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Engine - Engine and crankcase

Engine - Install

WARNING

Hot liquid under pressure!
Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.
Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then
remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.
Failure to comply could result in death or serious injury.

W0296A

RAIL12WEL0130FA

1

1. Engine mount bolt

5. Washers

2. Washer

6. Washer

3. Upper isolator

7. Nut

4. Lower isolator

8. Remote oil drain hose

1. Inspect the engine mounts. If the engine rubber isola-

tors require replacement, remove and discard the up-
per isolators

(3)

and lower isolators

(4)

. Install new up-

per isolators

(3)

and new lower isolators

(4)

.

48083741_EN 31/07/2018

10.1 [10.001] / 18

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Summary of Contents for 48083741

Page 1: ...1 2 SERVICE MANUAL 821G 921G Tier 2 Wheel Loader Part number 48083741 English July 2018 2018 CNH Industrial Italia S p A All Rights Reserved 821G 921G Wheel Loader Part number 48083741 SERVICE MANUAL ...

Page 2: ...SERVICE MANUAL 821G ZBAR EH NEW CAB TIER2 921G ZBAR EH NEW CAB TIER2 48083741_EN 31 07 2018 EN Find manuals at https best manuals com ...

Page 3: ...verter 21 3 Four Wheel Drive 4WD system 23 23 314 Drive shaft 23 1 Front axle system 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 108 Final drive hub steering knuckles and shafts 25 3 Rear axle system 27 27 100 Powered rear axle 27 1 27 106 Rear bevel gear set and differential 27 2 27 120 Planetary and final drives 27 3 Brakes and controls 33 33 202 Hydrau...

Page 4: ...5 734 Tool quick coupler hydraulic system 35 10 Frames and ballasting 39 39 100 Frame 39 1 Steering 41 41 101 Steering control 41 1 41 200 Hydraulic control components 41 2 41 216 Cylinders 41 3 41 910 Auxiliary steering 41 4 Wheels 44 44 511 Front wheels 44 1 44 520 Rear wheels 44 2 Cab climate control 50 50 100 Heating 50 1 50 200 Air conditioning 50 2 Electrical systems 55 55 100 Harnesses and ...

Page 5: ...5 7 55 DTC FAULT CODES 55 8 Front loader and bucket 82 82 100 Arm 82 1 82 300 Bucket 82 2 Platform cab bodywork and decals 90 90 150 Cab 90 1 90 120 Mechanically adjusted operator seat 90 2 90 124 Pneumatically adjusted operator seat 90 3 90 105 Machine shields and guards 90 4 48083741_EN 31 07 2018 Find manuals at https best manuals com ...

Page 6: ...INTRODUCTION 48083741_EN 31 07 2018 1 Find manuals at https best manuals com ...

Page 7: ...and precautions 14 Basic instructions Precaution for disassembly and assembly 16 Basic instructions Electrical equipment precautions 18 Torque Minimum tightening torques for normal assembly 19 Consumables 21 Consumables Biodiesel Fuel 23 Hydraulic contamination 24 Product identification 25 Product identification 26 48083741_EN 31 07 2018 2 Find manuals at https best manuals com ...

Page 8: ...CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Machine safety NOTICE Notice indicates a situation that if not avoided could result in machine or property damage Throughout this manual you will find the signal word Notice followed by special instruction...

Page 9: ...ion than the operator s seat TULI12WEX2004AA 1 Never carry out any operation on the machine when the engine is running except when specifically indicated Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps covers valves etc All repair and maintenance operations should be carried out with the greatest care and attention Service stairs and platforms ...

Page 10: ...th lateral shield or masks for eye protection Do not wear rings wristwatches jewelry unbuttoned or flapping clothing such as ties torn clothes scarves open jackets or shirts with open zips which could get caught into moving parts TULI12WEX2008AA 4 Engine Radiator Never leave the engine running in enclosed spaces with out proper ventilation which is able to evacuate toxic ex haust gases Keep the ex...

Page 11: ...e cap while engine is hot wear safety clothes and equipment then loosen the cap slowly to relieve the pressure gradually When checking the fuel oil and coolant levels use lights and lamps explicitly designated as explosion proof If these types of lamps are not used fires or explosions may occur TULI12WEX2011AA 7 Hydraulic systems Jets of fluids under pressure can penetrate the skin caus ing seriou...

Page 12: ...entally be pierced when the heat expands beyond the area immediately heated Arrange for temporary fire resistant shields to protect hoses or other components during welding or torch use Have any visible leakage repaired immediately Discharged oil pollutes the environment Soak up any oil that has spilled with a proper binding agent Sweep up binding agent and dispose of it separately from other wast...

Page 13: ...d outer sheath will allow water penetra tion Concealed corrosion of the wire reinforcement could subsequently occur along the hose length with resultant hose failure Ballooning of the hose indicates an internal leakage due to structural failure This condition rapidly deteriorates and total hose failure soon occurs Kinked crushed stretched or deformed hoses generally suffer internal structural dama...

Page 14: ...id vomiting Drink water to rinse your mouth Consult a doctor EYES Rinse abundantly with water for 15 min and con sult a doctor When the electrolyte of a battery is frozen it can ex plode if you attempt to charge the battery or if you try to start the engine using a booster battery Always keep the battery charged to prevent the electrolyte freezing Provide good ventilation when changing a battery o...

Page 15: ...il or fuel Fuel or oil spills can cause slipping hazards thoroughly contain and clean affected areas Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly Never use fuel to clean machine parts that will be exposed to dirt or debris Use a non flammable product for cleaning parts Always perform fuel or oil refilling in well aired and venti lated areas TULI12WEX2018AA 15 During r...

Page 16: ...y means of an inflation pistol complete with extension and pressure control valve Use an inflation cage TULI12WEX2020AA 17 Cleaning Clean the exterior of all components before carrying out any form of repair Dirt and dust can reduce the efficient working life of a component and lead to costly replace ment Solvents should be checked that they are suitable for the cleaning of components and also tha...

Page 17: ...nd pure an tifreeze Fuel Filter elements oil and fuel filters Filter elements air filters Battery Also polluted rags paper sawdust and gloves must be disposed in compliance with the same procedures Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping int...

Page 18: ...nsibility for damages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and or components not approved by the manufacturer The info...

Page 19: ...e at which reconditioning is impossible without replacement of parts If the value is expected to exceed the service limit before next inspection and correction are performed replace the parts immediately The operation over the specified values causes increase of damage and requires the down time of machine and also causes safety problems Cautions to be exercised at judgment EVALUATION OF MEASURED ...

Page 20: ... P and recommend that they should be replaced regularly INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance it is necessary for the user to familiarize themselves with the machine and handle safely Use caution when inspecting and replacing oils and grease Refer to the Operators Manuals as well 48083741_EN 31 07 2018 15 ...

Page 21: ...sassembling and assembling hydraulic equipment Before removing lines release the pressure of hydraulic oil tank or open the cover on the return side to tank and take out the filter Drain the oil in removed lines into an appropriate container to prevent oil contamination Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system Thoroughly clean...

Page 22: ...emoved o rings back up rings and oil seals with new ones Apply gear oil on them before reassembling Thoroughly clean and dry surfaces on which liquid sealant must be reapplied Before assembling remove rust preventives on new parts Use special tools to fit bearings bushing and oil seal Assemble parts matching to the marks After completion check that there is no omission of parts 48083741_EN 31 07 2...

Page 23: ...e equipment with care so as not to drop it or bump it Connector should be removed by unlocking while hold ing the connector Never disconnect electrical plugs by pulling on the wires Always use only the electrical connectors to make the disconnection Check that connector is connected and locked com pletely Engine key off before removing and connecting connec tor Engine key off before touching termi...

Page 24: ... m 42 lb ft 12 mm 100 N m 74 lb ft 14 mm 159 N m 117 lb ft 16 mm 248 N m 183 lb ft 18 mm 352 N m 260 lb ft 20 mm 500 N m 369 lb ft 22 mm 681 N m 502 lb ft 24 mm 865 N m 638 lb ft 27 mm 1262 N m 931 lb ft 30 mm 1719 N m 1268 lb ft 36 mm 2999 N m 2212 lb ft Markings for Grade 8 8 hardware Grade 10 9 bolts nuts and studs Size Nm lb ft 4 mm 5 N m 4 lb ft 5 mm 10 N m 7 lb ft 6 mm 17 N m 13 lb ft 8 mm 4...

Page 25: ...INTRODUCTION Grade 12 9 bolts nuts and studs Torque values specified for grade 10 9 hardware can be used for grade 12 9 hardware Markings for Grade 12 9 hardware 48083741_EN 31 07 2018 20 ...

Page 26: ...CASE AKCELA HY TRAN ULTRACTION Technical specifications ISO VG 46 CASE CONSTRUCTION specifications MAT 3540 Type of fluid CASE AKCELA HY TRAN ULTRACTION SSL low temperature CASE CONSTRUCTION specifications MAT 3541 Total system capacity 178 L 47 US gal Reservoir capacity 90 8 L 24 US gal Transmission Type of oil CASE AKCELA NEXPLORE FLUID Technical specifications SAE 10W 30 API GL 4 ISO VG 32 46 C...

Page 27: ...tem Type of fluid CASE AKCELA HY TRAN ULTRACTION Technical specifications ISO VG 46 CASE CONSTRUCTION specifications MAT 3540 Type of fluid CASE AKCELA HY TRAN ULTRACTION SSL low temperature CASE CONSTRUCTION specifications MAT 3541 Total system capacity 200 L 53 US gal Reservoir capacity 110 L 29 US gal Transmission Type of oil CASE AKCELA NEXPLORE FLUID Technical specifications SAE 10W 30 API GL...

Page 28: ... and may cause shortened filter life or filter blockages Blockages are more common in cold weather conditions Consult your dealer for information on cold weather operation and proper maintenance intervals when using any biodiesel fuel blend Biodiesel fuel may degrade natural rubber gaskets and hoses as it is more solvent than petro diesel Frequently inspect hoses and other engine components when u...

Page 29: ...ear rapidly Relief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times or a lack of power If your machine has any of these problems check the hydraulic oil for contamination There are two types of contamination microscopic and visible Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydrauli...

Page 30: ...ification The terms right hand left hand front and rear are used in this manual to indicate the sides as they are seen from the operator s seat 1 Front 2 Right hand 3 Rear 4 Left hand RCPH10WHL003BAH 1 48083741_EN 31 07 2018 25 ...

Page 31: ...IL16WHL2487FA 1 1 Roll Over Protection System ROPS cab 5 Steps 2 Cab door handle 6 Bucket Z bar version 3 Timed disconnect switch and optional battery jump post 7 Loader lift arms 4 Battery access 8 Bucket cylinder 48083741_EN 31 07 2018 26 ...

Page 32: ...NTRODUCTION LEIL16WHL2486FA 2 1 Pre cleaner 5 Bucket Z bar version 2 Sliding access panel 6 Cab air filter door 3 Cab side window 7 Windshield washer reservoir 4 Driving lights 48083741_EN 31 07 2018 27 ...

Page 33: ...INTRODUCTION 48083741_EN 31 07 2018 28 ...

Page 34: ...SERVICE MANUAL Engine 821G ZBAR EH NEW CAB TIER2 921G ZBAR EH NEW CAB TIER2 48083741_EN 31 07 2018 10 ...

Page 35: ...10 10 001 Engine and crankcase 10 1 10 202 Air cleaners and lines 10 2 10 400 Engine cooling system 10 3 10 414 Fan and drive 10 4 10 310 Aftercooler 10 5 10 304 Engine lubrication system 10 6 48083741_EN 31 07 2018 10 ...

Page 36: ...Engine 10 Engine and crankcase 001 821G ZBAR EH NEW CAB TIER2 921G ZBAR EH NEW CAB TIER2 48083741_EN 31 07 2018 10 1 10 001 1 ...

Page 37: ...ine 10 Engine and crankcase 001 TECHNICAL DATA Engine General specification 3 General specification 3 SERVICE Engine Remove 5 Install 18 Test 31 See content for specific models 48083741_EN 31 07 2018 10 1 10 001 2 ...

Page 38: ...TE hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open Throttle WOT in max power mode with transmission in manual mode and in 3rd gear Engine General specification 921G ZBAR EH NEW CAB TIER2 ANZ APAC LA MEA Engine with 4 Speed Transmission A Low idle 870 RPM to 930 RPM Alternate low idle 6...

Page 39: ...OTE hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open Throttle WOT in max power mode with transmission in manual mode and in 3rd gear 48083741_EN 31 07 2018 10 1 10 001 4 ...

Page 40: ...2 3 Put the key switch to ON position Press the hydraulic functions lock out button to unlock all hydraulic functions Move the control lever s back and forth at least 30 times to release any pressure from the hydraulic circuit Put the key switch to OFF position LEIL16WHL1286AA 3 4 Raise the grill located above the cooler box just behind the cab Then slowly loosen the hydraulic reservoir filler cap...

Page 41: ...hand and left hand side panels 1 Then remove the thumb screws 2 and inner fender panels 3 NOTE right hand side of the machine is shown The op eration is similar for the left hand side LEIL17WHL0027AB 7 8 Place a suitable container below the radiator drain plug remove the radiator cap and the radiator drain plug to drain the engine coolant Then reinstall the radi ator drain plug and the radiator ca...

Page 42: ...ll the engine oil drain plug NOTE see machine specifications for engine oil sump vol ume LEIL16WHL0198AA 9 10 Remove the drain hose 1 from the frame bracket 2 LEIL16WHL1250AB 10 11 Remove the engine hood refer to Engine hood Re move 90 105 LEIL17WHL0026AB 11 12 Remove the overflow tank of the engine coolant LEIL16WHL0574AB 12 48083741_EN 31 07 2018 10 1 10 001 7 ...

Page 43: ...coolant overflow tank LEIL16WHL0575AB 13 14 Remove the cooling fan guard LEIL17WHL0137AB 14 15 Loosen the four bolts to remove the engine guard 1 LEIL17WHL0118AB 15 16 Disconnect the crankcase vent hose from the engine LEIL17WHL0136AB 16 48083741_EN 31 07 2018 10 1 10 001 8 ...

Page 44: ...7 LEIL17WHL0119AB 18 18 Remove the clamp to disconnect the air cleaner from the engine LEIL17WHL0135AB 19 19 Tag and disconnect the AFS2 connector 4 from the air cleaner 3 Remove the hardware 1 to unfix the air cleaner sup port bracket 2 from the rear chassis Remove the air cleaner assembly from the machine LEIL17WHL0120AB 20 48083741_EN 31 07 2018 10 1 10 001 9 ...

Page 45: ...B connectors from the alternator Remove the alternator 2 and air conditioning com pressor 1 LEIL17WHL0116AB 22 22 Remove the clamp 2 that secures the heater supply hose 1 to the flywheel cover Tag and disconnect the heater supply hose 1 from the engine LEIL17WHL0115AB 23 23 Remove the clamps that secure the cables to the en gine LEIL16WHL0570AB 24 48083741_EN 31 07 2018 10 1 10 001 10 ...

Page 46: ... GND_ENG4 cables 5 and GND_CENG1 GND_CENG2 cables 6 from the engine LEIL17WHL0114AB 25 25 Tag and disconnect the breather line hose and vent ing check valve from the engine LEIL17WHL0094AB 26 26 Remove the U bolt clamp to unfix the top cooling line from the muffler support structure LEIL17WHL0095AB 27 27 Remove the clamps 2 to disconnect the top cooling line 1 from the elbow hose and engine Tag th...

Page 47: ...17WHL0092AB 29 29 Remove the clamps 2 to disconnect the turbo outlet air cooling line 1 from the charge air cooler and en gine Tag the hose LEIL17WHL0091AB 30 30 Remove the clamps 2 to disconnect the air intake cooling line 1 from the charge air cooler and engine Tag the hose LEIL17WHL0090AB 31 48083741_EN 31 07 2018 10 1 10 001 12 ...

Page 48: ...ct the fuel pre filter 4 from the sup port bracket Tag the GRD_WIF wire 5 35 Remove the fuel pre filter support bracket 3 from the rear muffler support 36 Remove the cable ties that secure the wires to the rear muffler support Tag and disconnect the wires 2 from the alarm back up 1 Remove the alarm back up 1 from the rear muffler support LEIL17WHL0055AB 32 37 Remove the clamp 2 to disconnect the e...

Page 49: ...ations to unfix the exhaust system assembly 1 from the rear chassis Lift and remove the exhaust system assembly 1 from the machine NOTE be sure all wire harness connections and hoses are out of the way LEIL17WHL0053BB 34 LEIL17WHL0051AB 35 39 Remove the nuts 3 and studs 2 to disconnect the engine starter 1 from the engine LEIL17WHL0052AB 36 48083741_EN 31 07 2018 10 1 10 001 14 ...

Page 50: ...connect the FFH connector from the fuel filter LEIL17WHL0049AB 38 42 Remove the clamp 1 to release the fuel return hose 2 Tag and disconnect the fuel return hose 2 from the fuel filter LEIL17WHL0046AB 39 43 At the noted location remove the clamp to release the fuel tank suction hose LEIL17WHL0086AB 40 48083741_EN 31 07 2018 10 1 10 001 15 ...

Page 51: ...ing LEIL17WHL0047AB 42 46 Connect a vacuum pump to the hydraulic reservoir and turn it on Tag and disconnect the suction hose 2 pressure hose 4 and attenuator hose 3 from the brake pump 1 Remove the brake pump 1 refer to Brake pump Remove 33 202 Turn off and dis connect the vacuum pump from the hydraulic reser voir LEIL17WHL0045AB 43 48083741_EN 31 07 2018 10 1 10 001 16 ...

Page 52: ... engine mount bolts 2 48 Slowly raise the engine from the rear chassis Make sure all wire harness connections and hoses have been disconnected and are clear of the engine Guide the oil drain hose from the frame as the engine is lifted Remove the engine from machine LEIL17WHL0034AA 44 LEIL17WHL0035AA 45 48083741_EN 31 07 2018 10 1 10 001 17 ...

Page 53: ...p Loosen the recovery tank cap slowly to allow any pressure to escape Failure to comply could result in death or serious injury W0296A RAIL12WEL0130FA 1 1 Engine mount bolt 5 Washers 2 Washer 6 Washer 3 Upper isolator 7 Nut 4 Lower isolator 8 Remote oil drain hose 1 Inspect the engine mounts If the engine rubber isola tors require replacement remove and discard the up per isolators 3 and lower iso...

Page 54: ...m 180 220 lb ft 4 Disconnect the lifting equipment from the engine mounts LEIL17WHL0034AA 2 LEIL17WHL0035AA 3 5 Connect a vacuum pump to the hydraulic reservoir and turn it on Install the brake pump 1 Connect the suction hose 2 pressure hose 4 and attenuator hose 3 to the brake pump following the tags applied during removal refer to Brake pump Install 33 202 Turn off and disconnect the vacuum pump...

Page 55: ...to 86 94 N m 63 69 lb ft 821G 4 speed transmission Tighten to 85 94 N m 63 69 lb ft 621G 721G 921G 4 speed transmission and 721G 5 speed trans mission Follow the bolt installation pattern in figure LEIL17WHL1383AA 7 9 Tighten to 130 140 N m 96 103 lb ft 621G 821G 921G 5 speed transmission Follow the bolt installation pattern in figure LEIL17WHL1382AA 8 10 Install the upper and lower drive shaft du...

Page 56: ...eturn hose 2 13 Connect the fuel line 2 to the top of the fuel filter LEIL17WHL0046AB 11 14 Connect the FFH connector to the fuel filter LEIL17WHL0049AB 12 15 Connect the EDC7 connector to the Engine Controller Unit ECU NOTE start the connector on the ECU with lever straight out from ECU Use a lever to pull connector into position LEIL17WHL0050AB 13 48083741_EN 31 07 2018 10 1 10 001 21 ...

Page 57: ... Install the engine starter 1 Torque the three starter mounting nuts 3 to 40 50 N m 29 37 lb ft LEIL17WHL0052AB 14 17 Connect a suitable lifting device to the exhaust system assembly 1 including muffler pipe support brack ets and carefully lift it Position and lower the exhaust system assembly 1 over the rear chassis of the ma chine NOTE be sure all wire harness connections and hoses are out of th...

Page 58: ... bolt head and nut and nuts 22 Install the fuel pre filter 4 to the support bracket with two bolts washers under bolt head and nut and nuts At this time connect the GRD_WIF wire 5 by using the same hardware 23 Connect the WIF connector 9 and WSH connector 6 to the fuel pre filter 24 Use the clamp 7 to secure the fuel tank suction hose to the rear muffler support 25 Connect the fuel pre filter to e...

Page 59: ...5 8 lb ft LEIL17WHL0091AB 20 28 Connect the bottom engine coolant line 1 to the en gine with the clamp 2 Torque the clamp to 10 1 11 3 N m 7 4 8 3 lb ft LEIL17WHL0092AB 21 29 Install the top cooling line 1 with clamps 2 Torque the clamps at the ends mating the elbow hose and engine to 10 1 11 3 N m 7 4 8 3 lb ft LEIL17WHL0093AB 22 30 Fix the top cooling line to the muffler support structure with U...

Page 60: ... the negative battery cable 2 ground strap 3 and XM1C cable 4 to the engine starter Install the GND_ENG1 GND_ENG3 GND_ENG4 ca bles 5 and GND_CENG1 GND_CENG2 cables 6 to the engine Torque the nuts to 22 24 N m 16 2 17 7 lb ft LEIL17WHL0114AB 25 33 Secure the cables to the engine with clamps LEIL16WHL0570AB 26 34 Install the heater supply hose 1 to the engine Se cure the hose to the flywheel cover w...

Page 61: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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