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INTRODUCTION

Safety rules

Personal safety

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

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 instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.

Information

NOTE:

Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.

51428211_EN 18/12/2017

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Summary of Contents for 621G Stage IV

Page 1: ...3 621G 721G Wheel Loader SERVICE MANUAL 621G 721G Stage IV Wheel Loader Part number 51428211 English November 2017 2017 CNH Industrial Italia S p A All Rights Reserved Part number 51428211 SERVICE MANUAL ...

Page 2: ...DER ZBAR EH NEW CAB TIER4B MULTIP 621G WHEEL LOADER ZBAR EH NEW CAB TIER4B 721G WHEEL LOADER XR EH New Cab TIER 4B 721G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP 721G WHEEL LOADER XT EH New Cab TIER 4B 721G WHEEL LOADER ZBAR EH New Cab TIER 4B 721G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP 51428211_EN 18 12 2017 EN Find manuals at https best manuals com ...

Page 3: ...R4B Europe F4HFE613W B003 621G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP Europe F4HFE613W B003 721G WHEEL LOADER ZBAR EH New Cab TIER 4B Europe F4HFE613T B002 721G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP Europe F4HFE613T B002 721G WHEEL LOADER XT EH New Cab TIER 4B Europe F4HFE613T B002 721G WHEEL LOADER XR EH New Cab TIER 4B Europe F4HFE613T B002 721G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP Eu...

Page 4: ...21 2 21 105 Powershift transmission hydraulic components 21 3 21 155 Powershift transmission internal components 21 4 21 109 Transmission cooler and lines 21 5 21 700 Torque converter 21 6 21 182 Differential 21 7 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 steeri...

Page 5: ...lic fan drive cooling system 35 7 35 820 Hydraulic driven cooling fans 35 8 35 355 Hydraulic hand control 35 9 35 701 Front loader arm hydraulic system 35 10 35 723 Front loader bucket hydraulic system 35 11 35 734 Tool quick coupler hydraulic system 35 12 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 4...

Page 6: ...ion EGR electrical system 55 8 55 640 Electronic modules 55 9 55 024 Transmission control system 55 10 55 020 Transmission speed sensors 55 11 55 022 Transmission temperature sensors 55 12 55 028 Transmission fluid sensors 55 13 55 512 Cab controls 55 14 55 415 Loader arm and bucket control system 55 15 55 530 Camera 55 16 55 DTC FAULT CODES 55 17 Front loader and bucket 82 82 100 Arm 82 1 82 300 ...

Page 7: ...51428211_EN 18 12 2017 Find manuals at https best manuals com ...

Page 8: ...INTRODUCTION 51428211_EN 18 12 2017 1 Find manuals at https best manuals com ...

Page 9: ...intenance standard and precautions 14 Basic instructions Precaution for disassembly and assembly 16 Basic instructions Electrical equipment precautions 18 Consumables 19 Consumables Biodiesel Fuel 21 Hydraulic contamination 22 Product identification Machine orientation 23 Product identification 24 51428211_EN 18 12 2017 2 Find manuals at https best manuals com ...

Page 10: ...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 11: ...rom any other position 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 st...

Page 12: ...otections Goggles with 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 hau...

Page 13: ...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 14: ...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 15: ...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 16: ...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 17: ...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 18: ...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 19: ...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 20: ...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 21: ...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 22: ... 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 51428211_EN 18 12 2017 15 ...

Page 23: ...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 24: ...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 51428211_EN 18 12 2...

Page 25: ...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 26: ... 39 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 CASE CONSTRUCTION specifications MAT 3525 Service capacity with filter change 26 7 L 28 2 US qt Axles Type of oil CASE AKCELA TRANSAXLE FLUID 80W 140 Technical specifications SAE 80W 140 API GL 4 CASE CONSTRUCTION specifications MAT 3510 Front...

Page 27: ...apacity 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 CASE CONSTRUCTION specifications MAT 3525 Service capacity with filter change 34 1 L 36 US qt Axles Type of oil CASE AKCELA TRANSAXLE FLUID 80W 140 Technical specifications SAE 80W 140 API GL 4 CASE CONSTRUCTION specifications MAT 3510 Front axle standard 35 L 37 U...

Page 28: ...s 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 ...

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: ...INE SIDES The terms right hand left hand front and rear when used in this manual indicate the sides of the ma chine as they are seen from the operator s seat 1 Front side 2 Rear side 3 Left hand side 4 Right hand side ITIL11WC0004C0B 1 51428211_EN 18 12 2017 23 ...

Page 31: ...INTRODUCTION Product identification LEIL17WHL1264FA 1 621G LEIL17WHL1502FA 2 721G 51428211_EN 18 12 2017 24 ...

Page 32: ...UCTION 1 Roll Over Protection System ROPS cab 5 Steps 2 Cab door handle 6 Bucket 3 Timed disconnect switch and battery jump post 7 Loader lift arms 4 Battery access 8 Bucket cylinder 51428211_EN 18 12 2017 25 ...

Page 33: ...INTRODUCTION LEIL17WHL1265FA 3 621G LEIL17WHL1499FA 4 721G 51428211_EN 18 12 2017 26 ...

Page 34: ...CTION 1 Pre cleaner 5 Bucket 2 Sliding access panel 6 Cab air filter door 3 Cab side window 7 Windshield washer reservoir 4 Driving lights 8 DIESEL EXHAUST FLUID DEF ADBLUE fill tank 51428211_EN 18 12 2017 27 ...

Page 35: ...INTRODUCTION 51428211_EN 18 12 2017 28 ...

Page 36: ...B TIER4B 621G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP 621G WHEEL LOADER ZBAR EH NEW CAB TIER4B 721G WHEEL LOADER XR EH New Cab TIER 4B 721G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP 721G WHEEL LOADER XT EH New Cab TIER 4B 721G WHEEL LOADER ZBAR EH New Cab TIER 4B 721G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP 51428211_EN 18 12 2017 10 ...

Page 37: ...0 1 10 202 Air cleaners and lines 10 2 10 500 Selective Catalytic Reduction SCR exhaust treatment 10 3 10 400 Engine cooling system 10 4 10 414 Fan and drive 10 5 10 310 Aftercooler 10 6 10 304 Engine lubrication system 10 7 51428211_EN 18 12 2017 10 ...

Page 38: ...AB TIER4B 621G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP 621G WHEEL LOADER ZBAR EH NEW CAB TIER4B 721G WHEEL LOADER XR EH New Cab TIER 4B 721G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP 721G WHEEL LOADER XT EH New Cab TIER 4B 721G WHEEL LOADER ZBAR EH New Cab TIER 4B 721G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP 51428211_EN 18 12 2017 10 1 10 001 1 ...

Page 39: ...General specification 3 General specification 3 General specification Engine Service Manual 4 Engine horse power 4 Engine horse power 5 SERVICE Engine Remove 7 Install 28 Remove 51 Install 71 Test 93 See content for specific models 51428211_EN 18 12 2017 10 1 10 001 2 ...

Page 40: ...raulic oil 54 57 C 129 135 F NOTE Hydraulic Stall and Converter 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 721G WHEEL LOADER XR EH New Cab TIER 4B WE 721G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP WE 721G WH...

Page 41: ... details about the engine overhaul Language Engine Service Manual P N English 48076871 French 47606125 German 47606126 Italian 47606127 Spanish 47606130 Engine Engine horse power 621G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP WE 621G WHEEL LOADER XR EH NEW CAB TIER4B WE 621G WHEEL LOADER XT EH NEW CAB TIER4B WE 621G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP WE 621G WHEEL LOADER ZBAR EH NEW CAB TIE...

Page 42: ...B WE 721G WHEEL LOADER XR EH NEW CAB TIER4B MULTIP WE 721G WHEEL LOADER XT EH New Cab TIER 4B WE 721G WHEEL LOADER ZBAR EH New Cab TIER 4B WE 721G WHEEL LOADER ZBAR EH NEW CAB TIER4B MULTIP WE Design characteristics Displacement 6728 cm 410 6 in Engine Configuration 6 cylinder in line 4 stroke Intake Air Turbocharged 4 valves cyl Fuel injection High pressure common rail EGR No 51428211_EN 18 12 20...

Page 43: ...145 kW at 2000 RPM Peak Torque 950 N m at 1300 RPM LEIL17WHL0357GA 1 NOTE these are bench tested power consumption curves that of course can not reflect the daily and specific use that each operator business owner makes of an earth moving machine NOTE BSFC indicates the Brake Specific Fuel Consumption 51428211_EN 18 12 2017 10 1 10 001 6 ...

Page 44: ...ng any service procedure in close proximity of emission sensors If the use of these tools cannot be avoided remove the sensors using extreme caution prior to performing any service procedure 1 Park the machine on a level surface and lower the bucket to the ground Put the articulation lock in LOCKED position and stop the engine LEIL16WHL0048AB 1 2 Actuate the brake pedal several times to discharge ...

Page 45: ...n the battery box Raise the engine hood and put the timed disconnect switch in the OFF position RCPH10WHL106AAH 5 6 Unhook the rubber T handle 1 and raise the upper panel 2 Make sure that the security levers are blocked LEIL13WHL0137AB 6 7 Raise both 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...

Page 46: ...ng system vol ume LEIL16WHL0198AA 8 9 Place a suitable container below the engine oil drain plug see the arrow in figure Remove the engine oil drain plug and drain oil into container Reinstall 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 Double up a nylon lifting str...

Page 47: ...he connector 1 of the rearview cam era wire harness 3 Cut the wire ties 2 that hold the rearview camera wire harness 3 to the rear grill LEIL16WHL0849AB 13 14 Cut the wire ties and remove the rearview camera wire harness from the engine hood Place the rearview camera wire harness off to the side in a safe location LEIL13WHL0140AB 14 15 Remove the engine hood wire harness clamp 1 from the cooler ho...

Page 48: ...ounting bolts see the arrows in figure from the cooler frame NOTE do not remove the engine hood hinge mounting bolts at this time LEIL14WHL0401AB 17 18 Disconnect the wiring harness 5 Put the timed disconnect switch in the ON position Retract the lifting motor cylinder 1 and remove the clevis pin 3 and the cotter pin 4 from the bottom of the lifting motor cylinder 1 Separate the lifting motor cyli...

Page 49: ...re from the cooler frame LEIL14WHL0401AB 20 21 Carefully raise and remove the engine hood from the machine Lower the engine hood onto a suitable plat form and disconnect lifting equipment from the ex haust stack 1 NOTE radiator overflow hose may interfere with left hand hood hinge movement and hood removal LEIL14WHL0400AB 21 22 Tag and disconnect the engine wiring harness con nector from the air f...

Page 50: ... on the crankcase ventilation hose 2 and disconnect the hose LEIL13WHL0144AB 24 25 Loosen the clamps on the turbocharger and air filter housing Remove the intake air hose 1 Cover the turbocharger inlet to prevent debris entry LEIL13WHL0145AB 25 26 Loosen the clamp from the elbow connected to the turbocharger LEIL14WHL0203AB 26 51428211_EN 18 12 2017 10 1 10 001 13 ...

Page 51: ...nlet hose at the air filter housing LEIL13WHL0148AB 28 29 Loosen the clamp 1 on the air inlet hose 2 at the exhaust support bracket Remove the air inlet hose 2 LEIL13WHL0151AB 29 30 Remove the securing bolts 1 with the related wash ers and nuts Remove the bracket 2 with the air filter 3 as an assembly LEIL15WHL0037AB 30 51428211_EN 18 12 2017 10 1 10 001 14 ...

Page 52: ...om the engine LEIL13WHL0155AB 32 33 If machine is equipped with the air conditioning sys tem identify tag and disconnect the engine wiring harness connectors from the air compressor clutch connector 1 and high pressure switch 2 Then re move the three mounting bolts 3 for the compressor and carefully set it on the left battery cover LEIL13WHL0156AB 33 34 Tag and disconnect the wiring from the alter...

Page 53: ...ound cable 2 and ground strap 3 from the starter NOTE move the starter cables away from the engine LEIL16WHL0569AB 36 37 Remove the bolts securing the wiring harness clamps to the engine LEIL16WHL0570AB 37 38 Remove the ground wires from the engine NOTE move the wiring harness away from the engine LEIL16WHL0572AB 38 51428211_EN 18 12 2017 10 1 10 001 16 ...

Page 54: ... aside LEIL15WHL0016AB 39 40 Loosen the clamp see the arrow in figure and dis connect the pipe LEIL15WHL0015AB 40 41 Loosen the clamps and remove the lower coolant hose from the engine RAPH12WEL0629AA 41 42 Remove the radiator hose from the engine LEIL13WHL0159AB 42 51428211_EN 18 12 2017 10 1 10 001 17 ...

Page 55: ...olant vent hose from the top of the radiator LEIL13WHL0141AB 43 44 Remove the overflow tank of the engine coolant LEIL16WHL0574AB 44 45 Remove the bracket of the overflow tank LEIL16WHL0575AB 45 46 Remove the cooling fan guard LEIL13WHL0160AB 46 51428211_EN 18 12 2017 10 1 10 001 18 ...

Page 56: ...hine LEIL13WHL0162AB 48 49 Tag and disconnect the fuel filter heater wire 1 and the water sensor 2 Then drain fuel filter and discon nect the inlet 3 and outlet 4 fuel lines from the fuel filter head Plug the lines and cap the fittings Remove the ground wire and the attachment bolt 5 of the fuel filter head LEIL13WHL0163AB 49 50 Tag and remove the grid heater cable 1 NOTE hold the rear nut with a ...

Page 57: ...es by the sup ply module Disconnect the end of the jumper harness near the supply module from the Diesel Oxidation Catalyst DOC support LEIL15WHL0034AB 52 53 Loosen the clamp 1 on the Diesel Oxidation Catalyst DOC LEIL14WHL0402AB 53 54 Tag and disconnect the connector 1 LEIL13WHL0167AB 54 51428211_EN 18 12 2017 10 1 10 001 20 ...

Page 58: ... Reduction muffler SCR and cut the connector wire clamps LEIL14WHL0411BB 55 56 Loosen the screws 1 and remove the bar 2 LEIL14WHL0408AB 56 57 Remove the bolt 1 with the related spacer to detach the DEF ADBLUE bundle and the coolant line from the SCR support structure LEIL15WHL0035AB 57 51428211_EN 18 12 2017 10 1 10 001 21 ...

Page 59: ... muffler and the Diesel Oxidation Catalyst DOC LEIL14WHL0404AB 58 59 Tag and disconnect the wire harness from the buzzer Remove the bolts 1 securing the front support struc ture of the SCR muffler and remove it NOTE tilt the top of the structure away from the engine the rear structure just about has to be laid on the counter weight to obtain clearance between its feet and the engine LEIL16WHL1878A...

Page 60: ...E storage tank Install a protective cap in the supply lines RAPH12WEL0070AA 62 63 Remove the support bracket of the hood lift cylinder RAPH12WEL0071AA 63 64 Remove the heater hose from the engine LEIL15WHL0009AB 64 65 Disconnect the main connector of the supply module LEIL13WHL0171AB 65 51428211_EN 18 12 2017 10 1 10 001 23 ...

Page 61: ...ors 3 and 4 and disconnect the sensors 3 and 4 Loosen the clamp 1 on the Diesel Oxidation Catalyst DOC and disconnect the exhaust pipe 2 from the Diesel Oxidation Catalyst DOC LEIL13WHL0229AA 67 68 Remove the SCR coolant supply line from the engine LEIL15WHL0008AB 68 69 Remove the bolts that secure the support structure of the Diesel Oxidation Catalyst DOC Use a suitable lifting device and careful...

Page 62: ... line from the top of the primary fuel filter plug the line and cap the fitting NOTE make note on how fuel lines are routed LEIL13WHL0176AB 71 72 Remove the support clamp of the fuel line NOTE make note on how fuel lines are routed for refer ence during the reassembly LEIL13WHL0177AB 72 73 Remove the upper and lower covers for the drive shaft RAPH12WEL0079AA 73 51428211_EN 18 12 2017 10 1 10 001 2...

Page 63: ...uum pump to hydraulic reser voir Tag and remove the hydraulic lines from the brake system pump arrow plug the lines and cap the fittings LEIL13WHL0178AB 75 76 Connect suitable lifting equipment to engine lifting brackets Take up all slack in lifting equipment Re move the engine mounting bolts RAPH12WEL0080AA 76 LEIL15WHL0036AA 77 51428211_EN 18 12 2017 10 1 10 001 26 ...

Page 64: ...e from the rear chassis Be 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 51428211_EN 18 12 2017 10 1 10 001 27 ...

Page 65: ...n death or serious injury W0296A NOTE emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations Use of tools that gen erate extreme vibrations such as impact wrenches and hammers will result in damage to emission sensors Avoid using these tools during any service procedure in close proximity of emission sensors If the use of these tools cannot be avoided remove the sensor...

Page 66: ...s connections and hoses are out of the way or positioned correctly for reconnecting before lowering engine RAPH12WEL0080AA 2 LEIL15WHL0036AA 3 3 Tighten the mounting bolts of the engine to a tighten of 244 298 N m 180 220 lb ft RAPH12WEL0080AA 4 4 Disconnect the lifting equipment from the engine lifting brackets 51428211_EN 18 12 2017 10 1 10 001 29 ...

Page 67: ...onnect vacuum pump from hy draulic reservoir LEIL13WHL0178AB 5 6 Connect the drain hose 1 of the engine oil to the frame bracket 2 LEIL16WHL1250AB 6 7 At front of engine position the drive shaft on engine coupling Use new bolts to secure the drive shaft to the engine coupling RAPH12WEL0080AA 7 8 Install the bolts to secure the drive shaft to the engine coupling according to the tightening pattern ...

Page 68: ...5 94 N m 63 69 lb ft LEIL17WHL1383AA 8 5 speed transmission Tighten the eight bolts to a torque of 130 140 N m 96 103 lb ft LEIL17WHL1382AA 9 9 Install the upper and the lower drive shaft dust covers Tighten to 20 27 N m 15 20 lb ft RAPH12WEL0079AA 10 51428211_EN 18 12 2017 10 1 10 001 31 ...

Page 69: ...es LEIL15WHL0012BB 11 11 Install bolt and clamp for fuel return hose LEIL13WHL0177AB 12 12 Remove the cap from the fitting Remove the plug from the hose Connect fuel line to the top of the primary fuel filter LEIL13WHL0176AB 13 51428211_EN 18 12 2017 10 1 10 001 32 ...

Page 70: ...rankcase 13 Connect wiring harness to ECU controller NOTE start the connector on the ECU with lever straight out from ECU Use lever to pull connector into position LEIL13WHL0175AB 14 51428211_EN 18 12 2017 10 1 10 001 33 ...

Page 71: ...service procedure in close prox imity of emission sensors If the use of these tools can not be avoided remove the sensors using extreme caution prior to performing any service procedure LEIL13WHL0172AB 15 15 Install the bolts securing the support structure of the Diesel Oxidation Catalyst DOC Tighten the bolts to 125 0 150 0 N m 92 2 110 6 lb ft Remove the lifting straps from the support structure...

Page 72: ... m 229 280 lb ft RAPH12WEL0071AA 19 19 Remove the caps and the plugs from lines and tag from wire harness Connect wire harness and DEF ADBLUE supply and return lines to the DEF ADBLUE storage tank RAPH12WEL0070AA 20 20 Install the DEF ADBLUE storage tank cover LEIL13WHL0170AB 21 51428211_EN 18 12 2017 10 1 10 001 35 ...

Page 73: ...device to the rear structure of the Selective Catalytic Reduction SCR muffler Con nect wire harness of the buzzer Install the bolts 1 securing the rear support structure of the SCR muf fler LEIL16WHL1878AB 23 23 Install a new gasket on the Diesel Oxidation Catalyst DOC outlet LEIL15WHL0014AB 24 51428211_EN 18 12 2017 10 1 10 001 36 ...

Page 74: ...TE be sure all wire harness connections and hoses are out of the way or positioned correctly for reconnecting NOTE emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations Use of tools that gener ate extreme vibrations such as impact wrenches and ham mers will result in damage to emission sensors Avoid us ing these tools during any service procedure in close prox imity o...

Page 75: ...ature sensor 1 to the SCR muffler and fix the connector wire with the clamps LEIL14WHL0411BB 27 27 Install the bar 2 and tighten the four screws 1 LEIL14WHL0408AB 28 28 Connect the wire harness 1 and remove the tag LEIL13WHL0167AB 29 51428211_EN 18 12 2017 10 1 10 001 38 ...

Page 76: ...re harness with the clamps 2 to the catalyst mounting support bracket using the hexagonal bolts 1 Secure the wire harness with the wire ties where ap propriate LEIL13WHL0223AB 31 31 Attach wire harness support clamp LEIL16WHL0490AB 32 32 Connect the grid heater cable 1 NOTE hold the rear nut with a second wrench to prevent grid heater damage LEIL13WHL0164AB 33 51428211_EN 18 12 2017 10 1 10 001 39...

Page 77: ...cooler outlet hose to the after cooler and secure the clamp Tighten to 10 1 11 3 N m 7 4 8 3 lb ft LEIL13WHL0162AB 35 35 Connect the after cooler outlet hose to the intake man ifold and secure the clamp 1 Tighten to 10 1 11 3 N m 7 4 8 3 lb ft Position the DEF ADBLUE tank vent filter and secure it with the clamp 2 LEIL13WHL0613AA 36 36 Connect the heater hose 1 and the SCR heater sup ply line 2 to...

Page 78: ...e engine coolant over flow tank LEIL16WHL0575AB 39 39 Install the overflow tank of the engine coolant LEIL16WHL0574AB 40 40 Connect the radiator hose 1 and the engine coolant vent hose to the top of the radiator Tighten the clamp to 10 1 11 3 N m 7 4 8 3 lb ft LEIL13WHL0141AB 41 51428211_EN 18 12 2017 10 1 10 001 41 ...

Page 79: ...lant hose to the engine and tighten the clamps Tighten the clamp to 10 1 11 3 N m 7 4 8 3 lb ft RAPH12WEL0629AA 43 43 Connect the engine coolant vent hose to the engine and secure the clamp Tighten the clamp to 3 4 N m 2 5 lb ft LEIL13WHL0158AB 44 44 Connect the engine block heater if machine is so equipped RAPH12WEL0626AA 45 51428211_EN 18 12 2017 10 1 10 001 42 ...

Page 80: ...ngine LEIL16WHL0570AB 47 47 Connect the wires to the starter solenoid 1 con nect the ground cable 2 and ground strap 3 to the starter Tighten to 22 5 29 4 N m 16 6 21 7 lb ft LEIL16WHL0569AB 48 48 Connect the coolant return line of the SCR and secure with clamp Tighten to 3 4 N m 2 5 lb ft LEIL16WHL0568AB 49 51428211_EN 18 12 2017 10 1 10 001 43 ...

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