sm_W190_EN

Workshop Manual

ECNAMROFREP NEVORP

W190

W190

Workshop Manual

Print No. 604.13.502.01

English - Printed in Italy

W190WHEEL LOADER

Workshop ManualPrint N 604.13.502.01 EnglishIX - 2005

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 consequencesfor the operators safety.

DANGER - These warnings qualify specifically potential dangers for the safety of the operator or otherpersons directly or indirectly involved.

IMPORTANT NOTICE

All maintenance and repair interventions explained in this Manual must be performed exclusively by theService Organization of the Manufacturer, observing strictly the instructions explained using, whenevernecessary, 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 defectscaused by parts and/or components not approved by the Factory for use in maintaining and/or repairing productsmanufactured or merchandized by the Factory.In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured ormerchandized by the Factory, when failures are caused by the use of parts and/or components not approvedby the Factory.

Read and heed carefully the safety instructions listed and follow the precautions recommended to avoidpotential risks and to safeguard your health and your safety.

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

WARNING

On machines having hydraulically, mechanicallyand/or cable controlled equipment (such asshowels, loaders, dozers, scrapers etc.) be certainthe equipment is lowered to the ground beforeservicing, adjusting and/or repairing.If it is necessary to have the equipment partially orfully raised to gain access to certain items, be surethe equipment is suitably supported by meansother than the hydraulic lift cylinders, cable and/ormechanical device used for controlling the equip-ment.

Most accidents and injuries occurring in industry, on thefarm, at home or on the road, are caused by the failureof some individual to follow simple and fundamentalsafety rules or precautions. For this reason, MOSTACCIDENTS CAN BE PREVENTED by recognizingthe real cause and taking the necessary precautions,before the accident occurs.Regardless of the care used in design and constructionof any type of equipment, there may be conditions thatcannot be completely safeguarded against without in-terfering with reasonable accessibility and efficient op-eration.A careful operator is the best insurance against acci-dents. The complete observance of one simple rulewould prevent many thousands serious injuries eachyear.This rule is: Never attempt to clean, lubricate or adjusta machine while it is in motion.

AVOID ACCIDENTS

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 1TRANSMISSION .................................................. Section 2BRAKE SYSTEM................................................. Section 3STEERING SYSTEM ........................................... Section 4BUCKET BOOMS AND FRAME ........................ Section 5EQUIPMENT HYDRAULIC SYSTEM ................. Section 6ELECTRICAL SYSTEM ...................................... Section 7CAB ...................................................................... Section 8

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

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SAFETY RULESGENERALITIESRead this Manual carefully before starting, operating,maintaining, fuelling or servicing the machine.Read and comply with all safety precautions before anyintervention.Do not allow unauthorised personnel to operate or servicethis machine.Do not wear rings, wrist watches, jewellery, loose orhanging garments, such as ties, torn clothing, scarves,unbuttoned or unzipped jackets that can get caught inmoving parts. Wear certified safety clothes such as: hardhat, no-slip footwear, heavy gloves, ear protection, safetyglasses, reflector vests, respirators. Ask your employerabout specific safety equipment requirements.Keep the operators compartment, step plates, grab-railsand handles clean and clear of foreign objects, oil, grease,mud or snow to minimize the danger of slipping or stum-bling. Remove mud or grease from your shoes beforeattempting to mount or operate the machine.Do not jump on or off the machine. Always keep both handsand one foot, or both feet and one hand in contact withsteps and grab rails.Do not use controls or hoses as hand holds when climbingon or off the machine. Hoses and controls are movableparts and do not provide solid support. Besides, controlsmay be inadvertently moved and cause unexpectedmovement of the machine or its attachments.Never operate the machine or its attachments from anyposition other than sitting in the drivers seat.Keep head, body, limbs, hands and feet inside the opera-tors compartment at all times to reduce exposure toexternal hazards .Be careful of possible slippery conditions of the steps andhand rails as well as of the ground around the machine.Do not leave the machine until it is has come to a completestop.Check the seat safety belt at least twice per year andreplace it if it shows signs of wear, fraying or otherweakness that could lead to failure.

STARTINGNEVER START OR OPERATE A FAILED MACHINE. Be-fore operating the machine, always ensure that any unsafecondition has been satisfactorily corrected.Check brakes, steering and attachment controls beforemoving off. Report any malfuctioning part or system to themaintenance managers for proper action.Ensure all protective guards and panels as well as allsafety devices provided are in place and in good operatingcondition.

Ensure that nobody is in the machine operating rangebefore moving off or operating the attachment. WALKCOMPLETELY AROUND the machine before mounting.Sound the horn.Before starting machine, check, adjust and lock the driver'sseat for maximum comfort and control of the machine.Fasten your seat belts(when fitted).Obey all flag signals and signs.Due to the presence of flammable fluids on the machine,never check or fill fuel tanks or accumulator batteries nearfires, open flames, or sparks.REMEMBER THAT SPECIAL STARTING FLUIDS AREFLAMMABLE. Scrupolously follow recommendationsprinted on the containers and in this Manual.DO NOT PUNCTURE OR BURN CONTAINERS.Containers must be stored in fresh, well ventilated placesand out of the reach of unauthorised persons. Strictlyfollow the instructions provided by the Manufacturer.Never use these products near fires, open flames, orsparks.

OPERATINGCheck 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 buildingswithout proper ventilation capable to remove harmfulexhaust gases.Roll Over Protective Structures (ROPS) are required onwheel or crawler loaders, dozers, or graders. NEVEROPERATE the machine if such protective structure isremoved.Keep the operators compartment free of foreign objects,especially if not firmly secured. Never use the machine totransport objects, unless proper securing points are pro-vided.DO NOT CARRY RIDERS ON THE MACHINEStudy and familiarize with escape routes alternate tonormal exit routes.According to law provisions, seat belts must be fitted withRoll Over Protection Structures or cabs. Keep safety beltsfastened during operation.For your personal safety, do not climb on or off the machinewhile it is in motion.Make sure that bystanders are clear of the machine oper-ating range before starting the engine and operating theattachment. Sound the horn. Obey all indications providedby flags, signs and signals.DO NOT COAST OR FREEWHEEL down hills. Engage themost suitable gear speed to keep the machine under control.


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When working on slopes or near sudden level drops in theterrain, avoid areas where ground is loose or soft sinceoverturn or loss of machine control could result.If noise level is high and continuosly exceeds 90 dBA over8 hours at the operator's ear, wear approved ear protectionin compliance with local regulations.Where counterweights are provided, do not operate themachine if they have been removed.When transporting a loaded bucket, keept it as rolled-backand low as possible for maximum visibility, stability andsafety of there machine. Ground speed should be ad-equate 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 machineand the materials to be handled. Follow the recommenda-tions concerning loading capacity, arrangement of thematerials, characteristics of the ground and job to beperformed.Do not lift and move loads overhead where persons arestanding or working, nor downhill when working crosswiseon slopes. In this case, the bucket should be unloaded onthe uphill side, whenever possible.Start and stop the machine carefully when the bucket is full.Do not move off without first reducing engine speed.Overtaking manoeuvres should be performed only whenabsolutely necessary and unavoidable. Beware possibleuneven terrains, poor visibility, presence of other machin-ery or persons out of sight.Operate the machine at a speed adequate to the workingsite conditions and in any case slow enough to ensurecomplete control at all times.Check instruments at start-up and frequently duringoperation. Stop the machine immediately should anymalfunction 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 obstaclesand/or difficulties you will encounter, such as narrowstreets, overhead doors, cables, piping, as well as ground,bridges, paving and ramps bearing load limitations.In case of road transfers, find out beforehand what condi-tions are likely to be encountered, such as size restrictions,heavy traffic, paving type, etc. . Beware fog, smoke or dustthat obscure visibility.When crossing gullies or ditches, move at an angle withreduced speed after ensuring ground conditions will per-mit a safe traverse.

Do not operate the machine if you are extremely tired or feelill. 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 ensurecomplete control at all times.Travel slowly over very rough terrain, slopes or near drop-offs, in congested areas or on frozen or slippery surfaces.When backing, always look to where the machine is to bemoved. Be alert of the position of bystanders. Shouldsomeone enter the work area, STOP THE MACHINE.Maintain a safe distance from other machines or obstaclesto ensure required visibility conditions. Give way to loadedmachines.Maintain a clear vision of the surroundings of the travel orwork area at all times. Keep cab windows clean andrepaired.When machines are operating in tandem, the pusher (rear)must be equipped with the appropriate deflectors to protectthe front unit driver against the air stream coming from theblower fan.When pulling or towing through a cable or chain, do notstart suddenly at full throttle. Take-up slack carefully.Carefuly inspect the towing items for flaws or problemsbefore proceedig.Avoid kinking or twisting chains or cables. Do not pullthrough a kinked chain or cable as the high stressesexisting in this condition may induce failures. Always wearheavy gloves when handling chains or cables.Chains and cables should be securely anchored. Anchorpoints should be strong enough to withstand the expectedload. Keep anyone clear of anchor points and cables orchains.DO NOT PULL UNLESS THE OPERATORS COMPART-MENTS OF THE MACHINES INVOLVED ARE PROP-ERLY PROTECTED AGAINST POSSIBLE BACKLAS INCASE OF CABLE OR CHAIN FAILURE OR DETACH-MENT.Be alert of soft ground conditions close to newly con-structed walls. The fill material and machine weight maycause the wall to collapse.In darkness, check area of operation carefully beforemoving in with the machine. Use all lights provided. Do notmove into low visibility areas.If the engine tends to stall for whatever reason under loador at idle, immediately report this problem to the mainte-nance managers for proper action. Do not operate themachine until this condition has been corrected.On machines fitted with suction radiator fans, regularlycheck the engine exhaust system for leaks, as exhaustfumes expelled towards the operator are toxic.

Operators must know thoroughly the performances of themachine they are driving.

SAFETY RULES


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Always inspect the working area to identify potential riskssuch as: inclines, overhangs, trees, demolition rubble,fires, ravines, steep slopes, rough terrain, ditches, crowns,ridge trenches, heavy traffic, crowded parking and serviceareas, closed ambients. In such conditions, proceed withextreme care.Whenever possible, avoid going over obstacles such asvery rough terrain, rocks, logs, steps, ditches, railroadtracks. When obstructions must be crossed, do so withextreme care and at an angle, if possible. Slow down andselect a lower gear. Ease up to the break-over point, passthe balance point slowly and ease down the other side.In steep down-hill operation, do not allow the engine toover-speed. Select the proper gear before starting downgrade.Avoid crosswise hill travel, whenever possible. Drive upand down the slope. Should the machine start slippingsideways when going uphill, steer and turn machine frontimmediately downhill.The gradient you may attempt to overcome is limited byfactors such as ground conditions, load being handled,machine type and speed, and visibility.There is no substitute for good judgement and experiencewhen working on slopes.Avoid operating the attachment too close to an overhangor high wall, either above or below the machine. Bewareof caving edges, falling objects and landslips. Rememberthat such hazards are likely to be concealed by bushes,undergrowth and such.When pushing-over trees, the machine must be equippedwith proper overhead guards. Never drive a machine upthe roots, particularly while the tree is being felled. Useextreme care when pushing over any tree with deadbranches.Avoid faggots, bushes, logs and rocks.NEVER DRIVE OVER THEM, nor over any other surfaceirregularities that discontinue adherence or traction withthe ground, especially near slopes or drop-offs.Be alert to avoid changes in traction conditions that couldcause loss of control. AVOID driving on ice or frozenground when working on steep slopes or near drop-offs.Working in virgin rough terrains is characterized by thepresence of all the perils and risks listed above. In theseconditions, it is emphasised the danger represented bylarge tree limbs (possibly falling on the machine), largeroots (which may act as a leverage under the machinewhen up-rooted and cause the unit to overturn), etc.

STOPPINGWhen the machine is to be stopped for whatever reason,do so following the instructions given in chapters Stop-ping the machine and Shutting off the engine" in theOperation and Maintenance Instruction Manual.

Always remember to move the gearshift lever to the neutralposition and engage the control lever lock for safetypurposes.Apply the parking brake (if fitted).NEVER LEAVE THE MACHINE UNATTENDED with theengine running.Prior to leaving the operators seat,and after making surethat all people are clear of the machine, always slowlylower the attachment until resting it safely to the groundPark the machine in a non-operating and no-traffic area.Park on firm level ground. If this is not possible, position themachine at a right angle to the slope, making sure there isno danger of uncontrolled sliding. Apply the parking brake.If parking in traffic lanes cannot be avoided, provideappropriate flags, barriers, flares and signals as requiredto adequately warn the oncoming drivers.Keep head, body, limbs, hands and feet clear of the dozer,arms, bucket or ripper when raised.Always switch off the battery isolator switch before serv-icing the machine in whatever manner (i.e., cleaning,repairing, maintaining, etc.). Do the same when themachine is to remain parked for prolonged periods of timeto avoid accidental or unauthorized starting.Never lower the attachments other than sitting in theoperators seat. Sound the horn. Make sure that nobody iswithin the machine operating range. Lower the attachmentslowly. DO NOT USE FLOAT POSITION in case of hydrau-lic controls.Securely block the machine and lock it every time youleave it unattended. Return keys to authorized security.Perform all necessary operations as detailed in the Opera-tion and Maintenance Instruction Manual. Apply the park-ing brake (if fitted) every time you leave the machine.

MAINTENANCE

GENERALITIESBefore operating or performing any intervention on themachine:- carefully read all the norms contained in this Manual;- read and observe all safety plates and instructions

located on the machine.Do not allow unauthorized personnel to service the ma-chine. Do not carry out any maintenance work without priorauthorization. Follow all recommended maintenance andservice procedures.Keep the operators compartment free of loose objects thatare not properly secured.Do not wear rings, wrist watches, jewellery, loose orhanging garments, such as ties, torn clothing,scarves,unbuttoned or unzipped jackets that can getcaught in moving parts.

SAFETY RULES


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Wear certified safety clothes such as: hard hat, no-slipfootwear, heavy gloves, ear protection, safety glasses,reflector vests, respirators. Ask your employer about spe-cific safety equipment requirements.

Never service the machine with someone sitting in thedriver's seat, unless this person is an authorized operatorassisting in the maintenance being carried out.Keep the operators compartment, step plates, grab railsand handles clear of foreign objects, oil, grease, mud orsnow to minimize the danger of slipping or stumbling.Clean mud or grease from your shoes before climbing onthe machine or driving it.Never attempt to operate the machine or its attachmentsfrom any position other than sitting in the operators seat.Never stand under the boom.Should it be necessary to move the attachment through thehydraulic controls for maintenance purposes, rememberthat 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 areabout to manoeuvre. Raise the attachment slowly.Always lock machine arms or any other parts that must belifted for maintenance purposes using adequate externalmeans. Do not allow anyone to pass near or even belowa raised yet unlocked attachment. If you are not absolutelysure about your safety, do not stay under a raised attach-ment, even if it is locked.Do not place body, limbs, or fingers near articulated cuttingedges of uncontrolled machine parts or deprived of thenecessary guards, unless they are suitably and safelylocked.Never perform any work on the machine with the enginerunning, except when this is specifically required. Do notwear loose clothing, jewellery or such near moving parts.When service or maintenance require access to areas thatcannot be reached from the ground, use a ladder or stepplatform conforming to regulations in force. If such meansare not available, use machine grab rails and steps.Always perform all service or maintenance work with thegreatest care and attention.Shop and/or field service platforms or ladders should bemanufactured in accordance with safety regulations inforce.

Disconnect batteries and label all controls to warn thatservice work is in progress. Block the machine and allattachments to be raised.Do not check or fill fuel tanks, batteries and accumulators,nor use the starting liquid if you are smoking or near openflames. These fluids are flammable!BRAKES ARE INOPERATIVE when manually released forservicing. Provisions must be made to maintain control ofthe machine using suitable blocks or other means.

The fuel filler pipe nozzle must be constantly kept in contactwith the filler neck. Keep this contact from the beginning tothe end of the fuelling operation to avoid possible genera-tion of sparks due to static electricity.Tow the machine only from the attaching points provided.Use care in making connections and ensure pins and/orbolt are firmly secured before pulling. Stay clear of draw-bars, cables or chains under load.

To move a failed machine, use a trailer or a low platformtruck, if available. In case towing is needed, use all neces-sary signals required by local regulations, and followdirections provided in this Manual.Load/unload the machine from transporter on firm levelground providing safe support to the wheels of the truck ortrailer. Use strong access ramps, with adequate height andangle. Keep the loading platform free of mud, oil or slipperymaterials.

Tie the machine securely to the platform of the truck ortrailer and opportunely wedge machine wheels or tracksas required.Never align holes or slots using your fingers; always useappropriate aligning tools.Remove all sharp edges and burrs from re-worked parts.Use only approved and effectively grounded auxiliarypower sources for heaters, battery chargers, pumps andsimilar equipment to reduce electrical shock hazard.

Lift and handle heavy components using hoisting devicesof appropriate capacity. Ensure the sling has been cor-rectly applied. Use lifting eyes if provided. Pay attention tobystanders.

Never pour gasoline or diesel fuel into open, wide and lowcontainers. Never use gasoline, solvents or other flamma-ble fluids to clean parts. Use proprietary certified non-flammable, non-toxic solvents only.

When using compressed air to clean parts, wear safetyglasses with side shields. Limit pressure to max 2 bars, inaccordance with local safety regulations in force.Do not run the engine in closed buildings without properventilation capable to remove lethal fumes.

Do not smoke, use open flames or produce sparks nearbywhile refuelling the unit or handling highly flammablematerials.

Do not use any flame as a light source during maintenancework or to look for leaks anywhere on the machine.

Make sure that all tools provided are in good condition atall times. NEVER USE tools with mushroomed or dam-aged heads. Always wear eye protections.Move with extreme care when working under the machine,its attachments, and even on or near them. Always wearprotective safety equipment as required, such as hard hat,goggles, safety shoes, and ear plugs.

SAFETY RULES


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In case tests during which the engine should be keptruninng, a qualified operator must sit in the drivers seatwith the mechanic in sight at all times. Place the transmis-sion in neutral, apply and lock the brakes. KEEP HANDSOFF MOVING PARTS.

In case of field service, move machine to level ground, ifpossible, and block it. If work on an incline cannot beadvised, 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. Neveruse them for lifting or pulling. Always wear heavy glovesto handle chains or cables.

Be sure chains and cables are firmly fastened and thatanchor points are strong enough to withstand the expectedload. Nobody should stay near the anchor points, cablesor chains. DO NOT PULL OR TOW UNLESS THE OPERA-TORS COMPARTMENTS OF THE MACHINES IN-VOLVED ARE FITTED WITH THE PROPER GUARDSAGAINST BACKLASH IN CASE OF CABLE OR CHAINFAILURE OR DETACHMENT.Keep the area where maintenance is carried out CLEANand DRY at all times. Clean immediately all water and oilspillages.

Do not pile up oily or greasy rags as they represent a majorfire hazard. Always store them in closed metal containers.

Before starting the machine or its attachment, check, adjustand lock the operators seat. Also ensure that nobody iswithin the machine operating range. Sound the horn.

Rust inhibitors are volatile and flammable. Use them onlyin well ventilated areas. Keep open flames away - DO NOTSMOKE - Store containers in a cool well ventilatedplacewhere they could not be reached by unauthorised people.

Do not carry loose objects in your pockets that might fallunnoticed into open compartments.

Wear safety glasses with side shields, hard hat, safetyshoes, heavy gloves when metal particles or similar maybe ejected and hit you.Wear appropriate protective equipment such as darksafety glasses, hard hat, protective clothing, specialgloves and footwear while welding. Nearby personsshould also wear dark safety glasses even if they are notwelding. DO NOT LOOK THE WELDING ARC WITHOUTPROPER EYE PROTECTION.Become acquainted with all your jacking equipment andits capacity. Remember that the jacking point on themachine should be appropriate for the load applied. Also,be sure the support area of the jack at the machine and onthe ground is appropriate and stable.Any load supported by a jack represents a possible haz-ard. Always transfer the load onto appropriate supportmeans according to local or national safety requirementsbefore proceeding with service or maintenance work.

Metal cables get frayed after prolonged use. Always wearappropriate protections (heavy gloves, goggles, etc.)while handling them.

Handle all parts carefully. Keep hands and fingers awayfrom gaps, gears, and similar. Always use and wear theappropriate protections.Water can build up in pneumatic systems from condensatemoisture due to changes in atmospheric conditions. Ifnecessary, drain such deposits following instructions.Before carrying out any maintenance work or service, lockthe machine articulated frame modules using the appro-priate safety device. Remember to remove and store itproperly at the end of work.If the machine is equipped with hydraulic brakes, makesure that the reservoir is always filled up to the correct level.Always block all wheels, front and rear, before bleedingthe braking system or disconnecting control hoses and/orcylinders.

STARTINGDo not run the engine in closed buildings without properventilation capable to remove lethal exhaust fumes.Do not place head, body, limbs, feet, hands or fingers nearrotating fans or belts.Be especially careful near blower fans.REMEMBER THAT THE STARTING FLUID IS HIGHLYFLAMMABLE. Follow recommendations provided in thisManual and printed on the containers. Containers must bestored in a cool, well ventilated place out of the reach ofunauthorised persons.DO NOT PUNCTURE OR BURN CONTAINERS.

ENGINELoosen the radiator cap very slowly to relieve systempressure before removing it. Always top-up coolant levelwith 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, asthis increases fire hazard.

Never attempt to check or adjust fan belt tensions when theengine 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.

SAFETY RULES


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ELECTRICAL SYSTEMAlways disconnect the batteries prior to any interventionon the machine or its electrical system (cleaning, repair,maintenance).Should booster batteries be used, remember to connectends of the booster cables in the proper manner: (+) to (+)and (-) to (-). Do not short-circuit terminals. Thoroughlyfollow instructions given in this Manual.Before any intervention, make sure that the battery isolatorswitch is off.BATTERY GAS IS HIGHLY FLAMMABLE. Leave the bat-tery compartment open during recharging to improveventilation. Never check battery charge by placing metalobjects across the posts. Keep sparks or open flames awayfrom batteries. Do not smoke near the battery to preventexplosion hazard.Before any intervention, make sure that there are no fuelor electrolyte leakages. If any, correct prior to proceedingwith further work. Do not recharge batteries in confinedspaces. Ensure proper ventilation is provided to avoidaccidental explosions due to build-up of gas releasedduring charging.

HYDRAULIC SYSTEMPressure fluid escaping from a very small hole can bealmost invisible and still have sufficient force to penetratethe skin. Always check any suspected pressure leaksusing a piece of cardboard or wood. DO NOT USE HANDS.If injured by escaping fluid, obtain medical attention imme-diately or serious infection or reaction may develop.Stop the engine and relieve all system pressure beforeremoving panels, housings, caps, plugs or covers.Always use gauges of adequate capacity (end-of-scalereading) and follow recommended procedures.

TOOLSAlways keep head, body, limbs, feet, or hands away frombucket, blade, or ripper when in the raised position. Priorto any intervention, install all safety devices according tocurrent regulations. In case the attachment is to be oper-ated through the machine hydraulic system for mainte-nance purposes, remember to do so only while sitting in thedriver's seat. Make sure that nobody is within the machineoperating range. Before operating the attachment, alertpeople by sounding the horn and by voice. Raise theattachment slowly.

SAFETY RULES

Do not use the machine to transport loose objects, unlessproper devices to this purpose are provided.Clutches and brakes of this machine as well as auxiliarydevices and attachments (such as drive cylinder or winchcontrol valves) should always be properly adjusted inaccordance with the instructions provided by the Manufac-turer. Never perform adjustments with the engine running,except when this is specifically required by the relevantprocedures.

TYRES AND WHEELSMake sure that the tyre inflation pressure corresponds tospecifications issued by the Manufacturer. Regularlycheck inflation pressure.Should pressure be changed, do this while staying on thetyre side and at a safe distance.Pressure checks should always be carried out with themachine unloaded and cold tyres.Never use reconditioned tyre rims, since possibleweldings, incorrect heat-treatments or repairs canweaken the wheels and cause damages or failures.Do not cut, nor weld rims with inflated tyres installed.The spare tyre should be inflated only enough to keep therim components assembled. Remember that when notinstalled on the disc, a tyre inflated to maximum pressurecan explode.Therefore, maximum care must be taken when handling afully inflated tyre.Before servicing tyres, block all wheels, front and rear. Afterjacking up the machine, block it in the raised position usingsuitable stands conforming to current safety regulations.Deflate the tyre before removing objects from the tyre tread.Never inflate tyres with flammable gas: explosions andsevere bodily injuries may result.When starting your work shift, check for loose wheel or rimbolts and brackets and retighten to correct torque asnecessary.


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SAFETY RULES

WARNINGEnsure that the attachment is safely resting on to the ground before repairing,adjusting, or servicingmachines 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 attachmentis adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/ormechanical devices used for controlling it.

For the decommissioning of the machine, the availabilityof particular tooling (hoists, hydraulic presses. contain-ers for liquids etc.) is required as well as specific toolslisted in the Repair Manuals, available from FIATKOBELCO Dealers.This has the purpose of avoiding that during disassem-bly operations, dangerous situations may arise both forthe 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, buck-

ets etc.)

DECOMMISSIONING THE MACHINE

WARNING The decommissioning of the machine must be

performed exclusively by personnel trained,qualified and authorised to perform such opera-tion.

Start the disassembly of hydraulic componentsonly after the same, the hydraulic oil and lubri-cants have fully cooled-off and after all residualpressures have been released, as described bythe Repair Instruction Manual.

Prior to proceeding with disassembly opera-tions, comply with the GENERAL SAFETY RULESand drain each components of the machine filledwith fluids, both in the reservoirs and the rel-evant systems.


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SPECIFICATIONS - WHEEL LOADER W190

ENGINEMake and model ................... IVECO NEF-TEKTORNet power at the flywheel .......... (ISO 9249) 151 kWMax power speed ...................................... 2175 rpmMax torque .................................................. 860 NmMax torque speed ..................................... 1500 rpmDiesel type, 4 stroke, direct injection, turbochargedNumber of cylinders .............................................. 6Bore x stroke .................................... 102 x 120 mmTotal displacement ................................ 5880 cu cmValve/rocker operation lash:- intake .......................................... 0.25 0.05 mm- exhaust ....................................... 0.50 0.05 mmFiring order ..............................................1-5-3-6-2-4Minimum 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 barThermostat: starts opening ............ (177.8 F) 81 C max, opening ............. (204.8 F) 96 C

ENGINE SPEEDSMinimum idle speed (no load) ......................850 rpmMaximum idle speed (no load) ................... 2300 rpmConverter stall speed ........................ 2110 50 rpmSteering stall at idle speed > .......................840 rpmAttachment stall ................................ 2190 50 rpmFull stall .......................................... 1900 100 rpm

TORQUE CONVERTERType ... : single stage, single phase, three elementsTorque converter pressure ........................... 4.3 barConversion ratio at stall ............................... 2.813:1

Main pressure on the control valve .......... 16 + 2 barTransmission disengagement sensor ...... 15 1 barTransmission induction sensors to gear teeth adjustclearance ........................................... 0,5 0,8 mmTransmission oil high temperature sensor setting .......................................... 119 3 C (246 37.4 F)

AXLESAxles 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 : 24.05Oscillating rear axle, support structure type- reduction ratio ........................................ 1 : 24.05

TYRESType ................................... 23.5 R25 XHA tubelessInflating pressure- Work: front = 3.25 bar

rear = 2.00 bar- Transfer: front = 2.00 bar

rear = 2.00 barWheel tightening torque ............................... 788 Nm

BRAKESDelivery brakes pumpat nominal speed ...............32 lt/min (7.03 USG/min)Accumulator recharge start pressure ....... 90 5 barAccumulator recharge end pressure ...... 130 5 barPre-charge pressure, service brake accumulator(1.4 lt) ............................................................ 45 barPre-charge pressure, parking brake accumulator(1.4 lt) ........................................................... 70 barSetting of pressure switch, transmission cut-off . 15 barSetting of sensor, brake oil low pressure ...... 73 barSetting of pressure switch, stop lights ........ 1.8 barSetting of pressure switch, parking brake ...... 82 bar

STEERING SYSTEMType ..................... Orbitrol, hydraulically controlled

with integrated priority valvePump .................... it uses one body of the hydraulic

system pumpMax. flow ...................... 162 lt/min (35.63 USG/min)Max. operating pressure ............................... 210 barCylinders ........................................ 2, double stroke bore x stroke .................................... 80 x 422 mmEmergency steering w/ bi-directional gear pump actu-ated by the transmission.

MARKING: ZEF00W19100940XXX

IDENTIFICATION - 530.130.190

TRANSMISSIONMaximum ground speeds (forward/reverse) in kph(with 23.5 R25 tyres):

Forward km/h Reverse km/hspeed (Mp/h) speed (Mp/h)

1 7.4 (4.5) 1 7.8 (4.8)2 12.9 (8) 2 13.7 (8.5)3 23.8 (14.7) 3 25.2 (15.6)4 36.6 (22.7)


0 - 9W190

EQUIPMENT HYDRAULIC SYSTEMType ................ sealed w/ anti-cavitation and safety

valvePumps ............. gear, steel made w/ wear automatic

compensationA sequence valve cuts-off the pump when the pres-sure exceeds 175 bar.- max. flow ..... 325 lt/min between (71.49 USG/min)

175 and 210 bar- max. operating pressure ............................ 210 barControl valve ................................................ 2-spool

3-spoolControl ......................................... piloted, dual lever

piloted, single leverHydraulic cylinders, double stroke boom control ...................................................... 2 bore x stroke .................................... 140x960 mm bucket control .................................................... 1 bore x stroke .................................... 190x505 mmTimes of equipment manoeuvres

lifting ........................................................6.2 sec.lowering....................................................3.1 sec.dumping ...................................................1.4 sec.

Pipes and connecting flanges are equipped withO-Ring seals.

L.T.S. deviceElectronic Load Travel Stabiliser device. Ideal duringloading applications and travel over rough ground.- Setting of accumulator safety valve ............ 120 bar

ELECTRICAL SYSTEMOperating voltage ........................................ 24 VoltBatteries in series ............................. 2 - 160 Amph- Maintenance-freeStarter motor ............................................... 24 VoltAlternator w/ voltage regulator ...... 24 Volt - 70 Amp

WEIGHTWeight of machine with tyres 23.5 R25 and 3.1 cu mbucket, supplied and w/operator 17,200 kg (37,920lbs).


0 - 10 W190

45

40

49

322 95

4451600

3200 2065 21602760

1230

3350

*

*

*

*

*

DIMENSIONS AND WEIGHT

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 With suppl. cutting With teethsegments edge

Bucket capacity cu cm 3.2 3.5 3.2 3.5 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) 1200 (47.2) 1060 (47.7) 1125 (44.2) 1135 (44.6) 1200 (47.2)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 (intransportation position) m (ft) 6.5 (21.3) 6.5 (21.3) 6.5 (21.3) 6.4 (21) 6.5 (21.3) 6.5 (21.3)


0 - 11W190

TAB

LE O

F FL

UID

CAPA

CITI

ES

ITEM

QUAN

TITY

FLUI

DS O

R LU

BRIC

ANT

CLAS

SIFI

CATI

ON

VISC

OSI

TYO

UT D

OO

R TE

MPE

RAT.

LITR

ES (U

SG)

SPEC

IFIC

ATIO

NS(S

AE)

OF

REF

EREN

CE (C

)

API C

F-4/

SG15

W-4

010

To

50

C

(14 To

122

F)EN

GIN

E16

(4.2)

Ambr

a

Supe

r Gol

dM

IL-L

-210

4E10

W-3

0

30 T

o 20

C (-2

2 To 6

8 F)

orAC

EA E

2

OIL

FIL

TER

1 (3)

Ambr

a-Su

per G

old H

SP*

API C

H-4

15W

-40

10

To

50

C

(14 To

122

F)AC

EA E

3

RADI

ATOR

27 (7

.1)Am

bra-

Agrif

lu (5

0%)

NH-9

00A

35 T

o 50

C (-3

1 To 1

22 F

)

API C

F-4/

SGTR

ANSM

ISSI

ON

22 (5

.8)Am

bra-

Supe

r Gold

MIL

-L-2

104E

10W

-30

30

To

20 C

(-22 T

o 68

F)AC

EA E

2

HYDR

AULI

C SY

STEM

135 (

35.7)

Ambr

a-Hy

dros

yste

mIS

O V

G 4

6, D

IN 5

1524

20 T

o 50

C (-4

To 12

2 F)

orPa

rt. 1

and

2, Q

FH58

3/HD

AXLE

Sfro

nt 3

1 (8.

2)Am

bra-

TX F

luid

API G

L585

W-9

0

20 T

o 50

C (-4

To 12

2 F)

rear 3

1 (8.2

)QF

H 58

4 TR

FUEL

252 (

66.57

)

TANK

GRE

ASE

FITT

ING

S

Ambr

a-M

G-2

QFH

58

5 G

R, N

LG12

40 T

o 50

C (-4

0 To 1

22 F

)

AIR

COND

ITIO

NER

0.2 (

0.05)

L BA

R 1

34

COM

PRES

SOR

Oil q

uant

ities i

ndica

ted

are

thos

e re

quire

d fo

r per

iodi

cal c

hang

es fo

llowi

ng th

e dra

inin

g and

fillin

g pro

cedu

res i

ndica

ted i

n deta

il for

eac

h gr

oup.

*In

the e

vent

engi

ne oi

l with

"CH4

" cla

ssific

atio

n is u

sed,

the c

hang

e int

erva

l can

be pr

olon

ged t

o 500

hour

s pro

vidin

g tha

t the o

ute

r tem

pera

ture

of op

erat

ion

does

not

exc

eed

38 C

(100

F) a

nd th

at the

perce

ntage

of su

lphur

in the

fuel

does

not e

xcee

d 0.5

%.In

the

even

t of r

eally

hea

vy d

uty

cond

itions

, red

uce

the

grea

sing

inte

rval

s.

Ambr

a M

aste

r Gol

d

Ambr

a Hi-T

ech 4

6


0 - 12 W190

The latter is identified by a coded eight digit number,allowing a complete description of the item.

Example.

I / a b c d e / f g

I - Standard index digit

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

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

It is a number always composed of five digits identify-ing dimensional specifications of the item.

f - Material index digit

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

g - Coating index digit

It indicates the coating applied to a defined item.

Note - In case, in the different sections, the tighteningtorque is not listed, refer to the table TIGHTENING TOR-QUES, only after identifying exactly the component.

UNITS OF MEASURE

Units of measure used in this manual are thoseadopted by the International System which replace theunits previously used by the M.K.S. system.

Force: newton (N)

Pressure: bar

Torque: newton x meter (Nm)

CLASSIFICATION OF STANDARD COMPO-NENTS TO DETERMINE THE TIGHTENING TOR-QUES


0 - 13W190

Materialindex (f) FIAT UNI DIN SAE BSI BNA

0 R40 4D - 4S - 4A 1 A 42

1 R50 5S - 6S 3 P 56

2 R80 8G 5 T 80

3 R100 100 10K 8 V 100

4 Brass Brass Messing Brass Brass Laiton

5 Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium

6 Copper Copper Kupfer Copper Copper Cuivre

7 Blank for other metallic materials

Resistance class and material

TORQUE TABLES

If correct torque is not specifically indicated in therelevant pages, refer to the following tables.

WARNING

- Lubricate all hardware until 24 dia., with engine oil.Use grease for larger diameters.

- Tolerance on torque: 5%

- Resistance classes R80, R100, R120 must beunderstood as follows:

10.9 replaces R100for screws

12.9 " R120

10 replaces R80for nuts

12 " R100

CDT= cadmed; FOSF= phosphated; ZNT= galva-nised.


0 - 14 W190

M6 x 1 13 12 - - M6 x 1 13 -

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

M16 x 2 - - - - M16 x 2 - -

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 -

normalNm

normal low type

Strength grade: 10 (R80)

mm

Diameterand pitch

SCREWS (ZNT/DEIDR)

normalZNTNm

self-lockingZNTNm

with polyamide ringlow type

Nm

Diameterand pitch

mmNm Nm

Strength grade: 10.9 (R100)

NUTS (ZNT)

SECTION 1

ENGINEINDEX

PARAGRAPH

1.1

1.2

1.3

1.41.4.11.4.21.4.31.4.4

1.51.5.11.5.21.5.3

1.6

1.71.7.1

1.7.2

1.8

SUBJECT

ENGINE IDENTIFICATION .....................................................................................

GENERAL FEATURES ...........................................................................................

DESCRIPTION OF ENGINE OPERATION .............................................................

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

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

ENGINE SUPPORTS .............................................................................................

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

TOOLING................................................................................................................

PAGE

1-1

1-5

1-14

1-161-171-181-191-21

1-331-341-351-37

1-46

1-471-591-591-611-621-651-691-701-801-861-871-881-881-891-911-911-931-104

1-107

ENGINE


1 - 1W190

1.1 ENGINE IDENTIFICATION

Engine data plateThe engine data plant provides specific informationabout your engine.

Note The engine plate must not be replaced without theauthorisation by the manufacturer.

TYPE - SERIAL NUMBER - APPROVAL

ENGINE DATA

Fig. 1-2

Fig. 1-1

E3

ENGINE TYPE

ENGINEFAMILY

EECAPPR. N

SERIALNUMBER

IVECO N. V.

F4AE0684F*D101F4AE43B00A

e3*85R02*1507e3*24R03*1503

e3*97/68EA*0005*00000000

ENGINE


W1901 - 2

ENGINE DIAGRAMS

The illustrations here below provide information aboutthe components of the engine, the location of filters,draining points and the access location for the instru-mentation and controls of the engine.

The illustrations and the configuration of componentsdescribed in these diagrams are of a general nature.the locations of some components can change, de-pending upon the arrangement.

Fig. 1-3

Air intake (from after-cooler)Common rail

High pressurepump

Engine flywheelcover

Engine oildipstick

Engine oilfiller neck

Fuel filterElectroniccontroller (EDC)

VIEW INJECTIONPUMP SIDE

Turbine exhaust(silencer)

Turbocharger

Pressure reliefvalve

Alternator

Engine oilfilter

Exhaustmanifold

VIEW TURBOCHARGERSIDE

ENGINE


1 - 3W190

Fig. 1-4 Rear view

Fig. 1-5 Front view

Flex-discmounting holesFlywheel

Water pumppulley

Alternator pulley

Belt tensioner

Drive belt

ENGINE


W1901 - 4

Fig. 1-6 Top view

Engine coolantby-pass seat Tappet cover

Injector

ENGINE


1 - 5W190

1.2 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 5900cu cm

Compression ratio 17 : 1

Max. power kW 155(CV) 211

rpm 2175

Max. torque Nm 860(kgm) 87.6

rpm 1500

Engine speed atlow idle

rpm 850

Engine speed athigh idle

rpm 2300

Torque converter stall rpm 2110

Equipment stall rpm 2190

Total stall rpm 1960

+ + +.. =

ENGINE


W1901 - 6

TURBOCHARGING w/after-cooler

Turbocharger type HOLSET HY 35 W

Radial play of turbocharger shaft Axial play of turbocharger shaft Minimum stroke of pressurerelief valve: mm Maximum stroke of pressurerelief valve: mm Pressure corresponding to minimum stroke: bar Pressure corresponding to maximum stroke: bar

LUBRICATION Forced by gear pump, pressure relief valve,oil filter

Oil pressurew/hot engine: at low idle bar 1.2 at high idle bar 3.8

COOLING By centrifugal pump, regulatingthermostat, radiator,

heat exchanger, after-cooler

Water pump drive Belt driven

Thermostat begins to open at: 81 C (177 F) max. opening at 96 C (204.8 F)CAPACITYTotal capacityof first filling:

litres (USG) 23 (6.07)kg (lbs)

Ambra Super Gold orAmbra Master Gold15W40 10W30

bar

ENGINE


1 - 7W190

TIMING

beginning BTDC A 8.5end ATDC B 8.5

beginning BBDC D 51end ABDC C 12.5

For timing checkmm

Xmm

Operational

mm 0.25 0.05X

mm 0.50 0.005

FUEL

Injection high pressure, common railType: Bosch CP3.3 EDC7 controller

Nozzle type Electric injectors

Firing order 1 - 5 - 3 - 6 - 2 - 4

Injection pressure bar 1350Setting of injector bar

{

{

bar

X

ENGINE


W1901 - 8

DATA - MOUNTING PLAYS(1 mm = 0.03937 in)

CYL. GROUP & CRANKING COMPONENTS mm

Cylinder sleeves 1 102.009 102.031

Cylinder sleeves:

outer diameter 2 length L

Cylinder sleeves - seats incylinder block (interference)

Outer diameter 2

Cylinder sleeves:

inner diameter 2

Spare pistons type:Dimensionfor measurement X 12Outer diameter 1 101.883 101.897Pin seat 2 40.008 40.014

Piston - cylinder sleeve 0.116 0.134

Piston diameter 1 0.5

Position of pistonsfrom cylinder block X 0.28 0.52

Piston pin 3 39.996 40.003

Piston pin - pin seat 0.005 0.018

X

L

3

X

1

X

X

3

ENGINE


1 - 9W190


X 1* 2.705 2.735Piston ring seat X 2* 2.420 2.440

X 3* 4.020 4.040

* measured on 99 mm

S 1* 2.560 2.605Piston rings S 2* 2.350 2.380

S 3* 3.975 4.000

* measured on 99 mm

1 0.100 0.175Piston rings - seats 2 0.040 0.90

3 0.020 0.065

Piston rings 0.5

Gap of tips pistonrings in cyl. sleeves:

X 1 0.20 0.32X 2 0.60 0.80X 3 0.25 0.45

Seat of conrod smallend bush 1 42.987 43.553Seat of conrod bearing

2 72.987 73.013

Diameter of conrod smallend bush Outer 4 43.279 43.553 Inner 3 40.019 40.033Spare conrod halfbearing S 1.955 1.968

Conrod small end bush - 0.266 0.566seat

Piston pin - bush 0.037 0.016

Conrod half-bearings

X 1X 2

X 3

S 1S 2S 3

X 3X 3X 3

1

2

4

3

S

(1 mm = 0.03937 in)

ENGINE


W1901 - 10


Measuring dimension X

Max. out-of-lineof parallelism

of conrod centre lines

Crankshaft journals 1 82.99 83.01Conrod journals 2 68.99 69.01Crankshaft halfbearings S 1 2.456 2.464Conrod halfbearings S 2 1.955 1.968

* supplied as spare part

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

Crankshaft journal halfbearings - journalsNos. 1 - 5 0.041 0.119nos. 2 - 3 - 4 0.041 0.103

Half bearings -conrod journals 0.033 0.041

Crankshaft half bearings Conrod half bearings

Thrust crankshaftjournal X 1 37.475 37.545

Thrust crankshaft journalsupport X 2 25.98 26.48

Thrust halfbearings X 3 37.28 37.38

Crankshaft thrust 0.068 0.41

X

1 2

S 1 S 2

3

X 1

X 2

X 3

(1 mm = 0.03937 in)

ENGINE


1 - 11W190

CYLINDER HEAD - TIMIMG mm

Valve guide seats oncylinder head 1 7.042 7.062

2 Valve guide

3

Valve guides and seatson head

Valve guide

Valves:

4 6.970 6.999 60 0.25

4 6.970 6.999 45 0.25

Valve stem andrelevant guide 0.052 0.092

Seat on head for valveseat:

1

1

Outer diameter ofvalve seat;Angle of valve seaton cylinder head:

2 60

2 45X 0.59 1.11

Sinking X 0.96 1.48

Between valve seat and head

Valve seats

1

2

3

4

1

2

X

(1 mm = 0.03937 in)

ENGINE


W1901 - 12


Height of valve spring:

free spring H 47.75

under a load of:339.8 9 N H1 35.33741 39 N H2 25.2

Protrusion of injectors X

Sets for camshaft bushesnos. 1-5

59.222 59.248

Seats for camshaftnos. 2-3-4 54.089 54.139

Camshaft supportpins:1 5 53.995 54.045

Outer diameter ofcamshaft bushes:

Inner diameter ofbushes 54.083 54.147

Bushes and seatsin cylinder block

Bushes and supportpins 0.038 0.162

Cam lift:H 6.045H 7.582

H H 1 H 2

X

1 2 3 4 5

2

1 3

H

(1 mm = 0.03937 in)

ENGINE


1 - 13W190


Seat of tappet incylinder block 1 16.000 16.030

Outer diameter oftappet:

2 15.924 15.954 3 15.960 15.975

Between tappets and seats 0.025 0.070

Tappet rods

Rocker arm shaft 1 21.965 21.977

Rocker arms 2 22.001 22.027

Between rocker arms 0.024 0.162and shaft

2

1

2

2

3

1

(1 mm = 0.03937 in)

ENGINE


W1901 - 14

1.3 DESCRIPTION OF ENGINE OPERA-TION

The illustrations the configuration and the shape ofsome components illustrated in these diagrams can

show some differences, being they indicative only.

Fig. 1-7

ENGINE CROSS SECTION

ENGINE


1 - 15W190

Fig. 1-8

ENGINE LONGITUDINAL SECTION

ENGINE


W1901 - 16

1.4 DESCRIPTION OF MAIN GROUPS

CYLINDER HEAD

On the pig iron made heads, the seats of the follow-ing items are located:

Valve seats:

A directly machined for lower power engines; B inserted, on higher power 4 or 6 cylinder en-

gines. Fuel discharge duct from the electric injectors, ob-

tained directly during the casting inside the cylinderhead.

Fig. 1-9

For engines with valve seats directly machined inthe cylinder head

For engines with valve seats inserted in thecylinder 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).

1

2

3

4

A

9

8

7

6

5

B

ENGINE


1 - 17W190

1.4.1 LUBRICATION

The forced circulation lubrication is provided by thefollowing 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;

Fig. 1-10

4

1

2

3

5

Flow of oil under pressure

Return flow of oil by gravity

Oil filler

oil pressure relief valve (1) incorporated in the fil-ter support;

by-pass valve (4) cutting-off the oil filter whenclogged, incorporated in the filter support;

cartridge oil filter (2).

ENGINE


W1901 - 18

Fig. 1-11

1.4.2 COOLING

The engine cooling system, of a closed-circuit, forcedcirculation type, includes the following components: radiator, dissipating the heat removed from the

engine by the coolant; fan;

a heat exchanger cooling lubricating oil (seelubrication);

a centrifugal type water pump located in the frontside of the cylinder block;

a thermostat regulating the circulation of the coolant.

Water flowing from thethermostat

Water re-circulating theengine

Water entering the pump

ENGINE


1 - 19W190

1.4.3 FAN DRIVE SYSTEM

General descriptionThe configuration of the cooling system of the engineis as follows:A hydraulic pump connected to engine (1) (fuel pumpside) powers two hydraulic motors driving, respec-tively, the coolant radiator fan and the aftercooler fan.A controlling valve is located between the two cir-cuits having a dual function: to modulate the oil flowto the hydraulic motors according to the engine rpmand to invert the rotation direction of the radiator fanupon a command by the button located in the cab.

Once the oil is sucked by pump (1) it is forwarded tocontrolling valve block (2) and through solenoid valve(3) it reaches bi-directional hydraulic motor (4) drivingthe main fan.Also through solenoid valve (3) oil under pressurereaches the second hydraulic motor (5) driving theaftercooler fan, then it is discharged.

Fig. 1-12

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

TO DISCHARGE LINEBI-DIRECTIONAL MOTOR (14 cu cm/rev.)

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

1011

3

729

86

1

4

5

200 BAR

220 BAR

220 BAR

1/2 BGP

P1 3/4"BSP

AB

G1

1/2 BGP

1/4 BGP

ENGINE


W1901 - 20

FAN HYDRAULIC CONTROL BLOCK

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.

DIMENSIONS OF PORTS

P1 T THREADED 3/4" BSP

A B T1 THREADED 1/2" BSP

G1 MT THREADED 1/4" BSP

T1AB

C1 T

P1

MT1

2

5

7

8

4

916

3

ENGINE


1 - 21W190

1.4.4 HIGH PRESSURE ELECTRONIC FUELINJECTION SYSTEM (COMMON RAIL)

DESCRIPTION OF SYSTEM

The system is composed of the electrical system andthe hydraulic system.

2

1

3

4

5

6

7

8

9

10

Electrical system

The controller directs the operation of the enginethrough the sensors installed on it.

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 heaterand fuel temperature sensor - 9. Pressure regulator - 10. EDC 7 controller.

ENGINE


W1901 - 22

INJECTION SYSTEM ASSEMBLY

REF. DESCRIPTION 1 Position sensor on accelerator pedal 2 Key switch 3 Parking brake engaged switch 4 Gearshift in neutral switch 5 EDC main fuse (20 Amp) 6 Diagnostic connector 7 Blink-Code button 8 Engine oil pressure 9 Coolant temperature10 Revolution counter11 Pre-heater ON indicator12 Starter motor13 Crankshaft sensor14 Pre-heater activation solenoid switch15 Fuel temperature sensor16 Fuel heater resistor17 Timing sensor18 Pressure regulator solenoid valve19 Coolant temperature sensor20 Pre-heater resistor21 Electric injectors22 Air temperature/pressure sensor23 Fuel pressure sensor24 Oil temperature/pressure sensor

ENGINE


1 - 23W190

w \ EH@ w \ EH@

w w w

w \

w \

OFFACC.

ON

START

P N

MEGAFUSE

INJECTION SYSTEM ASSEMBLY

Fig. 1-15

PEDAL PROXIMITY SENSOR

POTENTIOMETER

CAN LINE211

8 9 10

12 1314

1517

1816

2019

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76

5

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3 4

ACCELERAT. PEDAL

ENGINE


W1901 - 24

DESCRIPTION OF INJECTION SYSTEM

Control of engine pre-heater resistorThe pre-heater is activated every time even just oneof the coolant, air or fuel sensors measures a tem-perature < 5 C (41 F).

Timing recognitionThrough the signals of the sensor on the camshaftand the one on the crankshaft, the starting cylinderwhere the fuel must be injected is identified.

Control of injectionThe controller, in accordance with the information pro-vided by the sensors, controls the pressure regulator,changing the modes of the pre-injection and the maininjection.On tector engines, the pre-injection is activated at allengine speeds.

Closed circuit control of the injection pressureDepending upon the engine load, determined by theprocessing of the signals provided by the various sen-sors, the controller controls the regulator to provideconstantly an optimised pressure.

Control of pilot and main injection advanceThe controller, depending upon the signals providedby the various sensors, defines the optimised injec-tion point in accordance with an internal mapping.

Control of low idle speedThe controller processes the signals provided by thevarious sensors and regulates the quantity of fuel in-jected. It controls the pressure regulator and changesthe injection timing of the electric injectors.Within certain thresholds, it considers also the volt-age of the batteries.

Overheating protectionIn the event the coolant temperature reaches 110 C(230 F) the controller decreases the performance ofthe engine.Once the temperature drops below 100 C (212 F)the engine resumes normal operations.

Limitation of maximum speedAt 2300 rpm, the controller limits the delivery of fuelby reducing the opening time of the electric injectors.

Cut-offThe cutting-off of fuel during the engine slow down orwhen used to brake is managed by the controller byperforming these logics: it cuts-off supply to the electric injectors; it reactivates the electric injectors just before reach-

ing low idle speed; it controls the fuel pressure regulator.

Control of smoke emission during accelerationsWhen high loads are required, the controller, depend-ing upon the signals provided by the air intake meas-uring device and the crankshaft speed sensor, con-trols the pressure regulator and changes the actua-tion time of the electric injectors, to prevent the en-gine from smoking.

After RunWhen cutting-off the engine, the microprocessor ofthe controller memorises some data in the EPROMincluding a trouble memory, so that the data are avail-able when a new starting occurs.

ENGINE


1 - 25W190

Hydraulic systemThe common rail system is equipped with a specialpump keeping the fuel constantly at high pressure,independently from the timing and the cylinder goingto receive the injection and accumulates it in a com-mon rail duct for all the electric injectors.Thus, at the inlet of the electric injectors fuel at theinjection pressure calculated by the controller is al-ways available.

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

The high-pressure circuit is composed of the follow-ing 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: fuel suction pipe from tank to pre-filter;

pipes supplying the mechanical fuel pump throughthe controller heat exchanger, the manual primingpump and the pre-filter;

pipes supplying the high pressure pump through thefuel filter.

The fuel system is completed by the fuel dischargecircuit from the common rail, the injectors and thehigh-pressure pump cooling circuit.

Fig. 1-161. 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.

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Low pressure

High pressure

ENGINE


W1901 - 26

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

Hydraulic diagram

Fig. 1-17

1. High pressure pump - 2. High-pressure pump pressure relief valve, 5 bar - 3. Modulating valve installed on fuel returnfrom the injectors 1,3 - 2 bar - 4. Common rail pressure relief valve - 5. Common rail - 6. Pressure sensor - 7. Electricinjector - 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.

Pressure relief valve (3) located on the cylinder head,installed on the return of the electric injectors, regu-lates the fuel return flow from the electric injectors ata pressure of 1.3 to 2 bar (18 to 29 psi).Two by-pass valves are located in parallel to the fuelpump.By-pass valve (18) makes the fuel to re-flow from theoutlet of the mechanical pump to its inlet, when thepressure at the inlet of the fuel filter exceeds the al-lowed value.By-pass valve (17) allows the filling of the fuel sys-tem by manual priming pump (10).

DISCHARGESUCTION (LOW PRESSURE)HIGH PRESSURE PUMP SUPPLY(LOW PRESSURE)HIGH PRESSURE

4 5 6 7

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17

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ECUEDC7

ENGINE


1 - 27W190

FUEL MECHANICAL PUMP

Fig. 1-18

Pressure regulator on inletLocated on the inlet of the high-pressure pump,(3, Fig. 1-19) on the low-pressure system, it modu-lates the quantity of fuel supplied to the high-pres-sure pump in accordance with the commands receivedfrom the controller.It is mainly composed of the following components: trapezoidal section plunger; valve control pin; pre-load spring; solenoids.When no command signal is received, the pressureregulator is normally open, thus the high-pressurepump is in maximum flow condition.The controller modulates a PWM command to controlin a larger or smaller manner the fuel passage sectiontoward the high-pressure pump.The component cannot be replaced individually; thusit must not be removed.

HIGH PRESSURE PUMP CP3

Fig. 1-19

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

3-radial piston pump driven timing gear, without needfor timing setting, with fuel rotor pump mounted onthe rear side.

A

A

ASect. A-A

B

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D

E

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1

C

ENGINE


W1901 - 28

Internal structure of the high pressure pump

Fig. 1-20

1. Cylinder - 2. Three lobe element - 3. Plate type inlet valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft - 7. Low-pressure 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-of-line part of shaft (6) during the rotation of the shaftdoes not rotate with it but it is only moved circularlyon 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 beoverhauled, thus the securing screws must not betempered with nor it must be removed. The only inter-vention allowed is replacing the drive gear and replac-ing pressure regulator (3).

7Sect. B-B

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5

B C

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B C

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Sect. C-C

ENGINE


1 - 29W190

OperationThe cylinder is filled through the plate intake valveonly when the supply pressure is capable of openingthe delivery valves located on the pumping elements(about 2 bar) (29 psi).The quantity of fuel supplying the high-pressure valveis dosed by the pressure regulator, located on thelow-pressure system; the pressure regulator is con-trolled by the EDC7 controller through a PWM signal.When fuel is forwarded to the pumping element, therelevant piston is moving downward (suction stroke).Once the stroke of the piston is inverted, the intakevalve closes and the fuel in the pumping elementchamber, being prevented from getting-out, is com-pressed over the value of the supply pressure in therail.The pressure generated in this manner causes theopening of the discharge valve and compressed fuelreaches the high-pressure circuit.The pumping element compresses the fuel until itreaches the TDC (delivery stroke). Then, the pres-sure decreases until the discharge valve closes.The piston of the pumping element returns toward theBDC and the residual fuel decompresses.Once the pressure in the pumping element chamberbecomes lower than the supply pressure, the intakevalve opens again and the cycle is repeated.Delivery valves must always be free in their move-ment, free from impurities and oxidation.The delivery pressure to the rail is modulated between250 and 1350 bar (3625 to 19580 psi) by the control-ler, through the solenoid valve of the pressure regula-tor.

The pump is lubricated and cooled by the fuel itself.The cut-off/reactivation time of the radialjet pump onthe engine is greatly reduced compared with traditionalinjection pumps, since it does not require timing set-ting.In case of removal-reinstallation of the piping betweenfuel filter and high-pressure pump, keep your handsand components perfectly clean.

Rail

2

4

135

Fig. 1-21

1. Rail - 2. Flow limiters - 3. Fuel inlet from high pressurepump - 4. Pressure sensor - 5. Pressure relief valve.

The volume of the rail has reduced dimensions to pro-vide a fast pressurisation when starting, at low idleand in case of large flows.It has anyway, a volume sufficient to minimise thefluctuations caused by the opening and the closing ofthe injectors and the operation of the high-pressurepump. This function is further eased by a calibratedorifice located after the high-pressure pump.A fuel pressure sensor (4) is screwed on the rail. Thesignal forwarded by this sensor to the controller pro-vides a feedback information, on which the pressurevalue in the rail is measured and corrected, if required.

ENGINE


W1901 - 30

Pressure relief valveThe pressure relief valve (1750 bar) (25381 psi) onthe common rail protects the components of the

Fig. 1-211. 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 thedischarge toward the tank closed.

B. In case the fuel pressure of 1750 bar (25381 psi)in the rail is exceeded, the piston moves and thepressure excess is discharged into the tank.

Flow limitersThey are located on the rail fuel outlet connections.Their function is to protect the integrity of the engineor the vehicle in the event of internal spills (exampleinjector stuck open) or external (example: damagedhigh-pressure pipes).If this occurs, the operation of the system is provided,within certain limits, by the components of the othercylinders in operational conditions.

WARNINGAfter the intervention to block the leakage of fuelfrom the rail, the flow limiter is automatically re-set under the action of the spring. However, f thecause of its intervention is not eliminated, at thenext starting tentative the engine could operateonly at low idle or at low speed or to be cut-offagain, depending upon the entity of the leakage.

Fig. 1-221. 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 smalldiameter of the piston.Under normal conditions, the fuel pressure is onboth sides of the piston, kept by the spring in openposition.

B. In the event of a large pressure drop after thelimiter, the inlet pressure prevails and moves thepiston toward the opposite side, cutting-off theoutflow of fuel.

B

62135

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5 3 1 2 6

A

system in the event a flow limiter intervenes.

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35 2 4

A B

ENGINE


1 - 31W190

Electric injectorThe injector has a design similar to traditional ones.The electric injector can be considered composed oftwo parts: actuator-nozzle composed of pressure rod (1), nee-

dle (2) nozzle (3); control solenoid valve composed of coil (4) and pi-

lot valve (5).

The solenoid valve controls the lifting of the injectorneedle.

6

95

Injector in rest condition

Fig. 1-23

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

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ENGINE


W1901 - 32

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.

Beginning of injection

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

At the same time the fuel pressure in pressure cham-ber (8) causes the lifting of needle (2) with the subse-quent injection of the fuel into the cylinder.

6

95

End of injectionOnce solenoid (4) is de-energised, plunger (6) returnsinto position closed, re-creating equilibrium of forces

returning needle (2) into closed position, terminatingthe injection.

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ENGINE


1 - 33W190

1.5 TROUBLESHOOTING GUIDE

FOREWORD

Experience is the factor facilitating the solution of trou-bles.To partially overcome the lack of experience by therepair engineer on this new electronic device, sinceno previous systems to which refer existed, we list inthe pages to follow a TROUBLESHOOTING GUIDE.The troubleshooting guided is composed of two sec-tions, neatly defined: the first one, organised by Blink Code, refers to

troubles that can be directly identified by the EDC7controller. These troubles are of are mostly of anelectric- electronic nature;

the second, organised by symptom, describes pos-sible troubles not directly identifiable by the control-ler. These troubles are mostly of a mechanical-hy-draulic nature.

The troubleshooting guides do not replace the diag-nosis with electronic diagnostic equipment, but shouldbe considered as integration to the same.

ENGINE


W1901 - 34

K! K L CAN

P T - 0 1

1

K! K L CAN

2 34 5 67 8

1010

90

P T - 0 1

X

1.5.1 TROUBLESHOOTING WITH PT-01INSTRUMENT

The PT-01 380001218 diagnostic instrument shown

Fig. 1-25

in the illustration is supplied with a set of connectingcables as well as an Operation Manual.

1. outer power connection2. diagnostic connecting cable

1. HW failure 2. transm. K line comun. 3. transm. line K reception 4. transmission L line communication 5. line bus CAN

6. power

7. navigation buttons

8. communication statusindicators

9. numerical buttons

11. USB port indicator10. CANCEL button

12. OK button13. serial port indicator

1. serial port

2. porta USB

Connection point

Controller-instrumentconnecting cable

ENGINE


1 - 35W190

1.5.2 TROUBLESHOOTING WITH BLINKCODE

Performance of the EDC indicator lightsThe panel with the trouble indicator light is located inthe cab and can be reached after removing the plas-tic cover behind the operator's seat.

Fig. 1-26

ACTIVATION/READING THE BLINK CODE

By actuating the "ENGINE DIAGNOSTIC" switch itis possible to monitor the operational condition of thecontroller and to identify the presence of the errorcodes

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