SERVICE MANUAL Wheel Loader 621G 721G Tier 2 Part number 48083740 English July 2018 © 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICEMANUAL
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.202]Aircleanersandlines..............................................................10.2 [10.400]Enginecoolingsystem.............................................................10.3 [10.414]Fananddrive......................................................................10.4 [10.310]Aftercooler..........................................................................10.5 Transmission..............................................................................21 Four-WheelDrive(4WD)system..................................................23 [23.314]Driveshaft..........................................................................23.1 Frontaxlesystem.......................................................................25 Rearaxlesystem........................................................................27 [27.100]Poweredrearaxle..................................................................27.1 [27.106]Rearbevelgearsetanddifferential................................................27.2 [27.120]Planetaryandfinaldrives..........................................................27.3 Brakesandcontrols....................................................................33
[35.300]Reservoir,cooler,andfilters........................................................35.2 [35.106]Variabledisplacementpump.......................................................35.3 Framesandballasting.................................................................39 [39.100]Frame..............................................................................39.1 Steering.....................................................................................41 Wheels......................................................................................44 [44.520]Rearwheels........................................................................44.2 Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 [55.100]Harnessesandconnectors.........................................................55.1 [55.301]Alternator...........................................................................55.2
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[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.5 [55.530]Camera.............................................................................55.7 [55.DTC]FAULTCODES....................................................................55.8 Frontloaderandbucket...............................................................82 Platform,cab,bodywork,anddecals.............................................90 [90.120]Mechanically-adjustedoperatorseat...............................................90.2 [90.124]Pneumatically-adjustedoperatorseat..............................................90.3
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INTRODUCTION
Contents
Safetyrules.....................................................................................3 Personalsafety.................................................................................4 Basicinstructions-Howtousethemaintenancestandardandprecautions.................14 Basicinstructions-Electricalequipmentprecautions........................................18 Consumables-BiodieselFuel................................................................21 2
INTRODUCTION
Personalsafety
INTRODUCTION
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety. Information NOTE: 3
INTRODUCTION
structedstaff;specificprecautionshavetobetakenwhen grinding,weldingorwhenusingmalletsorheavyham-
outmaintenanceonthismachine.Donotcarryoutany Askyouremployeraboutthesafetyinstructionsinforce Nobodyshouldbeallowedinthecabduringmachine maintenanceunlessheisaqualifiedoperatorhelping fromanyotherpositionthantheoperator’sseat.
Nevercarryoutanyoperationonthemachinewhenthe engineisrunning,exceptwhenspecificallyindicated. Stoptheengineandensurethatallpressureisrelieved fromhydrauliccircuitsbeforeremovingcaps,covers, Allrepairandmaintenanceoperationsshouldbecarried Servicestairsandplatformsusedinaworkshoporinthe fieldshouldbebuiltincompliancewiththesafetyrulesin mediately. DANGER Unexpectedmovement! Makesureparkingbrakeisapplied.Secure machinewithwheelchocks. Failuretocomplywillresultindeathorserious injury. D0013A TULI12WEX2005AA 2 4
Personalsafety
mers.
TULI12WEX2004AA 1
INTRODUCTION Emergency ufacturer’sinstructions. SMIL12WEX0174AA 3 Equipment Wearclosefittingclothingandsafetyequipmentappropriateforthejob:
Safetyhelmet
Safetyshoes
Heavygloves
Reflectiveclothing
Wetweatherclothing equipmentshouldbeonhand:
Respirators(ordustproofmasks) • Earplugsoracousticearsprotections • Goggleswithlateralshieldormasksforeyeprotection jacketsorshirtswithopenzipswhichcouldgetcaughtinto TULI12WEX2008AA 4 Engine-Radiator NeverleavetheenginerunninginenclosedspaceswithTULI12WEX2009AA 5 5
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INTRODUCTION Payattentiontorotatingcomponentsanddonotallow Hands,clothingortoolsgettingcaughtinthefanbladesor Asurgingsprayofthecoolantfromtheradiatorcancause Beforecheckingthecoolantlevel,shut-offtheengine TULI12WEX2010AA 6 Ifitisnecessarytoremovethecapwhileengineishot, thesetypesoflampsarenotused,firesorexplosionsmay TULI12WEX2011AA 7 Hydraulicsystems ingseriousinjuries. inghydraulicorotherlines. Relievetheresidualpressurebymovingthehydraulic controlleversseveraltimes. Toprotecttheeyeswearafacialshieldorsafetygoggles. Protectyourhandsandbodyfrompossiblejetsoffluids underpressure. TULI12WEX2012AA 8 6
INTRODUCTION ofinjuryimmediately. Anyfluidpenetratingtheskinmustberemovedwithina fewhourstoavoidseriousinfections. Flammablesplashesmayoriginatebecauseofheating nearlineswithfluidsunderpressure,resultinginserious Linesunderpressurecanaccidentallybepiercedwhen Arrangefortemporaryfireresistantshieldstoprotect upbindingagentanddisposeofitseparatelyfromother hydraulichosesimmediatelyondetectinganydamaged TULI12WEX2013AA 9 7
Hosesandtubes
Alwaysreplacehosesandtubesiftheconeendorthe foretighteningtheconnections.Clampsshouldbetightenedsufficientlytoholdthehosewithoutcrushingandto
Afterreplacingahoseonamovingcomponent,checkthat thehosedoesnotfallbymovingthecomponentthrough
movementfromtheoriginalpositionhavefailedandwill subsequentlyoccuralongthehoselengthwithresultant hosefailure.
Ballooningofthehoseindicatesaninternalleakagedueto structuralfailure.Thisconditionrapidlydeterioratesand
sufferinternalstructuraldamagewhichcanresultinoil restriction,areductioninthespeedofoperationandultimatehosefailure.
Free-moving,unsupportedhosesmustneverbeallowed totoucheachotherorrelatedworkingsurfaces.This
INTRODUCTION
TULI12WEX2014AA O-rings
duringmountingwhichwilljeopardizesealing. 8
condition.AlwayslubricatenewsealringsandO-rings withhydraulicoilbeforeinstallationtorelevantseats.
INTRODUCTION Battery Batteriesgiveoffexplosivegases. Neverhandleopenflamesandunshieldedlightsources nearbatteries.(Nosmokingisaddressedinthenextininstructions:
Whendisconnectingthebatterycables,alwaysdiscon-
• Nevershort-circuitthebatteryterminalswithmetalob-
TULI12WEX2015AA 11 Treatment:
• mouth.Consultadoctor. • EYES:Rinseabundantlywithwaterfor 15min andconsultadoctor. • plodeifyouattempttochargethebatteryorifyoutryto Providegoodventilationwhenchangingabatteryorusing whenworkingnearabattery. TULI12WEX2016AA Disposeofusedbatteriesseparatelyfromotherwastein TULI12WEX2017AA 9
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INTRODUCTION Flammableliquids Whenhandlingflammableliquids: • • Keepawayfromunshieldedlightsourcesandopen Fuelsoftenhavealowflashpointandarereadilyignited. Use: • Drypowder • Carbondioxide • Foam stantaneouslyoncontactwithburningsubstancesand generatesshortcircuitsintheelectricalsystem,possibly TULI12WEX2016AA Stayawayfromopenflamesduringrefillingofhydraulic Fueloroilspillscancauseslippinghazards;thoroughly Alwaystightenthesafetyplugsoffueltankandhydraulic Neverusefueltocleanmachinepartsthatwillbeexposed Useanon-flammableproductforcleaningparts. TULI12WEX2018AA Duringrefuellingholdthepistolfirmlyandalwayskeepit TULI12WEX2019AA
INTRODUCTION Tires Beforeinflatingthetires,alwayschecktheconditionof rimsandtheouterconditionoftiresforthepresenceof Wheninflatingtires,ensuretirepressuredoesnotexceed pressureoftherighttirecorrespondstothepressureof NOTE: heattreatmentsorbrazingsnotperformedcorrectlycan thetiresbeforetheirdisassembly. itisnecessarytodeflatethetires.Inflatetiresbymeans ofaninflationpistolcompletewithextensionandpressure TULI12WEX2020AA Cleaning Cleantheexteriorofallcomponentsbeforecarryingout Solventsshouldbecheckedthattheyaresuitableforthe cleaningofcomponentsandalsothattheydonotriskthe Formachinecleaning,useajetofwarmwaterorsteam Avoiddirectsprayofsealsandseamstopreventwater TULI12WEX2021AA 11
Wastedisposal
• Coolantmixture,condensationrestsandpureantifreeze
Donotusefoodorbeveragecontainersthatmaymislead someoneintodrinkingfromthem.Donotpourwasteonto conditioningrefrigerantsescapingintotheaircandamage theEarth’satmosphere.Governmentregulationsmayrequireacertifiedairconditioningservicecentretorecover formationontheproperwaytorecycleordisposeofwaste
INTRODUCTION
isthereforeadvisabletopreparesuitablecontainersto collectandstoremomentarilyallsolidandfluidmaterials thatmustnotbescatteredintheenvironmenttoavoid ingdisposal:
• Lubricatingoil
• Brakesystemoil
• Fuel • • • Battery disposedincompliancewiththesameprocedures.
TULI12WEX2022AA
INTRODUCTION Basicinstructions-Importantnoticeregardingequipmentservicing
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein type,orchangestothelawsandregulationsofdifferentcountries.
INTRODUCTION Basicinstructions-Howtousethemaintenancestandardand precautions Application WHENTHEMACHINEISNEW ATSPECIFICSELFINSPECTION(RULEBYCOUNTRY) Usethedataforthecriterion,forthepurposeofcorrection,adjustmentandreplacement. WHENPERFORMANCESAREDETERIORATED Determinewhetheritiscausedbyafaultorendofservicelifeafterlonghoursofoperation,tobeusedforsafetyand WHENMAINCOMPONENTSAREREPLACED Terminology STANDARDVALUES Valuestobeusedtoconditionorassembleanewmachine.Wherespecialnotesarenotgiven,thesevaluesrepresent REFERENCEVALUESFORREMEDY machineoverthespecifiedvalues. SERVICELIMIT Thisisthelimitvalueatwhichreconditioningisimpossiblewithoutreplacementofparts.Ifthevalueisexpected Cautionstobeexercisedatjudgment EVALUATIONOFMEASUREDDATA Machineperformancesdeterioratewithtimeaspartswearandsomedeterioratedperformancesmayberestoredto Othercautionstobeexercised PARTSLIABLETODEGRADE
INSPECTIONANDREPLACEMENTOFOILSANDGREASES
INTRODUCTION
Criticalhosesthatarenecessarytosecuresafety,wedesignateasVeryImportantParts(V.I.P.)andrecommendthat
PARTSREQUIRINGREGULARREPLACEMENT
INTRODUCTION Basicinstructions-Precautionfordisassemblyandassembly Preparationsfordisassembly • machinecomponentstobecontaminatedduringdisassembling/assembling,resultingindamagetomachinecom• disassemblingofcomponentsaswellaspersonalinjury. • 3.Cloggingoffiltersandoil,waterorairleaks,ifany. 5.Looseordamagedparts. • • Wearappropriateclothing,safetyshoes,safetyhelmet,goggles,andclotheswithlongsleeves. • • Beforeperforminganyworkonthemachine,followlockout/tagoutproceduresbyattachinga“maintenancein progresstag”.Thistagcanbeappliedontheleft-handcontrollever,safetyleverorcabdoor.Notifythosewith Disassemblingandassemblinghydraulicequipment • • Draintheoilinremovedlinesintoanappropriatecontainertopreventoilcontamination. • • Disassemblinghydraulicequipment • Impairedperformanceandfunctionofhydraulicequipmentafterunauthorizedservicemaynotbecoveredunder • • • authorizeddealer. • • Ifpartscannotberemovedasspecifiedbytheprocedure,neverforceremoval.Checkforotherfailuresthatmay • • • • Forcommonparts,payattentiontothequantityandlocationsofeachgroupofcomponents.
