Diverter box fuse 150 Amp
Fuse holder
Fig. 7-26
W190
ELECTRICAL SYSTEM
7 - 23
7.4.1 MAIN SWITCH

LOCATION - Inside the battery left panel.
To ground
Battery
Fig. 7-27
7.4.2 STARTER SWITCH

LOCATION - Cab right console
OFF
AC
BG
ON
STAR
T
B
H
OFF
ACC
ON
G1
G2 ACC
ST
POSITION
B
ST
G2
G1
ACC
START
Fig. 7-28
WIRES
R724
804
949
907
POSITION
"B"
"ACC"
"M"
"ST"
TECHNICAL DATA
DC:
24 V
B-G1, G2: 8 A
B-ACC:
10 A
B-M:
5A
B-ST:
3A
7 - 24
ELECTRICAL SYSTEM
W190
7.4.3 SOLENOID SWITCHES AND DIODES

COLD STARTING SOLENOID SWITCH
780
782
IV-4
IV-16
782
To fuse 150 Amp

To resistor
To EDC7 controller PIN 4
To EDC7 controller PIN 16
TECHNICAL DATA
Nominal voltage: 24 V
Solenoid nominal current: 2 A
IV-4
IV-16
780
Fig. 7-29
LOCATION - Inside the connection box, right

side of engine compartment
W190-7R002
Fig. 7-30
1. Cold starting relay - 2. Engine oil low pressure indicator light relay - 3. Fuel filters heater relay - 4. Back-up alarm relay.
W190
ELECTRICAL SYSTEM
7 - 25
HOLDING RELAY 90 Amp
804
85
30
G
86
WIRES
804 to starter switch ("ACC")
N
to ground
R
to relay board (+B)
M
to fuse F5A (15 Amp)
TECHNICAL DATA
Nominal current: 90A
Resistance: 140
Contact closing voltage: 5 18V
Contact reopening voltage: 8 20V
Fig. 7-32
30 85
86 G
Electric diagram
Fig. 7-31
Location of solenoid switch: relay board,

inside the cab behind the operator's
seat
7 - 26
ELECTRICAL SYSTEM
W190
BACK-UP ALARM RELAY
556
WIRES
772 to battery
197 to fuse 3E (7.5 Amp)
558 to connection 21N
556 to connection 21M
87
87a
85
197
30
772
86
558
TECHNICAL DATA
Nominal current: 14 V
Releasing voltage: 4.8 V
Resistance at 20: 240
Maximum current 20 A (contacts N.O.)
Maximum current 10 A (contacts N.C.)
85 87 87a
Diode 1N4004
86
30
Electric diagram
Fig. 7-33
6 5 4
3 2 1
D
6 5 4
3 2 1
Fig. 7-34
Location of relay: inside connection box, right

side of engine compartment
W190
ELECTRICAL SYSTEM
RELAY 10/20 Amp
87
87a
85
30
86
WIRES
85 To diode (954)
30 To Brown Box controller CN1-23 8956)
86 To fuse 6C (5 Amp) (167)
87 To timer Pin + (B)
RELAY 10/20 Amp
87
87a
85
86
30
WIRES
85 To timer Pin C (H)
30 To solenoid valve 3 (2)
86 To timer Pin b+ (B)
87 To timer Pin +(B)
87a To solenoid valves 1-2 (4)
85 87 87a
Diode 1N4004
86
30
Fig. 7-35
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
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
REL PARKING BRAKE
87
87a
85
86
30
WIRES
85 To diode (996)
30 Auxiliary detector enable SW (ZF45)
86 To fuse 8C (7.5 Amp) (ZF45)
87a To ZF EST 37 PIN X19/21 (ZF21)
85 87 87a
Diode 1N4004
86
30
Fig. 7-37
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)
REL DEVICE ENGINE OIL PRESS.

INDICATOR LIGHT
87
87a
85
86
30
WIRES
85 To EDC7 controller PIN 63 (63)
30 To ground (000)
86 To EDC7 controller PIN B+ (8)
87 Brown-Box controller CN7-21 (23)
85 87 87a
Diode 1N4004
86
30
Fig. 7-38
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)
HORN REL 10/120A
87
87a
85
86
30
WIRES
85 To Ground (N)
30 To fuse 11A (7.5 Amp) (R925)
86 To ZF (Z)
87 To horn (138)
85 87 87a
Diode 1N4004
86
30
Fig. 7-39
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
FUEL PREHEATER REL
87
87a
85
86
30
WIRES
85 EDC7 controller (IV6)
30 Fuse 150A (CU16)
86 Controller EDC 7 (IV4)
87 Resistor
85 87 87a
Diode 1N4004
86
30
Fig. 7-40
W190
W190
ELECTRICAL SYSTEM
7 - 33
LTS TIMER
WIRES
3
To connection sol. valve EV2-EV3
B
To pos. 87 relay "1"
B
H
3
B
Fig. 7-42
Fig. 7-41
K1
K2
K3
K4
K5
K6
K7
K8
High beam relay

Reserve
Flasher unit
Low beam relay
Safety starting relay in neutral
Horn relay (control on gearshift selector)
Horn relay (control on pedal button)
Parking brake relay
Location of LTS relay and timer: inside

box APV12 on front frame
K1
K2
K3
Note For the specific connections of the relays,

please refer to the relevant diagram.
K4
Fig. 7-43
K5
K6
K7 K8
Location: relay board, inside the cab

behind the operator's seat
7 - 34
ELECTRICAL SYSTEM
W190
RELAY BOARD ELECTRIC DIAGRAM (CAB)
D11 IN4007
P. BRAKE INDIC. X3 - 21
567
D9 IN4007
P. BRAKE PRESS. X3 - 19
K8
V23074
996PB
D10 IN4007
ZF 21
X3 - 13 + F2
X3 - 16 I. P. BRAKE SW
30
996
P. BRAKE X3 - 20
ZF 45
87A
87
X3 - 14 N.C.
86
N.C. X3 - 12
85
X3 - 17 N.C.
D7
IN4007
X3 - 18 N.C.
F2 X3 - 11
ZF45
K7
V23074
R925
X3 - 1 + HORN RELAY
87A
30
87
138
X3 - 4 HORN
86
85
D6
IN4007
11
N.C. X3 - 5
X3 - 6 HORN PEDAL. BUTT.
K6
V23074
87A
30
87
DIVERT. BUTT. X3 - 2
86
595
85
X3 - 15 N.C.
D5
IN4007
GND X34 X3 - 3
K1
V23074
R923
87A
87
X2 - 2
594
11
219
30
86 LOW BEAM
RELAY
J1 + 30
J2 B + FUSES
J3 30 RELAY 90A
N1
221
+B
X2 - 6 + HIGH BEAM RELAY
X2 - 9 HIGH BEAM IND.
X2 - 8 LH HIGH BEAM
X2 - 7 RH HIGH BEAM
86
85
D1
IN4007
K4
V23074
R924
X2 - 3 + LOW BEAM RELAY
87A
223
30
87
86 HIGH BEAM
X2 - 1
RELAY
593
231
X2 - 4 RH LOW BEAM
X2 - 4 LH LOW BEAM
86
85
D3
IN4007
GND
K3
FLASHER UNIT
K5
V23074
802
X2 - 11 STAT. SAF.
X3 - 10
+ FLASHER
87A
102
86
190
85
30
87
30
87
86 START.
SAF.
X2 - 15
ZF67
907
X2 - 10 30 START
86
X3 - 7
49 FLASHER
85
87A
D4
IN4007
P.B. PRESS
X2 - 12
996PB
K2
V23074
X2 - 14 N.C.
87A
M FROM KEY
ACC FROM KEY X3 - 9
804
87
X3 - 13 N.C.
85
X1
86
D2
IN4007
1
A
30
N.C. X2 - 16
86 RELAY 90A
GND X34 X3 - 8
N1
85 RELAY 90 A
N.C. X2 - 17
Fig. 7-44
W190
ELECTRICAL SYSTEM
7 - 35
7.4.4 PRESSURE SWITCHES - SENSORS - SWITCHES
2
1
Fig. 7-45
1 - STOP LIGHTS PRESSURE SWITCH

WIRES
117
To fuse 1E (4E)
175
To stop lights
TECHNICAL DATA
Thread:
M10 x 1
Setting:
1.8 0.5 bar (26.10 7.25 psi)
3 - BRAKE ACCUMULATOR LOW PRESSURE

PRESSURE SWITCH
WIRES
613
To Brown Box CNI-3 controller
000
To ground on front frame
TECHNICAL DATA
Thread:
R 1/8 taper
Setting:
73 5 bar (1058 72.51 psi)
2 - TRANSMISSION CUT-OFF PRESSURE SWITCH

WIRES
974
To controller ZF at PIN X/9-66
975
To pos. 1 transmission cut-off switch
TECHNICAL DATA
Thread:
Setting:
Tightening torque:
M10 x 1
15 1 bar (217 14.50 psi)
20 Nm
7 - 36
ELECTRICAL SYSTEM
W190
MAIN ELECTRICAL AND ELECTRONIC COMPONENTS OF EDC 7 SYSTEM
13
6
12
11
10
Fig. 7-46
Ref.
Description
Coolant temperature sensor
Electric injector
Rail pressure sensor
Air temperature/pressure
Starter motor
Timing sensor
Pressure regulation solenoid valve
Fuel temperature sensor
EDC 7 electronic controller
10
Crankshaft sensor
11
Engine oil level sender (*)
12
Engine oil pressure/temperature sensor
13
Pre-post-heater resistor
W190
ELECTRICAL SYSTEM
7 - 37
ELECTRONIC CONTROLLER EDC 7
Fig. 7-47
A. Injector connector - B. connector for powering and for functions scheduled in the application - C. Sensors connector.
It is installed directly on the engine by a heat exchanger providing its cooling, using elastic pads reducing the
vibrations transmitted by the engine.
It is powered through a 20 Amp fuse. The main relay normally used to power the system is located inside the
controller itself.
7 - 38
ELECTRICAL SYSTEM
W190
INJECTOR CONNECTION (A)
12
16
11
Fig. 7-48
View form wire input side

ECU PIN
WIRE
COLOUR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
RU
WP
WV
RW
RG
UN
UG
WR
RY
W
UO
UY
FUNCTION
Injector cylinder 2
Injector cylinder 3
Injector cylinder 4
Injector cylinder 2
Ground
Ground
Injector cylinder 1
Injector cylinder 6
Injector cylinder 5
Injector cylinder 3
Injector cylinder 1
Injector cylinder 4
Injector cylinder 6
Injector cylinder 5
Legenda of colours
B
black
R
red
U
blue
W
white
P
ciano
G
green
N
brown
Y
yellow
O
orange
W190
ELECTRICAL SYSTEM
7 - 39
SENSORS CONNECTORS (C)
1 3
23
16 9
15 22
4
5
30 36
29
Fig. 7-49

ECU PIN
WIRE
COLOUR
2
4
5
7
9
10
12
17
18
19
20
21
23
24
25
27
28
29
30
31
32
33
34
35
36
NW
NP
PY
NY
GY
YR
YN
PN
GN
N
U
U
R
GO
NG
UO
R
PO
YU
PG
YO
FUNCTION
Negative for pressure regulator
Positive for pressure regulator
Positive for engine oil temperature pressure sensor
Positive for air pressure temperature sensor
Positive for rail pressure sensor
Negative for fuel temperature sensor
Negative for coolant temperature sensor
Negative for engine oil pressure temperature sensor
Negative for rail pressure sensor
Positive for air pressure/temperature sensor
Camshaft sensor
Crankshaft sensor
Crankshaft sensor
Signal from rail pressure sensor
Signal from air pressure sensor
Signal from air temperature
Signal from camshaft
Signal from engine oil temperature sensor
Positive from fuel temperature sensor
Signal from engine oil pressure sensor
Positive from coolant temperature sensor
7 - 40
ELECTRICAL SYSTEM
CONTROL UNIT
CONNECTOR A to C (COMMOIN FOR ALL APPLICATIONS)
Fig. 7-50
W190
W190
ELECTRICAL SYSTEM
7 - 41
CONNECTOR (B) POWERING THE COMPONENTS AND

ALL THE FUNCTIONS PROVIDED BY THE APPLICATION
71
89
72
54
11
1
7
12
53
35
18
36
17
Fig. 7-51

ECU
PIN
1
2
3
4
7
8
9
12
13
14
15
16
19
20
27
28
WIRE
774
2
000
4
774
8
000
774
774
000
000
16
19
802
270156
28
FUNCTION
Positive direct from fuse 1E (20 Amp)
Fuel pre-heater relay 10/120A
Ground
Colt start relay
Engine oil pressure device relay indic. Light/switch/ pre-heater indicator/
pus-button/switch/pre-heater indicator light
Ground
Ground
Ground
Colt start relay
Neutral relay
Accelerator pedal pressed
Push button switch
Positive for diagnostic indicator EDC
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
W190
W190
ELECTRICAL SYSTEM
STARTING
ENGINE
REL
GOLD START
REL
PREHEARTER
Fig. 7-52
EDC 7 electronic controller electric circuit diagram
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
W190
ELECTRICAL SYSTEM
7 - 45
RESISTOR AND SOPLENOID SWITCH FOR PRE-POST-HEATING

It is a resistor located in the intake manifold.
It is used to warm-up the air in the pre/post heating operations. It is powered by a solenoid switch located on the
left side of the frame.
The resistance is about 0.5 .
RESISTOR
Fig. 7-55
Fig. 7-56
A. Control solenoid switch.
The control solenoid switch is connected to the controller at pins 4B 16B.

The control occurs with water and/or fuel temperature below 5 C (41 F).
The resistance of the solenoid switch is about 15 .
7 - 46
ELECTRICAL SYSTEM
W190
COOLANT TEMPERATURE SENSOR

It is a variable resistance type sensor capable of measuring the coolant temperature to provide the controller with
an indication of the thermal condition of the engine.
The same signal is used by the controller to pilot a temperature gauge installed on the dashboard (if any).
It is connected to controller pins 18C 36C.
The resistance at 20 C (68 F) is about 2.50 k
Fig. 7-57
A. Coolant temperature sensor.
W190
ELECTRICAL SYSTEM
7 - 47
FUEL TEMPERATURE SENSOR

It is a sensor equal to the previous one.
It monitors the fuel temperature to provide to the controller an indication of the thermal condition of the fuel.
It is connected to controller at pins 17C 34C.
Its resistance at 20 C (68 F) is about 2.5 kW
1
2
Fig. 7-58
1. Fuel temperature sensor - 2. Resistor for filter heating.
The ECU pilots the control solenoid valve for the filter heating to a fuel temperature of 36 C (97 F).
CONNECTOR
Fig. 7-59
Fig. 7-60
Ref.
1
2
DESCRIPTION
Ground
Temperature signal
CONTROLLER PIN
WATER
FUEL
18C
36C
17C
34C
7 - 48
ELECTRICAL SYSTEM
W190
AIR TEMPERATURE-PRESSURE SENSOR

It is a component integrating a temperature and a pressure sensor.
Installed on the intake manifold, it measures the maximum flow of air taken in and it calculates in an accurate
manner the quantity of fuel to be injected at each cycle.
It is connected to the controller at pins 21C 29C 10C 28C.
It is powered at 5 Volt.
The voltage present on the output is proportional to the pressure or temperature measured by the sensor.
Pin 21C 29C Temperature
Pin 10C 28C Pressure
ENGINE OIL TEMPERATURE PRESSURE SENSOR
It is a sensor equal to the previous one.
It is installed vertically on the engine oil filter support.
It measures the temperature and pressure of the engine oil.
It is connected to the controller at pins 19C - 33C - 9C - 35C.
It is powered at 5 Volt. The signal monitored is forwarded to the EDC controller that in turn controls the indicator
instrument on the dashboard (indicator + low-pressure indicator light).
The oil temperature is not visualised by any instrument; it is only used by the controller.
Pin 19C 33C Temperature

Pin 9C 35C Pressure
ELECTRIC DIAGRAM
Fig. 7-61
Fig. 7-62
Ref.
DESCRIPTION
CONTROLLER PIN
OIL
AIR
Ground
19C
21C
Signal NTC (temperature)
33C
29C
Power + 5 Volt
9C
10C
Signal (pressure)
35C
28C
W190
ELECTRICAL SYSTEM
7 - 49
HIGH-PRESSURE PUMP - PRESSURE REGULATOR
Fig. 7-63
A. Pressure regulator
The quantity of fuel supplying the high-pressure pump is dosed by the pressure regulator located on the lowpressure system; the pressure regulator is controlled by the EDC 7 controller.
The delivery pressure to the rail is modulated between 250 and 1450 bar (3626 and 21030 psi) by the electronic
controller actuating the pressure regulator solenoid valve.
It is a N. O. solenoid valve.
It is connected to the controller at pins C5 - C7.
Its resistance is about 3.2 .
7 - 50
ELECTRICAL SYSTEM
W190
FUEL PRESSURE SENSOR

Installed at one end of the rail, it measures the existing pressure of the fuel and informs the controller (feedback).
The value of the injection pressure is used to control the pressure itself and to determine the duration of the
electric control of the injection.
It is connected to the controller at pins 20C 27C 12C.
It is powered at 5 Volt.
FUEL PRESSURE SENSOR CONNECTOR

Fig. 7-64
Ref.
1
2
3
Description
Ground
Signal
Power
Controller pin
20 C / 68 F
27 C / 80.6 F
12 C / 53.6 F
W190
ELECTRICAL SYSTEM
7 - 51
ENGINE CRANKSHAFT SENSOR

It is a sensor of induction type and it is located on the front left side of the engine. It generates signals obtained
by the lines of magnetic flow that are closed through the openings of the phonic wheel mounted on the crankshaft.
It is connected to the controller at pins 25C-24C. The value of the resistance of the sensor is ~ 900 .
CRANKSHAFT SENSOR
Fig. 7-65
TIMING SENSOR
It is a sensor of induction type and it is located on the rear left side of the engine. It generates signals obtained by
the lines of magnetic flow that are closed through the openings on the gear installed on the camshaft. The signal
generated by this sensor is used by the electronic controller as a timing signal of the injection.
Although it is similar to the flywheel sensor it is NOT interchangeable since it has a different external shape.
It is connected to the controller at pins 23C-30C. The value of the resistance of the sensor is ~ 900 .
TIMING SENSOR
Fig. 7-66
1
3
1
3
2
CONNECTOR
ELECTRIC DIAGRAM
Fig. 7-68
Fig. 7-67
Controller Pin
Ref.
Description
Cranfshaft sensor
1
2
3
Signal
Signal
Shielding
24C
25C
Timing
sensor
30C
23C
7 - 52
ELECTRICAL SYSTEM
W190
ENGINE CLUTCH SENSORS F4AE0684H E

It is a proximity electronic switch powered at 24 Volt.
It is installed on the clutch pedal and monitors that the clutch engagement occurred.
It is equipped with a yellow signalling led lighting when the pedal is released.
It is connected to the electronic controller at pins 62B-8B.
1 (GROUND)
2 (+24)
3 (SIGNAL)
1
Fig. 7-69
1. Sensor sensing part - 2. Securing screws (torque 10 Nm) - 3. Brass body - 4. Yellow led - 5. Connector.
Ref.
1
2
3
Description
Ground
Power + 24 V
Signal
Controller Pin
8B
62B
W190
ELECTRICAL SYSTEM
PRESSURE SWITCH FOR STEERING MAIN CIRCUIT LOW PRESSURE

WIRES
835 To Brown Box CN1-17
000 To ground
TECHNICAL DATA
Thread:
M14 x 1.5
Setting:
(Push-OFF)
Fig. 7-70
PRESSURE SWITCH FOR EMERGENCY STEERING CIRCUIT LOW PRESSURE
WIRES
844 To Brown Box CN1-19
000 To ground
TECHNICAL DATA
Thread: M10 x 1 taper
Setting: 1 0.2 bar (14.5 2.9 psi)
Fig. 7-71
7 - 53
7 - 54
ELECTRICAL SYSTEM
PARKING BRAKE PRESSURE SWITCH
W190
996
996
978
978
WIRES
978 To ground
996 Parking brake relay
TECHNICAL DATA
N.C.
Thread: M10 x 1
Setting: 82 1 bar (1189 14.5 psi)
LOCATION - Rear side of transmission

Fig. 7-72
TRANSMISSION OIL TEMPERAURE SENSOR

570
570
574
574
WIRES
570 To controller ZF PIN X19-46
TECHNICAL DATA
Thread: M16 x 1.5
LOCATION: Left side of torque converter cover

Fig. 7-73
W190
ELECTRICAL SYSTEM
7 - 55
BUCKET POSITIONER PROXIMITY SENSOR
WIRES
BLUE
BROWN
BLACK
BLACK
To ground
To connection 31 way (994)
BLUE
BROWN
TECHNICAL DATA
Thread:
M18 x 1
Tightening torque:
25 Nm
Setting of sensor intervention gap: 5 mm max.
981
LOCATION: On bucket cylinder

Fig. 7-74
BOOM KICK-OFF PROXIMITY SENSOR
WIRES
BLUE
BROWN
BLACK
BLACK
To ground
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
7 - 56
ELECTRICAL SYSTEM
W190
TRANSMISSION SPEED SENSOR

B1
SPEED SNEOR B1 (ENGINE)

WIRES
GE2 To controller ZF PIN X19-19
BL2 To controller ZF PIN X19-3
536
536
SPEED SENSOR B2
WIRES
GN3 To controller ZF PIN X19-41
SW To controller ZF PIN X19-3
537
537
B2
534
534
SPEED SENSOR B3
WIRES
BL4 To controller ZF PIN X19-3
RT4 To controller ZF PIN X19-42
SPEED SENSOR B4
WIRES
508 508 To use 8C (7.5 Amp)
535
535
B3
534
534
535
535
Fig. 7-76
INSTALLATION NOTE FOR SENSORS:

Apply LOCTITE 572 to the sensors.
Setting: To obtain a correct installation of the sensors, tighten them until touching the transmission gear,
then loosen the sensor one and a half turn.
B1
B2
B3
B4
Fig. 7-77
W190
ELECTRICAL SYSTEM
7 - 57
FUEL LEVEL SENSOR

WIRES
555 To Brown Box controller CN1-7
000 Ground
LOCATION: Inside the tank
FULL
3/4
409
262
272
25
(55)
1/2
320
409
227
R500
110
1/4
(55)
557
555
WARNING
POINT
EMPTY
FULL
3/4
1/2
1/4
EMPTY
()
10
19
32
49.5
80
Floater
Fig. 7-78
7 - 58
ELECTRICAL SYSTEM
W190
7.4.5 ALTERNATOR
BOSCH
B+
BOSCH
BOSCH
BS
L
IS
BS
DFN
80A
B.B.
4A
(4E)
4A
(5E)
B+
707
637
DFN
BS
15
L
S
875
24V
18/10
ENGINE SOLENOID TERMINAL OR POINT

NEAR THE BATTERY CONNECTED TO THE
BATTERY BY LARGE DIAMETER CABLE
Fig. 7-79
WIRES
773 To LINK fuse (80A)
637 To connector "18/10" (cab connections)
000 Ground
TECHNICAL DATA
Nominal voltage of electrical system: 24 Volt
Nominal current output: 70 Amp
LOCATION: left side of engine compartment
W190
ELECTRICAL SYSTEM
7 - 59
AIR CLEANER CLOGGING PRESSURE SWITCH

WIRES
000 The ground
TECHNICAL DATA
Setting (closing of contacts): 57 to 67 mbar
Tightening: tighten manually, without tools.
LOCATION: On air cleaner inside engine hood.
663
000
Fig. 7-80
7 - 60
ELECTRICAL SYSTEM
W190
7.5 ACOUSTIC TRANSDUCERS

HORN
LOCATION: Inside front frame
WIRES
138 To connector 31/5
000 To ground
TECHNICAL DATA
Current absorption: 5A (0.2 )
Sound level: 117 db at 1.2 m
000
138
Fig. 7-81
BACK-UP ALARM
LOCATION: Radiator compartment.
000
163
WIRES
163 To back-up alarm relay through fuse 3E
(7.5 Amp)
000 Ground
TECHNICAL DATA
Sound level: adjustable (97 - 107 - 112 db)
VIEW OF BRIDGE FOR SETTING

OF ACOUSTIC POWER
MIN.
MED.
MAX
Fig. 7-82
W190
ELECTRICAL SYSTEM
7 - 61
7.6 CLIMATISATION SYSTEM

When this button is pressed all the climate
system functions are fully automatically controlled.
The system provides to reach and maintain constant
the temperature selected for the compartment.
This button intervenes on the panel switching

from outer air to re-circulation and viceversa.
The air re-circulation is automatically activated when
outside temperature exceeds 26 C (79 F).
Fig. 7-83
Selection of desired temperature inside the

compartment.
Each push corresponds to a variation of 1 C (86 F)
of the value indicated by the display.
For values below 8 C (46.4 F) or exceeding 30 C
(86 F). the display shows LO and HI respectively.
Under these extreme conditions, the system is
configured in a stable setting so that it always provides
maximum cold LO or maximum heat HI.
Activation/deactivation of air conditioner

compressor.
The activation of the compressor is signalled by the
activation of the relevant led.
In this case if an inner temperature lower than the outer
one is required, the led flashes for a few seconds to
warn the operator indicating that the system is unable
to cool the air.
When the outer temperature is below 3 C (37.5 F) the
compressor is deactivated.
(rightward). Manual selection of the quantity

of air injected into the compartment.
By actuating these buttons, led AUTO goes OFF. The
system still regulates automatically except for the
manual selection.
By pressing the speed decrement button with zero
speed, the controller goes to condition OFF (everything
inoperative and functions deactivated).
Indication of outside temperature.

When the outside air temperature approaches 0 C
(32 F) the display flashes for a few seconds at regular
intervals, indicating the danger of ice formations on the
ground.
7 - 62
ELECTRICAL SYSTEM
W190
CLIMATISATION DIAGRAM
16 AZZURRO-GIALLO/LIGHT BLUE-YELLOW
+Batteria/+Battery
15 ROSSO/RED
+Chiave/+Key
6 BIANCO-NERO/WHITE-BLACK
+Luci/+Light
12 NERO/BLACK
Massa/Ground
Sensore temperatura aria miscelata

Mixed air temperature sensor
8 VIOLA-BIANCO/VIOLET-WHITE
18 VIOLA-BIANCO/VIOLET-WHITE
9 ROSA-NERO/PINK-BLACK
Sensore temperatura aria esterna
External air temperature sensor
19 ROSA-NERO/PINK-BLACK
11 1
12 2
10 ROSSO-NERO/RED-BLACK
13 3
14 4
Sensore temperatura aria interna

Internal air temperature sensor
20 ROSSO-NERO/RED-BLACK
15 5
16 6
2 AZZURRO-BIANCO/LIGHT BLUE-WHITE
17 7
18 8
13 BIANCO-WHITE
Connettore (per la centralina) da utilizzare nel cablaggio:

Molex MiniFit 20 vie porta femmina cod. 557-20R
19 9
20 10
Centralina
Control Unit
Pin femmina:cod.5556
Valvola ad acqua motorizzata
Water valve with motor
Energized
= blow-by
Rel.
energized=blow-by
4 MARRONE-BIANCO/BROWN-WHITE
87
Usato per attuatore di ricircolo

Used only for recycling acuator
87
85
30
86
1 VERDE/GREEN
87
87
85
30
86
Tasto A/C
A/C Switch
All'impianto di
condizionamento
To A/C system
11 BLU/BLUE
3 GIALLO/YELLOW
5 MARRONE/BROWN
2
+Key
+Key
2.5 mm
87
86
87
85
30
87
86
87
85
30
87
86
85
30
+key
+Key
a
2 Velocit
nd
2 Speed
a
3 Velocit
th
3 Speed
a
1 Velocit
st
1 Speed
Electric
Electricfan
fan
Brown
Black
Brown
Blue
Blue
Light
blue-yellow
Light
blue- yellow
Fig. 7-84
W190
ELECTRICAL SYSTEM
7 - 63
CLIMATISATION ELECTRIC CIRCUIT

711
x1-12
x1-12+24V
+24 VALIMENTAZIONE
POWER
UI
R1
470 ohm 1/2 w

+C3
000F
50V
C1
100nF
63V
+C3
10F 63V
190
7812 0
GND
+C3
10F
63V
CLIMA04
191
RL1
24V
85
87 87a
86
30
OUT +12
x1-1
GND X1
C2
100nF
63V
NI
D1
x1-7
RELAY
x1-14 85
85RECIRCULATION
RELE' RICIRCOLO
MOTOR
x1-13 RECIRCULATION
MOTORE RICIRCOLO
IN4007
CLIMA11
01
D2
RL2
24V
85
87 87a
86
30
x1-6
x1-4
st RELE 1a
185
SPEED RELAYVELOCITA
VELOCITA
11sta SPEED
x1-8
x1-9
nd RELE 2a VELOCITA
285
SPEED RELAY
22ndaSPEED
VELOCITA
IN4007
CLIMA03
02
D3
RL3
24V
85
87 87a
86
30
IN4007
CLIMA05
03
RL4
24V
85
87 87a
86
30
a
rd RELE 3
x1-10 386
VELOCITA
SPEED RELAY
x1-13 33rdaSPEED
VELOCITA
D4
IN4007
CLIMA01
824
D5
RL5
24V
85
87 87a
86
30
X1-2 CONDITIONER
86 RELE CONDIZIONATORE
RELAY
X 1-3 CONDITIONER
USCITA CONDIZIONATORE
OUTPUT
IN4007
Fig. 7-85
7 - 64
ELECTRICAL SYSTEM
W190
SECTION 8
CAB
TABLE OF CONTENTS
PAGE
PARAGRAPH
SUBJECT
8.1
8.2
8.2.1
REPAIR .................................................................................................................. 8-2

Cab (Removal/Installation) ...................................................................................... 8-2
8.3
WINDSCREEN WIPERS AND WASHERS .............................................................. 8-4
8.4
8.4.1
8.4.2
HEATER ................................................................................................................. 8-5

Generalities ............................................................................................................. 8-5
Main components and specifications ...................................................................... 8-5
8.5
8.5.1
CAB GLAZING ........................................................................................................ 8-6

Disassembly and assembly ................................................................................... 8-7
8.6
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.6.8
8.6.9
8.6.10
AIR CONDITIONING UNIT .....................................................................................

Operating instructions ............................................................................................
Technical data .......................................................................................................
Cab climate control and error code .........................................................................
Service precautions ...............................................................................................
Tools connections ..................................................................................................
Discharging ............................................................................................................
Refrigerant charching .............................................................................................
Leak inspection ......................................................................................................
Troubleshooting chart .............................................................................................
Special tools ..........................................................................................................
8-11
8-11
8-12
8-14
8-16
8-18
8-19
8-19
8-20
8-22
8-29
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.
Loosen the four safety screws and the four screws

securing the cab to the frame.
Install an appropriate lifting device over the cab hooking the 4 lifting eyes previously tightened (weight of
the cab about 700 kg - 1540 lbs) and set a slight tension on the lifting chain.
WARNING
Always disconnect the battery isolator switch
before cleaning, repairing, overhauling or parking
the machine.
WARNING
Always use hoists or similar devices of suitable
capacity to lift or move heavy components. Ensure that the sling is perfectly made.
Use the lifting eyes.
ON
OFF
Fig. 8-3
Remove the guards around the bottom of the cab from
both sides.
Disconnect the ground plait and the electric connections between cab and frame.
Fig. 8-5 Lifting cab
Slightly raise the cab taking care not to tension any

electrical cables or hoses.
Lifting height should be such to allow detachment of
all lines and cables from machine assemblies.
Fig. 8-4
W190
CAB
8-3
Close the heater feeding valves.
Disconnect the two heater hoses located in the rear
right side of the cab.
Make sure that all connections on the machine are
disconnected, then lift the cab, moving it sideways.
Disconnect the sensor and potentiometer wires from

the accelerator pedal.
Disconnect, after labelling them, the pipes to orbitrol
(6). Loosen the screws securing the brake pedal valve
and remove the pedal assembly without sisconnecting
the pipes.
Open the panel on the right side of the machine and
label the hoses of equipment control levers (3) and
three-way valve (4). Disconnect the pipes of the
windshield washer from the washer liquid tank.
Close the heater feeding valves.
Reinstallation
The installation is the reversal of the removal.
Tighten the cab screws to the frame to the specified
torque.
12
5
4
3
10
11
6
1
11
Fig. 8-6
Note -
Screw M16 - Tightening torque 230 Nm
1. Safety screw M30 - 2. Safety screw M24 - 3. Equipment control lever pipes - 4. Three-way valve pipes - 5. Potentiometer 6. Orbitrol valve - 7. Cab and frame front securing nut M16 - 8. Cab and frame rear securing nut m16 - 9. Accelerator pedal 10. Steering column - 11. Elastic pads - 12. "HOLD" function sensor.
8-4
CAB
W190
8.3 WINDSCREEN WIPERS AND WASHERS

The front windscreen wiper motor (1) is located at the
front of the steering column. The front windscreen wiper
has two intermittent working speeds: 35 strokes per
min (slow) and 55 strokes per min (fast).
A dog-leg mechanism transforms the motor shaft rotary motion into 45 strokes of the wiping arm.
The rear windscreen wiper motor (2) is located under

the cab trim behind the drivers seat, on the right-hand
side. The rear windscreen motor has but one speed
(approx. 54 strokes per min).
Internal gears provide an 80 oscillation of the wiping
arm.
Note 1 Before setting the wiper blades in motion,

operate the windscreen washer to minimise the risk
of scratching the glass.
Note 2 Use the cleaning fluid DP1 diluted with water

dependent upon working temperature. A 50% detergent/water solution does not freeze down to -10 C
(50 F). Below this temperature, use cleaning fluid only.
Pump hoses are connected to the nozzles located at

the sides of the wiping arms.
3
4
Fig. 8-7
The windscreen washer fluid bottle (3) is located inside the engine compartment, on the left-hand side.
The bottle is fitted with two pumps (4) and (5) for the
front and rear windscreens, respectively.
Specifications
Bottle capacity .......................... 2.5 lt. (0.87 US/gal)
Rated voltage .................................................... 24V
Absorbed current .............................................. 2A
Max. flow ........................ 3 lt./min (0.6 USG/min)
Fig. 8-8
In case of motor or arm assembly replacement, it will
be necessary to reassemble the arm assembly to the
drive part correctly to centre the wiping action over
the glass width.
To this aim, select the most suitable position for the
arm on the knurled drive part shown by the arrow in
the figure.
W190
CAB
8-5
8.4 HEATER
8.4.1 GENERALITIES
The cab heater is placed in a special compartment,
on the cab right-hand side.
The associated switches are located on the control
console and are used to:
6
2
- adjust air temperature;

- control air flow intensity;
- admit air from the outside or recirculate the air inside
the cab.
In case of air intake from the outside, air is drawn in
through the filter A. If air is being recirculated, internal
cab air is driven through the filtering panel B.
Both filter A and filtering panel B should be replaced
periodically.
7
5
A
Fig. 8-10
8.4.2 MAIN COMPONENTS AND

SPECIFICATIONS
The heater main components are:
Fig. 8-9
1.
2.
3.
4.
5.
6.
7.
8.
9.
Electrical fan
Outside air filter
Filtering panel
Heat exchanger
Shroud
Housing
Water lines
Air ducting
Feed valve
Specifications
Heat value .......................................... 10 000 Kcal/h
Air flow ........................................... 575 10% m3/h
Absorbed power ........................................... 400 W
Working temperature range
....................................... 15 + 50 C (14 + 122 F)
8-6
CAB
W190
8.5 CAB GLAZING

All cab glasses are differential hardening type.
Glasses should be ordered from the manufactured.
They should be kept clean at all times to guarantee
good visibility. When cleaning the glasses, pre-wash
them with a water and detergent solution or other proprietary product using a squeegee to reduce abrasion
and make cleaning easier.
4
6
2
Notice - Never use hot water over cold glasses.
All glasses fitted to the cab have been subjected to

differential hardening and have a 5 0.2 mm thickness. They are firmly bonded to their seats by means
of a polyurethane sealant.
1
7
Fig. 8-12
5 0.2 mm
0.19 0.007 in
1. Front windscreen - 2. Rear windscreen - 3. Door glass

- 4. RH side glass (emergency exit) - 5. LH rear glass 6. RH rear glass - 7. Bonding kit.
Fig. 8-11
W190
CAB
8-7
8.5.1 DISASSEMBLY AND ASSEMBLY

Disassembly
Preparing the replacement glass
1. Push a pointed object through the adhesive from

inside the cab and insert the wire.
1. Place the glass momentarily in position and mark

with adhesive tape to position it correctly during
final bonding.
2. Using the wire, cut the adhesive all around the

glass. Lift out the glass using two suction cups.
3. To leave a smooth bevel of approximately 1 or 2
mm, which should be kept clean as it will be the
bonding base for the polyurethane adhesive. Should
the paint be partially damaged, apply some glass
primer as a protection against corrosion.
Note Work only in well ventilated premises. The
polyurethane adhesive does not contain low molecular weight (monomolecular) volatile isocyanates. Therefore, there is no danger of irritation for the respiratory
tract. However, all precautions required when using
chemicals should be observed. Avoid contact with
the eyes and skin.
Fig. 8-14
2. Thoroughly clean the glass edge using the special
cloth moistened in the degreaser supplied.
Important - After degreasing, wipe the degreased part

using a clean dry cloth.
Fig. 8-13
WARNING
Always wear gloves and use special suction cups
with handles when replacing the glasses.
Do not strike the glasses to remove.
Fig. 8-15
8-8
CAB
3. Shake well the glass activator bottle before use (at

least 1 minute after ball separation from the sediment). Apply an even continuous bead of activator
along the black stencil using the applicator supplied.
W190
5. Punch the membrane in the threaded connection.
Important - Once applied, allow the activator to dry for

at least 10 minutes keeping the surface clean.
Fig. 8-18
Fig. 8-16
4. Remove the sealant cartridge bottom cover and

salts therein.
6. Cut off the nozzle and apply a smooth continuous

bead of BETASEAL sealant-adhesive along the
edge of the body or windscreen keeping the gun
vertical.
Fig. 8-19
Fig. 8-17
W190
CAB
8-9
Glass assembly
WARNING
1. Position the glass in its seat slightly pressing it.
Any variation to instructions specified, such as

use of materials after expire date or improper work
procedures, may negatively affect the results of
the operation. The manufacturer does not assume
any responsibility for damages which may derive
to persons and/or things.
Fig. 8-20
Note The glass must be fitted to the machine within

maximum 15 minutes after applying the BETASEAL
sealant-adhesive.
Note Work only in well ventilated premises. The

polyurethane adhesive does not contain low molecular
weight (monomolecular) volatile isocyanates. Therefore, there is no danger of irritation for the respiratory
tract. However, all precautions required when using
chemicals should be observed. Avoid contact with the
eyes and skin.
Note The BETASEAL sealant-adhesive hardens

with air moisture. Hardening depends upon ambient
humidity and relative penetration degree. Therefore,
machine downtime ranges from 2 to 3 hours at a
temperature of 23 C (73 F). During this period the
machine should not be submitted to any stress whatever.
8 - 10
CAB
W190

W190
CAB
8 - 11
8.6 AIR CONDITIONING UNIT

8.6.1 OPERATING INSTRUCTIONS
The principle of operation can be summarised as follows: the refrigerant, R134a, in its gaseous state, is sucked
by the compressor at low pressure and taken to a final pressure. The gas, heated by the compression, flows, still
in a gaseous state, into the condenser where, under the effect of the cooling provided by the air flowing through
it by the action created by the fan, reaches the condensation point, passing into a liquid state at high pressure.
Subsequently, the refrigerant, at liquid state, reaches a dehydration filter, which has the function of capturing
impurities, absorb moisture trapped into the system and operate as a reserve reservoir for the refrigerant itself.
Then, the Freon reaches the expansion thermostatic valve, which has the purpose of regulating the refrigerant
flow into the evaporator at low pressure, causing its passage from liquid to gaseous state. At the same time, the
air flowing through the evaporator, under the action of the fan, having a temperature which is higher than the
refrigerator contained by the evaporator itself, causing its boiling and full evaporation, releasing heat.
The air, being cooled, deposits on the fins of the evaporator parts of its moisture content, under the form of little
drops, which drop into the tanks and are discharged outside the cab.
Air cooled and dehumidified, is sent into the cab. The refrigerant, at the outlet of evaporator, is sucked again by
the compressor, beginning a new cycle.
Fan unit
Evaporator
Compressor
Expansion valve
Condenser
Intake
High
pressure
Low
pressure
Filter
Pressure switch
W190-8R001
Fig. 8-21
8 - 12
CAB
W190
8.6.2 TECHNICAL DATA

Cab Air Fan
Voltage
Electrical input
Air flow
Speed
24 V
17 A
1190 m3/h
3
Heater
Power
Rate of flow
Air flow
Input air temperature
11,7 KW
500 l/h
575 m3/h
-15 C (5 F)
Evaporator
Power
Rate of flow
Air flow
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
Relative humidity
Vaporisation temperature
Condensation temperature
375 x 480 x 37,5 mm

35 C (109 F)
50%
5 C (41 F)
60 C (140 F)
Expansion valve
Type
Gas
Superheat
TGK TEV 216 PO-2

Freon R134A
4 C (39 F)
Compressor
Type
Displacement
Pulley
Lubricant oil q.ty
SANDEN SD7H15 md 7948 for 134A

154.9 cc
135.6 mm
200 cc
Dehydrator filter
Type
Dimension
Capacity
Dehydrating
Pipe fitting
SKG CC164
141 x 76 mm
415 cc
140 gr
5/8'' - 18 UNF
Pressure switch
Type
Interruption:
3L-F LMH-971-641
Low pressure
High pressure
(Fan)
Thermostat
Type
Setting
RANKO K50-L9421
Cold
OFF
ON
OFF
ON
OFF
ON
2.45
2.6
28
25
12
17
bar (36 psi)

bar (38 psi)
bar (406 psi)
bar (363 psi)
bar (174 psi)
bar (247 psi)
OUT 0 C (32 F)
IN
5 C (41 F)

W190
CAB
CONTROL
BOARD
8 - 13
ELECTRONIC CONTROLLER
CONDENSER
AIR COMPRESSOR
HOSE
DRIVE FAN
HOSE
SENDER
FILTER
Sensor
PRIMARY AIR
FILTER
EVAPORATOR
SECONDARY AIR
FILTER
Sensor
HYDRAULIC
ONNECTION
VALVE
FAN
RADIATOR
ENGINE
HOSE
THERMOSTAT
W190-8R002
Conditioner components
8 - 14
CAB
W190
8.6.3 CAB CLIMATE CONTROL AND ERROR

CODES
3
6
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inner temperature increment.

Inner temperature decrement.
Indication of inner temperature.
Fan speed increment.
Fan speed decrement.
Automatic operation.
Compressor act./deact. button.
Re-circulation.
Outer temperature.
ERROR CODES TABLE

In the event of troubles, the following error codes are
indicated:
ERROR
ERROR DESCRIPTION
E1
The outer air temperature sensor is cut-off.
E2
The outer air temperature sensor is short circuited.
E3
The operators compartment air temperature sensor is cut-off.
E4
The operators compartment air temperature sensor is short circuited.
E5
The mixed air temperature sensor is cut-off.
E6
The mixed air temperature sensor is short circuited.

W190
CAB
Electronic temperature control (E.C.S.)

The E.C.S. controls the temperature and the quantity
of air flowing into the compartment.
This control is ensured within a temperature range
between - 20 C (- 4 F) and + 50 C (122 F).
Buttons selecting the desired temperature

inside the compartment.
A variation of 1 C of the value displayed corresponds
to each pressing.
For values lower than 18 C (64 F) or exceeding
30 C (86 F) the symbols LO and HI respectively,
appear on the display.
Under these extreme conditions, the system is
configurated in a stable manner so that it always
provides maximum cold in LO and maximum heat in
HI.
8 - 15
the outside temperature exceeds 26 C (79 F)
When actuating this button, the outer

temperature is displayed for about 6 seconds.
When the temperature of outer air is near 0 C (32 F)
the display flashes for a few seconds at regular
intervals, to warn of danger of formation of ice on the
road.
(at the right). Buttons changing manually the

quantity of air flowing into the compartment.
When actuating these buttons, the AUTO led goes
OFF. The system still regulates in automatic mode,
with the exception of the manual selection.
When pressing the speed decrement button with zero
speed, the controller goes into OFF condition (all
switched-off and functions deactivated).
When pressing this button, all climatisation

functions are automatically controlled.
Button to switch ON/OFF the operation of

the air conditioner.
The switching ON of the compressor is signalled by
the glowing of the relevant led.
When the compressor is inoperative (led OFF) the
system is not cooling.
When the outside temperature drops below 3 C
(37 F) the compressor is cut-off.
This button actuates the panel switching
from outside air to re-circulation and viceversa.
The air re-circulation is automatically activated when
8 - 16
CAB
W190
Conditioning Performance
Piping precautions
IN ACCORDING WITH ISO 10263
- Position the O-Ring against the bulge in the pipe

when connecting hoses and pipes.
8.6.4 SERVICE PRECAUTIONS
- Coat the piping connections and the O-Rings with

PAG oil.
WARNING
Direct contact with refrigerant can cause frostbite
or blindness.
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face.
- Fit the nuts and unions tightly against the base of

the companion pieces then hand tighten the nut as
much as possible. Then, tighten to the specific
torque.
Note Always use oil specified for R134a system to
coat the O-Rings.
CAUTION
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere.
O-Ring
Union
Handle the air conditioner components carefully. Do

not knock or drop them.
Nut
1850-2R392
Fig. 8-23

W190
CAB
Do not release refrigerant into the air

Although R134a is not subject to CFC regulations, it
can have an effect on global warming, and so should
not be released into the air.
8 - 17
WARNING
Cap the oil container after use and the air conditioner system parts, when servicing.
Never mix compressor oil with other types of oil.
WARNING
When removing refrigerant from the air conditioner
system, always use a refrigerant recovery unit
made especially for R134a (Attrezzatura specifica
380001326).
OIL
Do not release the

refrigerants
into the atmosphere
Cap all container and components
Fig. 8-25
R134a
The oil must be replaced or replenished in the following cases:
- when refrigerant or oil leaks from the system;
Recovery unit
- when refrigerant is suddenly discharged from the

system;
- when system components are replaced.
Fig. 8-24
Note The oil plug O-ring must be replaced with a

new one.
Compressor oil
Use compressor oil made specifically for use with
R134a.
R134a system compressor oil has an extremely high
moisture absorption capacity.
Refrigerant charge inspection

As shown in the left hand figure seguente, compressor oil will not blend with refrigerant (R134a) at certain
temperatures. At these temperatures, the refrigerant
may appear 'cloudy' when checked using the
sightglass, and the charge may be mistakenly judged
as insufficient.
Fig. 8-26
8 - 18
CAB
W190
8.6.5 TOOL CONNECTIONS

1. Fully close both manifold gauge valves.
WARNING
Do not connect hoses to the air conditioner system when the manifold gauge valves are open.
2. Connect the three hoses securely to the manifold

gauge.
3. Connect the utility hose to the vacuum pump or
refrigerant source
CAUTION
If there is any refrigerant in the air conditioner system, connect the hoses only after the service hoses
and the manifold gauge have been evacuated.
4. Connect the couplers to the high and low pressure

hoses. Turn the knob on the fitting to depress the
core if so equipped.
Before disconnecting hoses, close both manifold
gauge valves.
Manifold gauge
Low pressure
High pressure
Charging hose
Charging hose
Coupler
Vacuum pump
Refrigerant container
Fig. 8-27

W190
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.
If the pointer moves toward 0 (zero) the system is

not sealed. Inspect the system to identify the leakages and repair them.
The recovered refrigerant must be recycled trough a

refrigerant recovery unit to ensure that it is clean and
free of moisture.
Refer to the user's instruction manual for refrigerant
recovery unit handling and operations.
8.6.7 REFRIGERANT CHARGING

There are various methods of charging refrigerant into
the air conditioner system. These include using refrigerant recovery units and direct charging using a
scale.
Fig. 8-28
Evacuation
1. Operate the vacuum pump.
2. Open both manifold gauge valves
3. Evacuate the system for at least 20 minutes.
4. Close both manifold gauge valves.
Initial charge
1. Put the refrigerant container on the scale.
Note Change refrigerant in the system of wheel

loader every 2 years.
Initial evacuation
1. Close both manifold gauge valves.
2. Connect the high and low pressure hoses to the
system.
3. Connect the utility hose to the vacuum pump.
4. Open the manifold gauge's high and low pressure
valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to stabilize the vacuum inside the system.
7. Close both valves and stop the vacuum pump.
Checking air tightness

1. Leave the system as it is for 5 to 10 minutes.
Ensure the low pressure gauge needle does not move
towards the atmospheric pressure side (gauge pressure 0).
Fig. 8-29
2. Disconnect the utility hose from the vacuum pump
and connect it to the refrigerant container.
3. Purge air from the utility hose.
4. Record the refrigerant weight.
5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side
valve to charge refrigerant from the low pressure
side valve to charge refrigerant from the low pressure side.
8 - 20
CAB
W190
7. Charge with refrigerant until the low pressure manometer exceeds the minimum threshold of pressure switch 0.26 mPa (2.6 bar).
The optimal refrigerant's weight is approximally
1300 gr.
8. Close the instrument manifold low pressure valve.
CAUTION
Do not overcharge the system.
Initial check for leakages
Use an electronic leakage sensor to check the connections of the system for possible leakages.
Fig. 8-31
Inspection procedure
Evacuation
Refrigerant
charging
Electronic leak detector
380001327
A22090
Operate compressor for

at last 5 min
Check for refrigerant

leaks from high
pressure side parts
8.6.8 LEAK INSPECTION

To facilitate refrigerant leak detection, operate the air
conditioner at the full cooling setting with the fan running at maximum speed for at least 5 minutes.
Stop the engine and, using a leak detector, check for
refrigerant leaks on the high pressure side.
This must be done immediately because when the
refrigerant stops circulating, the high pressure decreases gradually, as shown in the graph, while the
low pressure side pressure increases gradually.
Operation test
Repair

W190
CAB
8 - 21
Inspection sequence
High pressure side
Compressor
discharge port
Condenser
inlet and outlet
Cooling unit
inlet
Receiver drier inlet

and outlet
Low pressure side

Compressor
suction port
Cooling unit
outlet
CAUTION
Clean all inspection points.
Check all connections carefully.
To prevent incorrect diagnoses, ensure there is
no refrigerant or cigarette smoke in the vicinity of
the vehicle.
Inspection points
W190-8R003
Fig. 8-32
8 - 22
CAB
W190
8.6.9 TROUBLESHOOTING CHART

(a) Fan motor does not operate
Inspection
Possible cause
Remedy
1. Blown fuse
Inspect the air conditioner fuse.
Replace.
2. Broken wiring
or bad connection
Check the fan motor earth and connectors.
Repair the wiring or

connect correctly.
3. Fan motor
malfunction
Check the two lead wires from the motor with a circuit
tester. If there is no conductance, the motor is malfunctioning.
Replace.
4. Broken resistor wiring
Check resistor conductance using a circuit tester. If there is

no conductance, the wiring is broken.
Replace.
5. Fan motor switch

failure
Operate the fan switches in sequence and check whether

the fan operates.
Replace.
(b) Fan motor operates normally, but air flow is insufficient

Inspection
Possible cause
Remedy
1. Evaporator iniet
obstruction
Check the iniet.
Remove the obstruction

and clean.
2. Air leak
Check the cooling unit case fittings.
Repair of adjust.
3. Defective thermo
switch
Check whether the evaporator is frozen. Check the switch

using a circuit tester.
Replace.
(c)
Insufficient cooling although air flow and compressor operation are normal
Inspection
Remedy
1. Insufficient
refrigerant.
There will be little temperature difference between the lowand high-pressure sides. Air bubbles or a "cloudy" flow will
be visible in the sightglass.
Repair any leaks and

recharge the refrigerant
to the correct level.
2. Excessive refrigerant
The high-pressure side pressure will be high and even if

the condenser is cooled using water, air bubbles will not
appear in the sightglass.
Drain small quantity of

refrigerant until air bubbles appear periodically
through the window.
Possible cause

W190
CAB
8 - 23
(d) The compressor does not operate at all, or operates improperly

Possible cause
Inspection
Remedy
1. Loose V-belt
The belt oscillates considerably.
Adjust the tension.
2. Internal compressor
malfunction
The V-belt slips.
Repair or replace.
Low battery voltage
Clutch slips.
Recharge the battery.
Faulty coil
Same as above.
Replace the magnetic

clutch.
Oil on the clutch

surface
The magnetic clutch face is dirty, causing it to slip.
Replace, or clean the

clutch surface.
3. Magnetic clutch related
Excessive clearance
between the clutch
plate and clutch disk.
The clutch plate clings
when pushed.
Adjust the clearance, or

replace.
Open coil
Clutch does not engage and there is no reading when a

circuit tester is connected between the coil terminals.
Replace.
Broken wiring or poor

earth
Clutch will not engage at all. Inspect the earth and connections.
Repair.
Wiring harness components
Test the conductance of the pressure switch,

thermoswitch, relay, etc.
Check operation, referring to the wiring diagram, and replace defective parts.
8 - 24
CAB
W190
Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35 C (86 ~ 95 F) and
engine speed of approx. 1500 rpm are:
High pressure side pressure: 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm2, 213 ~ 242 psi)
Low pressure side pressure: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm2, 18 ~ 28 psi)
Remedy
Possible cause
Inspection
Low -pressure side pressure too high.
The pressure in the low-pressure side becomes, normally, too high

when the pressure on the high-pressure side is excessive. As
explained here below, the check that follows is performed only when
the pressure on the low-pressure side is too high.
1. Defective thermoswitch.
The magnetic clutch switch turns off before the outlet air temperature
is sufficiently low.
Adjust or replace.
2. Defective compressor
gasket or valve.
The high- and low-pressure side gauge pressures equalize when the
magnetic clutch is turned off.
Repair or replace the compressor.
3. Poor expansion valve temperature sensor contact.
Frost has adhered to the compressor connector so that the temperature is lower than that of the evaporator outlet side piping.
Install the temperature sensor against the low-pressure

pipe.
4. The expansion valve

opens too far.
Same as above, or there is little pressure fluctuation when the

temperature sensor is places against the pipe and then removed.
Replace.
5. Clogged compressor suction filter.
The compressor connector is cool but the low-pressure hose is not.
Remove and clean the filter.
1. Insufficient refrigerant.
Refer to "Insufficient refrigerant" on previous page.
Same as at left.
2. Clogged receiver drier.
Considerable temperature difference between the inlet and outlet

sides, or the tank is frosted.
Replace the receiver drier.
3. Clogged expansion valve.
The expansion valve's inlet side is frosted.
Clean the filter or replace the

expansion valve.
4. Expansion valve temperature sensor gas leak (damaged capillary tube, etc.)
The expansion valve's outlet side is chilled, and low pressure gauge
indicates a vacuum.
Clean or replace the piping.
5. Clogged or blocked piping.
When the piping is clogged or blocked, the low-pressure gauge reading

will decrease, or a negative reading may be shown.
Clean or replace piping.
6. Defective thermoswitch.
The evaporator is frozen.
Adjust or replace.
1. Poor condenser cooling.
Dirty or clogged condenser. Cooling fan does not operate correctly.

Blown fuse, broken wiring or poor contact. Fan motor malfunction.
Clean, and repair the fan.

Repair the wiring or replace
the fuses.
2. Excessive refrigerant.
Refer to "Excessive refrigerant" on previous page.
Low-pressure side pressure too low.
High-pressure side pressure too high.
3. Air in the system.
Evacuate and recharge with

refrigerant.
High-pressure side pressure too low

1. Insufficient refrigerant.
Refer to "Insufficient refrigerant" on previous page.
Same as at left.

W190
CAB
Gauge pressure diagnosis
Low pressure side
1.47 - 1.67 MPa

{15 - 17 kg/cm2,
213 - 242 psig}
1.5
9
10
10
11
12
2
0
15
1.0
15
2.0
2.5
20
10
25
0.5
3.0
30
0
13
15
Problems in the system can be diagnosed using a

manifold gauge by reading the system's low and high
pressures.
High pressure side
0.13 - 0.2 MPa

{1.3 - 2.0 kg/cm2,
18 - 28 psig}
8 - 25
Normal pressures
Low-pressure side: 0.13 ~ 0.2 MPa {1.3 ~ 2.0 kgf/
cm2, 18 ~ 28 psig}
High-pressure side: 1.47 ~ 1.67 MPa {15 ~ 17 kgf/
cm2, 213 ~ 242 psig}
35
3.5
14
Conditions
Atmospheric temperature:
Engine speed:
Blower speed:
Temperature switch:
30 ~ 35 C
(86 ~ 95 F)
1 500 r/min
HI (high-speed)
Full cooling
Fig. 8-33
Low pressure side
High pressure side
98 MPa
{1.0 kg/cm2,
18 psig}
0.78 - 0.98 MPa

{8 - 10 kg/cm2,
114 - 142 psig}
5
4
10
1.5
9
10
11
12
2
0
1
0
15
15
13
14
1.0
15
10
5
0.5
Indications: Low pressures on both the low pressure and high-pressure sides;
Discharge temperature will not decrease.
2.0
2.5
20
25
3.0
30
0
Insufficient refrigerant
35
Cause:
Refrigerant leakage.
Remedy:
Inspect using a gas leak detector, repair the leak, and replenish the refrigerant.
3.5
Fig. 8-34
8 - 26
CAB
Low pressure side
High pressure side

2.26 MPa
{23 kg/cm2,
327 psig}
0.25 - 0.29 MPa

{2.5 - 3.0 kg/cm2,
36 - 43 psig}
5
4
10
10
1.5
9
11
12
2
0
15
1.0
2.5
25
0.5
Excessive refrigerant
(poor condenser radiation)
Indication:
Both the low and high pressures are too

high.
Causes:
Pressure increment due to excessive

refrigerant.
Insufficient condenser cooling.
Remedy:
Clean the condenser.

Inspect and adjust the fan belt and condenser motor.
Check the refrigerant level.
2.0
20
10
3.0
30
0
13
15
15
W190
35
3.5
14
Fig. 8-35
Low pressure side
High pressure side
0.25 - 0.34 MPa

{2.5 - 3.5 kg/cm2,
36 - 50 psig}
1.96 - 2.45 MPa

{20 - 25 kg/cm2,
284 - 356 psig}
5
4
1.5
10
10
11
12
2
0
1
0
15
15
13
14
1.0
15
10
5
0.5
2.5
25
3.0
30
0
2.0
20
Air in cooling system

(insufficient suction)
Indications: Both the low and high pressures are too
high.
The low-pressure side piping is not cold.
Cause:
Air entered the cooling system. When

the suction is not applied, the reading of
the instruments are indicated in the illustration on the left.
Remedy:
Evacuate the system, replenish the refrigerant and check the gauge readings.
After prolonged operation with air in the
system, the receiver drier must be replaced.
35
3.5
Fig. 8-36

W190
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
Defective expansion valve

Indication:
Both the low and high pressures are too

high.
Causes:
Improper refrigerant charge.

Defective expansion valve.
Improper temperature sensor installation.
Remedy:
Check temperature sensor installation,

and insulation.
If normal, replace the expansion valve.
2.5
20
10
25
35
0.5
13
15
8 - 27
3.0
30
3.5
14
Fig. 8-37
Insufficient compressor compression
Low pressure side
High pressure side
0.39 - 0.59 MPa

{4 - 6 kg/cm2,
18 psig}
0.69 - 1.08 MPa

{7 - 11 kg/cm2,
99 - 156 psig}
5
4
1.5
10
10
11
12
2
0
1
0
15
15
13
14
1.0
15
10
5
0.5
2.5
25
3.0
30
0
2.0
20
Indications: High pressure on the low-pressure side,

pressure too low on the high pressure
side.
The high and low pressures are already
equal when operation is stopped.
35
3.5
Causes:
Insufficient compression due to a defective compressor gasket or damaged suction valve.
Remedy:
Disassemble and repair the compressor.
Fig. 8-38
8 - 28
CAB
High pressure side
Low pressure side
0.59 - 1.77 MPa

{6 - 18 kg/cm2,
85 - 256 psig}
Vide - 0.13 MPa

{Vide - 1.3 kg/cm2,
Vide - 18 psig}
7
5
4
1.5
10
1.0
10
11
12
2
0
15
2.5
20
25
Indication:
The low-pressure side pressure alternates between a vacuum and normal

pressure.
Causes:
Moisture has frozen in the air conditioner

system, clogging the expansion valve,
which then blocks the air conditioner system. When the ice melts, normal operation resumes.
Remedy:

Evacuate the system.
Recharge with refrigerant to the proper
level
35
3.5
14
15
3.0
30
0
13
Infiltration of moisture
2.0
15
10
0.5
W190
Fig. 8-39
High pressure side
Low pressure side
0.49 - 0.59 MPa

{5 - 6 kg/cm2,
71 - 85 psig}
- 101.3 MPa
{- 760 mm Hg,
- 29.92 in Hg}
5
4
10
11
12
2
0
1
0
Fig. 8-40
1.5
10
15
15
13
14
1.0
15
10
5
0.5
2.5
25
Indications: The low pressure side pressure becomes

a vacuum and the high pressure side
pressure reads 0.49 ~ 0.59 MPa {5 ~ 6
kgf/cm2, 71 ~ 85 psi}.
3.0
30
0
2.0
20
Refrigerant does not circulate
35
Ice or condensation are forming on the

piping connections of the drier receiver
or the expansion valve.
3.5
Causes:
The air conditioner system is blocked

by ice or dirt.
The air conditioner system is shut off
by a defective expansion valve temperature sensor.
Remedy:
Stop operation and check for ice or contamination.

If the problem is moisture, evacuate the
system.
Replace the expansion valve temperature sensor if defective.
Recharge with refrigerant to the proper
level.

W190
CAB
8 - 29
8.6.10 SPECIAL TOOLS
Tool Code
Description
Refrigerant recovery, recycling and changing

station
380001326
Electronic leak detector
380001327
Belt tension test tool

380001325
Sanden compressor overhauling tools

380050012
8 - 30
CAB
W190

SM W190 EN

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Copyright New Holland

Print No. 604.13.502.01

Copyright New Holland

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

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Copyright New Holland

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

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

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Copyright New Holland

Ensure that nobody is in the machine operating range

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

Obey all flag signals and signs.

Keep the operators compartment, step plates, grab-rails

DO NOT PUNCTURE OR BURN CONTAINERS.

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

Never use these products near fires, open flames, or

Do not use controls or hoses as hand holds when climbing

Due to the presence of flammable fluids on the machine,

According to law provisions, seat belts must be fitted with

Copyright New Holland

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

When working on slopes or near sudden level drops in the

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

Do not lift and move loads overhead where persons are

Carefuly inspect the towing items for flaws or problems

Avoid kinking or twisting chains or cables. Do not pull

Overtaking manoeuvres should be performed only when

Copyright New Holland

Always inspect the working area to identify potential risks

Always remember to move the gearshift lever to the neutral

There is no substitute for good judgement and experience

Avoid operating the attachment too close to an overhang

Never lower the attachments other than sitting in the

When pushing-over trees, the machine must be equipped

Securely block the machine and lock it every time you

Avoid faggots, bushes, logs and rocks.

Be alert to avoid changes in traction conditions that could

Working in virgin rough terrains is characterized by the

- carefully read all the norms contained in this Manual;

Before operating or performing any intervention on the

Keep the operators compartment free of loose objects that

When the machine is to be stopped for whatever reason,

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

Copyright New Holland

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

The fuel filler pipe nozzle must be constantly kept in contact

Never service the machine with someone sitting in the

Tow the machine only from the attaching points provided.

Keep the operators compartment, step plates, grab rails

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

When service or maintenance require access to areas that

When using compressed air to clean parts, wear safety

Shop and/or field service platforms or ladders should be

Do not smoke, use open flames or produce sparks nearby

Disconnect batteries and label all controls to warn that

Do not use any flame as a light source during maintenance

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

Do not run the engine in closed buildings without proper

Make sure that all tools provided are in good condition at

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In case tests during which the engine should be kept

Metal cables get frayed after prolonged use. Always wear