Part number 47829079B 2nd edition English May 2015 Replaces part number 47829079 SERVICE MANUAL 21F 121F 221F 321F Tier 4B (final) Compact Wheel Loader
SERVICEMANUAL 121FXT,121FZB,21FXT,21FZB,221FHS,221FSTD,321FHS,321FSTD
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.216]Fueltanks..........................................................................10.2 Transmission..............................................................................21 Frontaxlesystem.......................................................................25 [25.100]Poweredfrontaxle.................................................................25.1 [25.102]Frontbevelgearsetanddifferential...............................................25.2 [25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3 Rearaxlesystem........................................................................27 [27.124]Finaldrivehub,steeringknuckles,andshafts.....................................27.4 Brakesandcontrols....................................................................33 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.300]Reservoir,cooler,andfilters........................................................35.2 [35.104]Fixeddisplacementpump..........................................................35.3
Framesandballasting.................................................................39 [39.140]Ballastsandsupports..............................................................39.1 Steering.....................................................................................41 Electricalsystems.......................................................................55 [55.000]Electricalsystem...................................................................55.1 [55.100]Harnessesandconnectors.........................................................55.2 [55.045]Frontaxlecontrolsystem..........................................................55.3 [55.408]Warningindicators,alarms,andinstruments......................................55.4 [55.DTC]FAULTCODES....................................................................55.5 Platform,cab,bodywork,anddecals.............................................90
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INTRODUCTION
1
Contents INTRODUCTION Safetyrules.....................................................................................6 Personalsafety.................................................................................7 Productidentification-Machineorientation..................................................29 Basicinstructions-Howtousethemaintenancestandardandprecautions.................31 Basicinstructions-Precautionfordisassemblyandassembly...............................33 Basicinstructions-Electricalequipmentprecautions........................................35 2
INTRODUCTION Basicinstructions-Importantnoticeregardingequipmentservicing Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein type,orchangestothelawsandregulationsofdifferentcountries. 3
Shimming
INTRODUCTION Basicinstructions-Shopandassembly
Rotatingshaftseals NOTE: andthedustlipondoublelipsealswithgrease. O-ringseals Sealingcompounds compound,preparethesurfacesasdirectedbytheproductcontainer. Spareparts OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts. partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal Whenorderingspareparts,alwaysprovidethefollowinginformation: • Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4
INTRODUCTION Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices: • • • weld. NOTICE: Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery. Specialtools WARNING Batteryacidcausesburns.Batteriescontainsulfuricacid. Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):flush quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately. W0111A repairoperations.Thespecialtoolsareaccuratelybuiltandrigorouslytestedtoofferefficientandlong-lastingoperation. • Operatinginoptimaltechnicalconditions • Obtainingthebestresults • Savingtimeandeffort • Workinginsafeconditions 5
Safetyrules
Personalsafety
INTRODUCTION
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: Noteindicatesadditionalinformationwhichclarifiessteps,procedures,orotherinformationinthismanual. otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage. 6
Personalsafety
INTRODUCTION
structedstaff;specificprecautionshavetobetakenwhen grinding,weldingorwhenusingmalletsorheavyhammers. Notauthorizedpersonsarenotallowedtorepairorcarry outmaintenanceonthismachine.Donotcarryoutany Askyouremployeraboutthesafetyinstructionsinforce Nobodyshouldbeallowedinthecabduringmachine maintenanceunlessheisaqualifiedoperatorhelping fromanyotherpositionthantheoperator’sseat. TULI12WEX2004AA 1 Nevercarryoutanyoperationonthemachinewhenthe engineisrunning,exceptwhenspecificallyindicated. Stoptheengineandensurethatallpressureisrelieved fromhydrauliccircuitsbeforeremovingcaps,covers, Allrepairandmaintenanceoperationsshouldbecarried Servicestairsandplatformsusedinaworkshoporinthe fieldshouldbebuiltincompliancewiththesafetyrulesin mediately. DANGER Unexpectedmovement! Makesureparkingbrakeisapplied.Secure machinewithwheelchocks. Failuretocomplywillresultindeathorserious injury. D0013A TULI12WEX2005AA 2 7
INTRODUCTION Emergency ufacturer’sinstructions. SMIL12WEX0174AA 3 Equipment Wearclosefittingclothingandsafetyequipmentappropriateforthejob: • Safetyhelmet • Safetyshoes • Heavygloves • Reflectiveclothing • Wetweatherclothing equipmentshouldbeonhand: • Respirators(ordustproofmasks) • Earplugsoracousticearsprotections • Goggleswithlateralshieldormasksforeyesprotection jacketsorshirtswithopenzipswhichcouldgetcaughtinto TULI12WEX2008AA 4 Engine-Radiator NeverleavetheenginerunninginenclosedspaceswithTULI12WEX2009AA 5 8
INTRODUCTION Payattentiontorotatingcomponentsanddonotallow toanyonetoapproachtheseareastoavoidbecoming Hands,clothingortoolsgettingcaughtinthefanblades Forthisreasonavoidtouchingorapproachingallrotating Asurgingsprayofthecoolantfromtheradiatorcancause TULI12WEX2010AA 6 andlampsexplicitlydesignatedasexplosionproof.If TULI12WEX2011AA 7 Hydraulicsystems Relievetheresidualpressurebymovingthehydraulic Protectyourhandsandbodyfrompossiblejetsoffluid Swallowinghydraulicoilisaseverehealthhazard. TULI12WEX2012AA 8 9
INTRODUCTION ofinjuryimmediately. Anyfluidpenetratingtheskinmustberemovedwithinfew hourstoavoidseriousinfections. Flammablesplashesmayoriginatebecauseofheating nearlineswithfluidsunderpressure,resultinginserious Linesunderpressurecanaccidentallybepiercedwhen Arrangefortemporaryfireresistantshieldstoprotect upbindingagentanddisposeofitseparatelyfromother hydraulichosesimmediatelyondetectinganydamaged TULI12WEX2013AA 9
Hosesandtubes
INTRODUCTION
Alwaysreplacehosesandtubesiftheconeendorthe foretighteningtheconnections.Clampsshouldbetightenedsufficientlytoholdthehosewithoutcrushingandto Afterhosereplacementtoamovingcomponent,check thatthehosedoesnotfoulbymovingthecomponent movementfromtheoriginalpositionhavefailedandwill sultanthosefailure. Ballooningofthehoseindicatesaninternalleakagedueto structuralfailure.Thisconditionrapidlydeterioratesand sufferinternalstructuraldamagewhichcanresultinoil restriction,areductioninthespeedofoperationandultimatehosefailure. Free-moving,unsupportedhosesmustneverbeallowed totoucheachotherorrelatedworkingsurfaces.This TULI12WEX2014AA O-rings condition.AlwayslubricatenewsealringsandO-rings withhydraulicoilbeforeinstallationtorelevantseats. duringmountingwhichwilljeopardizesealing. 11
INTRODUCTION Battery Batteriesgiveoffexplosivegases. Neverhandlenakedflamesandunshieldedlightsources instructions: • Whendisconnectingthebatterycables,alwaysdiscon• • Nevershort-circuitthebatteryterminalswithmetalob• TULI12WEX2015AA 11 Antidote: • • mouth.Consultadoctor. • EYES:Rinseabundantlywithwaterfor 15min andconsultadoctor. • plodeifyouattempttochargethebatteryorifyoutryto Providegoodventilationwhenchangingabatteryorusing whenworkingnearabattery. TULI12WEX2016AA Disposeofusedbatteriesseparatelyfromotherwastein TULI12WEX2017AA
INTRODUCTION Flammableliquids Whenhandlingflammableliquids: • • Keepawayfromunshieldedlightsourcesandnaked Fuelsoftenhavealowflashpointandarereadilyignited. Use: • Drypowder • Carbondioxide • Foam stantaneouslyoncontactwithburningsubstancesand generatesshortcircuitsintheelectricalsystem,possibly TULI12WEX2016AA Stayawayfromopenflamesduringrefillingofhydraulic Fueloroilspillscancauseslippinghazards;thoroughly Alwaystightenthesafetyplugsoffueltankandhydraulic Neverusefueltocleanmachinepartsthatwillbeexposed Useanon-flammableproductforcleaningparts. TULI12WEX2018AA Duringrefuellingholdthepistolfirmlyandalwayskeepit alwaysincontactwiththefillerneckuntiltheendofthe TULI12WEX2019AA
Tires
Cleaning
INTRODUCTION
Beforeinflatingthetires,alwayschecktheconditionof Wheninflatingtires,ensuretirepressuredoesnotexceed pressureoftherighttirecorrespondstothepressureof NOTE: heattreatmentsorbrazingsnotperformedcorrectlycan ures.Deflatethetiresbeforetheirdisassembly. itisnecessarytodeflatethetires.Inflatetiresbymeans ofaninflationpistolcompletewithextensionandpressure TULI12WEX2020AA
Cleantheexteriorofallcomponentsbeforecarryingout Solventsshouldbecheckedthattheyaresuitableforthe cleaningofcomponentsandalsothattheydonotriskthe plebecausetheycancreateslippingortrippinghazards Formachinecleaning,useajetofwarmwaterorsteam Avoiddirectsprayofsealsandseamstopreventwater TULI12WEX2021AA
INTRODUCTION Wastedisposal isthereforeadvisabletopreparesuitablecontainersto collectandstoremomentarilyallsolidandfluidmaterials thatmustnotbescatteredintheenvironmenttoavoid quiringdisposal: • Lubricatingoil • Brakesystemoil • tifreeze • Fuel • • Filterelements,airfilters • Battery Alsopollutingrags,paper,sawdustandglovesmustbe Donotusefoodorbeveragecontainersthatmaymislead conditioningrefrigerantsescapingintotheaircandamage theEarth’satmosphere.Governmentregulationsmayrequireacertifiedairconditioningservicecentretorecover formationontheproperwaytorecycleordisposeofwaste TULI12WEX2022AA
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INTRODUCTION Foreword-Ecologyandtheenvironment productsofachemicalandpetrochemicalnature.
Thefollowingarerecommendationsthatmaybeofassistance: • • Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,antifreeze,cleaning • Helpfulhints • Avoidfillingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable • • Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems. • Donotmixdrainedbrakefluidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofinaproper • • Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere. YourCASECONSTRUCTIONdealerorairconditioningspecialisthasaspecialextractorforthispurposeandwill • Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately. • •
