Part number 47829079C 1st edition English April 2017 SERVICE MANUAL 21F 121F 221F 321F Tier 4A (interim) Compact Wheel Loader
SERVICEMANUAL 121FXT,121FZB,21FXT,21FZB,221FHS,221FSTD,321FHS,321FSTD 47829079C_EN-NA04/04/2017
Product
CARRIER
CARRIER
CARRIER
CARRIER
Engine
LinkProduct/Engine
MarketProduct
121FXTCWLTIER4TOOL
NorthAmerica F5HFL463C*F001 121FZBCWLTIER4Z-BARNorthAmerica F5HFL463C*F001 21FXTCWLTIER4TOOL
NorthAmerica F5HFL463B*F001 NorthAmerica F5HFL463B*F001 221FHSCWLTIER4TOOL
NorthAmerica F5HFL463A*F001 221FSTDCWLTIER4Z-BARNorthAmerica F5HFL463A*F001 321FHSCWLTIER4TOOL
NorthAmerica F5HFL463A*F001 NorthAmerica F5HFL463A*F001 47829079C_EN-NA04/04/2017
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.216]Fueltanks..........................................................................10.2 Four-WheelDrive(4WD)system..................................................23 Frontaxlesystem.......................................................................25 [25.100]Poweredfrontaxle.................................................................25.1 [25.102]Frontbevelgearsetanddifferential...............................................25.2 [25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3 Rearaxlesystem........................................................................27 Hydrostaticdrive.........................................................................29 [29.100]Transmissionandsteeringhydrostaticcontrol.....................................29.1 Brakesandcontrols....................................................................33 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.300]Reservoir,cooler,andfilters........................................................35.2 [35.104]Fixeddisplacementpump..........................................................35.3 [35.106]Variabledisplacementpump.......................................................35.4 47829079C_EN-NA04/04/2017
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Framesandballasting.................................................................39 [39.100]Frame..............................................................................39.1 [39.140]Ballastsandsupports..............................................................39.2 Steering.....................................................................................41 Cabclimatecontrol.....................................................................50 [50.100]Heating.............................................................................50.1 [50.200]Airconditioning.....................................................................50.2 Electricalsystems.......................................................................55 [55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.4 [55.DTC]FAULTCODES....................................................................55.6 Frontloaderandbucket...............................................................82 47829079C_EN-NA04/04/2017
Platform,cab,bodywork,anddecals.............................................90 [90.150]Cab.................................................................................90.1 47829079C_EN-NA04/04/2017
47829079C_EN-NA04/04/2017
INTRODUCTION
47829079C_EN-NA04/04/2017 1
Contents INTRODUCTION Safetyrules.....................................................................................6 Personalsafety.................................................................................7 Torque........................................................................................16 Basicinstructions-Howtousethemaintenancestandardandprecautions.................27 Basicinstructions-Precautionfordisassemblyandassembly...............................29 Basicinstructions-Electricalequipmentprecautions........................................31 Productidentification-Machinecomponents.................................................35 47829079C_EN-NA04/04/2017 2
INTRODUCTION Basicinstructions-Importantnoticeregardingequipmentservicing Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein type,orchangestothelawsandregulationsofdifferentcountries. 47829079C_EN-NA04/04/2017 3
Shimming
INTRODUCTION Basicinstructions-Shopandassembly
Rotatingshaftseals NOTE: andthedustlipondoublelipsealswithgrease. O-ringseals Sealingcompounds compound,preparethesurfacesasdirectedbytheproductcontainer. Spareparts OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts. partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal Whenorderingspareparts,alwaysprovidethefollowinginformation: • Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 47829079C_EN-NA04/04/2017 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 47829079C_EN-NA04/04/2017 5
Safetyrules
Personalsafety
INTRODUCTION
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: Noteindicatesadditionalinformationwhichclarifiessteps,procedures,orotherinformationinthismanual. otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage. 47829079C_EN-NA04/04/2017 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 47829079C_EN-NA04/04/2017 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 47829079C_EN-NA04/04/2017 8
INTRODUCTION Payattentiontorotatingcomponentsanddonotallow toanyonetoapproachtheseareastoavoidbecoming Hands,clothingortoolsgettingcaughtinthefanblades Forthisreasonavoidtouchingorapproachingallrotating Asurgingsprayofthecoolantfromtheradiatorcancause TULI12WEX2010AA 6 andlampsexplicitlydesignatedasexplosionproof.If TULI12WEX2011AA 7 Hydraulicsystems Relievetheresidualpressurebymovingthehydraulic Protectyourhandsandbodyfrompossiblejetsoffluid Swallowinghydraulicoilisaseverehealthhazard. TULI12WEX2012AA 8 47829079C_EN-NA04/04/2017 9
INTRODUCTION ofinjuryimmediately. Anyfluidpenetratingtheskinmustberemovedwithinfew hourstoavoidseriousinfections. Flammablesplashesmayoriginatebecauseofheating nearlineswithfluidsunderpressure,resultinginserious Linesunderpressurecanaccidentallybepiercedwhen Arrangefortemporaryfireresistantshieldstoprotect upbindingagentanddisposeofitseparatelyfromother hydraulichosesimmediatelyondetectinganydamaged TULI12WEX2013AA 9 47829079C_EN-NA04/04/2017
INTRODUCTION Hosesandtubes 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. 47829079C_EN-NA04/04/2017 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 47829079C_EN-NA04/04/2017
INTRODUCTION Flammableliquids Whenhandlingflammableliquids: • • Keepawayfromunshieldedlightsourcesandnaked Fuelsoftenhavealowflashpointandarereadilyignited. Use: • Drypowder • Carbondioxide • Foam stantaneouslyoncontactwithburningsubstancesand generatesshortcircuitsintheelectricalsystem,possibly TULI12WEX2016AA Stayawayfromopenflamesduringrefillingofhydraulic Fueloroilspillscancauseslippinghazards;thoroughly Alwaystightenthesafetyplugsoffueltankandhydraulic Neverusefueltocleanmachinepartsthatwillbeexposed Useanon-flammableproductforcleaningparts. TULI12WEX2018AA Duringrefuellingholdthepistolfirmlyandalwayskeepit alwaysincontactwiththefillerneckuntiltheendofthe TULI12WEX2019AA 47829079C_EN-NA04/04/2017
Cleaning
INTRODUCTION Tires Beforeinflatingthetires,alwayschecktheconditionof Wheninflatingtires,ensuretirepressuredoesnotexceed pressureoftherighttirecorrespondstothepressureof NOTE: heattreatmentsorbrazingsnotperformedcorrectlycan ures.Deflatethetiresbeforetheirdisassembly. itisnecessarytodeflatethetires.Inflatetiresbymeans ofaninflationpistolcompletewithextensionandpressure TULI12WEX2020AA
Cleantheexteriorofallcomponentsbeforecarryingout Solventsshouldbecheckedthattheyaresuitableforthe cleaningofcomponentsandalsothattheydonotriskthe plebecausetheycancreateslippingortrippinghazards Formachinecleaning,useajetofwarmwaterorsteam Avoiddirectsprayofsealsandseamstopreventwater TULI12WEX2021AA 47829079C_EN-NA04/04/2017
