Case 21E 121E 221E 321E Series 3 Compact Wheel Loaders Service Manual 87734636C - PDF DOWNLOAD

21E 121E 221E 321E Series 3 Compact Wheel Loaders Service Manual

Print No. 87734636C

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TO THE READER This manual has been printed for a skilful engineer to supply necessary technical information to carry out service operations on this machine.

CNH ITALIA S.p.A. Via Plava, 80 10135 TORINO - Italy

Read carefully this manual to collect correct information relevant to repair procedures.

For any question or remark, or in case of any error relevant the contents of this manual, please contact:

REFERENCES Beyond this Repair Manual, also refer to documents listed hereunder:  Operator’s Manual  Parts Catalogue

COMPLETE REPAIR MANUAL The complete Repair Manual consists of two volumes:  21E - 121E - 221E - 321E Repair Manual for “Wheel loaders”  21E - 121E - 221E - 321E Repair Manual for “Engine”

VOLUME

The Repair Manuals for “Wheel loaders” and “Engine” contain the necessary technical information to carry out service and repair on machine and on engine, necessary tools to carry out those operations and information on service standard, on procedures for connection, disconnection, disassembly and assembly of parts.

The complete Repair Manual which covers the loader models 21E - 121E - 221E - 321E consists of the following volumes, which can be identified through their print number as stated below:

MACHINE TYPE

PRINT NUMBER

Repair Manual - “Wheel loaders”

21E - 121E - 221E - 321E

87734636C

Repair Manual - “Engine”

21E - 121E - 221E - 321E

87736548A

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TO PREVENT ACCIDENTS The majority of accidents and injuries which occur in industry, on the farm, at home or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs.

Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient operation.

A careful operator and / or technician is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands of serious injuries each year.

This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.

S WARNING Before carrying out any maintenance operation, adjustment and or repair on machines equipped with attachments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on the ground. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.

NOTE: in this manual, the abbreviations of the models are the same as in the following table.

21E Series 3

21E

121E Series 3

121E

221E Series 3

221E

321E Series 3

321E

CNH S.p.A. Via Plava, 80 10135 TORINO - Italy All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.

INDEX SECTION 00 - INTRODUCTION 1. SAFETY INSTRUCTIONS ............................................................................................................................ 1 1. GENERAL SAFETY INSTRUCTIONS.......................................................................................................... 2 1. TECHNICAL SPECIFICATIONS................................................................................................................. 12

SECTION 10 - ENGINE 1. DIESEL ENGINE .......................................................................................................................................... 1 2. FUEL SYSTEM ............................................................................................................................................. 2 3. COLD START DEVICE (NORTH AMERICA) ............................................................................................... 5

SECTION 25 - FRONT AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 4 3. TECHNICAL SPECIFICATIONS................................................................................................................... 5 4. OIL CHANGE.............................................................................................................................................. 10 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 13 5.1 DISC BRAKE ASSY (21E)................................................................................................................... 13 5.2 BRAKE CALIPER ................................................................................................................................ 20 5.3 REDUCTION GEAR (21E)................................................................................................................... 25 5.4 REDUCTION GEAR (121E, 221E, 321E)............................................................................................ 28 5.5 WHEEL HUB (21E).............................................................................................................................. 31 5.6 WHEEL HUB (121E, 221E, 321E) ....................................................................................................... 40 5.7 WHEEL SHAFT (121E, 221E, 321E)................................................................................................... 46 5.8 BRAKE AND WHEEL SHAFT (121E, 221E, 321E “STANDARD” and “HIGH SPEED”) ..................... 50 5.9 DIFFERENTIAL SUPPORT ................................................................................................................. 58 5.10 DIFFERENTIAL ASSY....................................................................................................................... 66 5.11 PINION............................................................................................................................................... 73 6. TROUBLESHOOTING................................................................................................................................ 79 7. SPECIAL TOOLS........................................................................................................................................ 82

SECTION 27 - REAR AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 3 3. TECHNICAL SPECIFICATIONS................................................................................................................... 7 4. OIL CHANGE.............................................................................................................................................. 14 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 18 5.1 MOTOR TB150 .................................................................................................................................... 18 5.2 MOTOR TB138.5 “HIGH SPEED” ....................................................................................................... 21 5.3 TRANSMISSION BOX TB150 ............................................................................................................. 25 5.4 TRANSMISSION TB138.5 “HIGH SPEED” ......................................................................................... 34 5.5 REDUCTION GEAR (21E)................................................................................................................... 54 5.6 REDUCTION UNIT (121E, 221E, 321E).............................................................................................. 57

INDEX 5.7 WHEEL HUB (21E) .............................................................................................................................. 61 5.8 WHEEL HUB (121E, 221E, 321E) ....................................................................................................... 70 5.9 WHEEL SHAFT (121E, 221E, 321E) ................................................................................................... 76 5.10 DIFFERENTIAL SUPPORT ............................................................................................................... 80 5.11 DIFFERENTIAL ASSY ....................................................................................................................... 88 5.12 LIMITED SLIP DIFFERENTIAL ASSY ............................................................................................... 94 5.13 PINION............................................................................................................................................. 101 6. TROUBLESHOOTING .............................................................................................................................. 107 7. SPECIAL TOOLS...................................................................................................................................... 110

SECTION 33 - BRAKE SYSTEM 1. BRAKE SYSTEM DIAGRAM ........................................................................................................................ 1 1.1 STANDARD DIAGRAM (21E)................................................................................................................ 1 1.2 “HIGH SPEED” DIAGRAM (121E, 221E, 321E) .................................................................................... 2 2. TECHNICAL SPECIFICATIONS................................................................................................................... 3 2.1 BRAKE PEDAL VALVE.......................................................................................................................... 3 2.2 PRESSURE SWITCHES ....................................................................................................................... 3 3. OPERATION ................................................................................................................................................. 4 3.1 SERVICE BRAKE OPERATION ............................................................................................................ 6 3.2 PARKING BRAKE OPERATION............................................................................................................ 8 4. BRAKE PEDAL VALVE................................................................................................................................. 9 5. PRESSURE SWITCHES ............................................................................................................................ 11 6. BRAKE ACCUMULATOR ........................................................................................................................... 12 6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 12 7. CHECKS AND ADJUSTMENTS ................................................................................................................. 13 7.1 SERVICE BRAKE SYSTEM PRESSURE CHECK .............................................................................. 13 7.2 ACCUMULATOR PRESSURE CHECK ............................................................................................... 14 7.3 PEDAL ANGLE ADJUSTMENT ........................................................................................................... 15 7.4 “INCHING” VALVE ADJUSTMENT...................................................................................................... 16 8. TROUBLESHOOTING ................................................................................................................................ 17

SECTION 35 - HYDRAULIC SYSTEM 1. HYDRAULIC DIAGRAMS ............................................................................................................................. 1 1.1 HYDRAULIC DIAGRAM FOR 21E......................................................................................................... 1 1.2 HYDRAULIC DIAGRAM FOR 21E WITH OPTIONAL OUTFITS........................................................... 3 1.3 HYDRAULIC DIAGRAM FOR 121E....................................................................................................... 5 1.4 HYDRAULIC DIAGRAM FOR 121E WITH OPTIONAL OUTFITS......................................................... 7 1.5 HYDRAULIC DIAGRAM FOR 221E....................................................................................................... 9 1.6 HYDRAULIC DIAGRAM FOR 221E WITH OPTIONAL OUTFITS....................................................... 11 1.7 HYDRAULIC DIAGRAM FOR 321E..................................................................................................... 13 1.8 HYDRAULIC DIAGRAM FOR 321E WITH OPTIONAL OUTFITS....................................................... 15 2. TRANSMISSION......................................................................................................................................... 17 2.1 HYDRAULIC DIAGRAM....................................................................................................................... 17 2.2 OPERATION ........................................................................................................................................ 18 2.3 ADJUSTMENTS................................................................................................................................... 20 3. VARIABLE-DISPLACEMENT PISTON PUMP............................................................................................ 22 3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 23 3.2 MAIN VALVES ..................................................................................................................................... 24

INDEX 3.3 DISASSEMBLY.................................................................................................................................... 32 3.4 ASSEMBLY.......................................................................................................................................... 51 4. GEAR PUMP .............................................................................................................................................. 58 4.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 58 4.2 COMPONENTS ................................................................................................................................... 59 4.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 60 5. PRIORITY VALVE ...................................................................................................................................... 63 5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 63 6. TRAVEL MOTOR........................................................................................................................................ 64 6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 64 6.2 MAIN COMPONENTS ......................................................................................................................... 66 6.3 OPERATION........................................................................................................................................ 67 6.4 REMOVAL ........................................................................................................................................... 70 6.5 DISASSEMBLY AND ASSEMBLY....................................................................................................... 71 7. ONE-WAY DISTRIBUTOR VALVE............................................................................................................. 85 8. HYDRAULIC OIL TANK.............................................................................................................................. 86 8.1 OIL FILTER.......................................................................................................................................... 87 9. TROUBLESHOOTING................................................................................................................................ 88

SECTION 39 - FRAME 1. ARTICULATED JOINT.................................................................................................................................. 1 1.1 COMPONENTS ..................................................................................................................................... 1 1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 2

SECTION 41 - STEERING SYSTEM 1. OPERATION................................................................................................................................................. 1 1.1 EMERGENCY STEERING .................................................................................................................... 3 1.2 PRESSURE ADJUSTMENT .................................................................................................................. 4 2. POWER STEERING ..................................................................................................................................... 5 2.1 TECHNICAL SPECIFICATIONS............................................................................................................ 6 2.2 COMPONENTS ..................................................................................................................................... 7 2.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8 2.4 TROUBLESHOOTING......................................................................................................................... 24 2.5 SPECIAL TOOLS................................................................................................................................. 25 3. STEERING CYLINDER .............................................................................................................................. 26 3.1 REMOVAL AND INSTALLATION ........................................................................................................ 27 3.2 DISASSEMBLY.................................................................................................................................... 29 4. TROUBLESHOOTING................................................................................................................................ 34

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 1. HEATING ...................................................................................................................................................... 1 2. AIR CONDITIONING .................................................................................................................................... 3 3. TROUBLESHOOTING................................................................................................................................ 29

INDEX SECTION 55 - ELECTRICAL SYSTEM 1. ELECTRICAL DIAGRAMS............................................................................................................................ 1 2. FUSES AND RELAYS ................................................................................................................................ 17 3. VOLTAGE AND CONTINUITY CHECK ...................................................................................................... 20 4. BATTERY.................................................................................................................................................... 21 4.1 REPLACEMENT .................................................................................................................................. 24 5. BULBS ........................................................................................................................................................ 25 6. TROUBLESHOOTING ................................................................................................................................ 29

SECTION 82 - WORKING EQUIPMENT 1. HYDRAULIC DIAGRAM................................................................................................................................ 2 2. OPERATION ................................................................................................................................................. 3 3. REMOVAL AND INSTALLATION ................................................................................................................. 4 4. QUICK TOOL COUPLER.............................................................................................................................. 6 4.1 COMPONENTS ..................................................................................................................................... 7 4.2 QUICK TOOL COUPLER CYLINDERS ................................................................................................. 8 5. BUCKET........................................................................................................................................................ 9 5.1 ASSEMBLY............................................................................................................................................ 9 5.2 DISASSEMBLY.................................................................................................................................... 10 5.3 BUCKET TEETH - REPLACEMENT.................................................................................................... 11 6. FORKS........................................................................................................................................................ 12 6.1 DISASSEMBLY AND ASSEMBLY....................................................................................................... 13 6.2 CHECKS .............................................................................................................................................. 14 7. CYLINDERS................................................................................................................................................ 16 7.1 BOOM CYLINDER ............................................................................................................................... 16 7.2 DUMPING CYLINDER ......................................................................................................................... 20 8. CONTROL VALVE ...................................................................................................................................... 24 9. LOAD HOLDING VALVE ............................................................................................................................ 27 9.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 27 10. TROUBLESHOOTING .............................................................................................................................. 28

SECTION 00 - INTRODUCTION 1. SAFETY INSTRUCTIONS ............................................................................................................................ 1 2. GENERAL SAFETY INSTRUCTIONS.......................................................................................................... 2 3. TECHNICAL SPECIFICATIONS................................................................................................................. 12

SECTION 00 - INTRODUCTION

SECTION 00 - INTRODUCTION

1.

SAFETY INSTRUCTIONS

Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

In this manual you will find the following indications:

S WARNING This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

S DANGER With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved.

The non compliance with the warning preceded by the above mentioned key-words (WARNING and DANGER) can cause serious accidents or even the death of the persons involved.

Moreover in the present Manual have been given some instructions with texts in italics, preceded by the words NOTE and CAUTION, with following meanings for machine protection: NOTES: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

S WARNING It warns the operator of a possible hazard of machine damage in case he does not follow a determined procedure.

Your safety and that of people around you depends on you. It is essential that you understand this manual for the correct operation, inspection, lubrication and maintenance of this machine.

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2.

SECTION 00 - INTRODUCTION

GENERAL SAFETY INSTRUCTIONS

Carefully read this Manual before proceeding with maintenance, repairs, refuelling or other machine operations.

Repairs have to be carried out only by authorized and instructed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy hammers.

Not authorized persons are not allowed to repair or carry out maintenance on this machine. Do not carry out any work on the equipment without prior authorization.

Ask your employer about the safety instructions in force and safety equipment.

Nobody is allowed to seat on the operator’s place during machine maintenance unless he is a qualified operator helping with the maintenance work.

If it is necessary to move the equipment to carry out repairs or maintenance, do not lift or lower the equipment from any other position than the operator’s seat.

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 used in a workshop or in the field should be built in compliance with the safety rules in force.

Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

SECTION 00 - INTRODUCTION 2.1

EMERGENCY

Be prepared for emergencies. Always keep at disposal on the machine a first aid kit and a fire extinguisher. Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.

2.2

EQUIPMENT

Wear close fitting clothing and safety equipment appropriate for the job:  safety helmet;  safety shoes;  heavy gloves;  reflective clothing;  wet weather clothing.

If the environment conditions make it necessary, the following personal safety equipment should be at hand:  respirators (or dustproof masks);  ear plugs or acoustic ears protections;  goggles with lateral shield or masks for eyes protection.

Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught into moving parts.

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4 2.3

SECTION 00 - INTRODUCTION PLACING THE MACHINE IN SAFE CONDITIONS

Before carrying out any repair operation on this machine, place it in safe conditions.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Make sure that the door and the engine guard are correctly fastened and lock the operator’s compartment door.

Check that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in compliance with the relevant regulations.

SECTION 00 - INTRODUCTION 2.4

ENGINE - RADIATOR

Never leave the engine run in closed spaces without ventilation and not able to evacuate toxic exhaust gases. Keep the exhaust manifold and tube free from combustion materials.

Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage.

Never attempt to check or adjust the fan belts when the engine is running.

Never lubricate the machine with the engine running.

Pay attention to rotary pieces and do not allow to anyone to approach to avoid becoming entangled.

If hands, clothes or tools get caught in the fan blades or in the transmission belt, this can cause amputations, violent tears and generate condition of serious danger; for this reason avoid touching or to come close to all rotary or moving parts.

A violent jet of the coolant from the radiator can cause damages and scalds.

If you are to check the coolant level, you have to shut off the engine previously and to let cool down the radiator and its pipes. Slowly unscrew the cap to release the inside pressure.

If necessary, remove the cap with hot engine, wear safety clothes and equipment, then loosen the cap slowly to relieve the pressure gradually.

When checking the fuel, oil and coolant levels, use exclusively explosion proof classified lamps. If this kind of lamps are not used fires or explosions may occur.

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6 2.5

SECTION 00 - INTRODUCTION HYDRAULIC SYSTEMS

Splashes of fluids under pressure can penetrate the skin causing serious injuries.

Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Relieve the residual pressure by moving the hydraulic control levers several times.

Tighten all connections before applying pressure.

To protect the eyes wear a facial shield or safety goggles.

Protect your hands and body from possible splashes of fluids under pressure.

Swallowing hydraulic oil is a severe health hazard.

When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Any fluid penetrating the skin must be removed within few hours to avoid serious infections.

Flammable splashes may originate because of the heat near pipes with fluids under pressure, with the result of serious scalds for the persons hit. Do not weld or use torches near pipes containing fluids or other flammable materials.

Pipes under pressure can accidentally be pierced when the heat expands beyond the area immediately heated.

Arrange for fire resistant temporary shields to protect hoses or other components during welding.

Have any visible leakage repaired immediately.

Escaping oil pollutes the environment. Soak up any oil that has escaped with a proper binding agent.

Sweep up binding agent and dispose of it separately from other waste.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

Never repair damaged piping; always replace it. Replace hydraulic hoses immediately on detecting any damage or leak.

Always store hydraulic oil in the original containers.

SECTION 00 - INTRODUCTION HOSES AND TUBES Always replace hoses and tubes if the cone end or the end connections on the hose are damaged.

When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connections. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing.

After hose replacement to a moving component, check that the hose does not foul by moving the component through the complete range of travel.

Be sure any hose which has been installed is not kinked or twisted.

Hose connections which are damaged, dented, crushed or leaking, restrict oil flow and the productivity of the components being served. Connectors which show signs of movement from the original position have failed and will ultimately separate completely.

A hose with a frayed outer sheath will allow the water penetration. Concealed corrosion of the wire reinforcement will 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 damage which can result in oil restriction, a reduction in the speed of operation and ultimate hose failure.

Free-moving, unsupported hoses must never be allowed to touch each other or related working surfaces. This causes chafing which reduces hose life.

O-RINGS Replace O-rings, seal rings and gaskets whenever they are disassembled.

Never mix new and old seals or O-rings, regardless of condition. Always lubricate new seal rings and Orings with hydraulic oil before installation to relevant seats.

This will prevent the O-rings from rolling over and twisting during mounting which will jeopardize sealing.

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8 2.6

SECTION 00 - INTRODUCTION BATTERY

Batteries give off explosive gases.

Never handle naked flames and unshielded light sources near batteries, never smoke.

To prevent any risk of explosion, observe the following instructions:  when disconnecting the battery cables, always disconnect the negative (-) cable first;  to reconnect the battery cables, always connect the negative (-) cable last;  never short-circuit the battery terminals with metal objects;  do not weld, grind or smoke near a battery.

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

Antidote:  EXTERNAL: rinse well with water, removing any soiled clothing.  INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor.  EYES: rinse abundantly with water for 15 minutes and consult a doctor.  When the electrolyte of a battery is frozen, it can explode 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 or using a battery in an enclosed space. Always protect your eyes when working near a battery.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

SECTION 00 - INTRODUCTION 2.7

FLAMMABLE LIQUIDS

When handling flammable liquids:  do not smoke;  keep away from unshielded light sources and naked flames.

Fuels often have a low flash point and are readily ignited.

Never attempt to extinguish burning liquids with water. Use:  dry powder;  with carbon dioxide;  with foam.

Water used for extinguishing purposes would vaporize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing new hazards.

Stay away from open flames during refilling of hydraulic oil or fuel.

Fuel or oil splashes can cause slipping and therefore accidents; clean immediately and accurately the areas eventually smeared.

Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly.

Never use fuel to clean the machine parts eventually smeared with oil or dust.

Use a non-inflammable product for cleaning parts.

Always perform fuel or oil refilling in well aired and ventilated areas.

During refuelling hold the pistol firmly and keep it always in contact with the filler neck until the end of the refuelling, to avoid sparkles due to static electricity.

Do not overfill the tank but leave a space for fuel expansion.

Never refuel when the engine is running.

Take all the necessary safety measures when welding, grinding or when working near a naked flame.

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10 2.8

SECTION 00 - INTRODUCTION TYRES

Before inflating the tyres, always check the condition of rims and the outer condition of tyres to find out the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tyre, make sure that there are no nearby persons, then position yourself at tread side.

Make sure that the inflating pressure of tyres is the same prescribed by manufacturer and that the pressure of the right tyre corresponds to the pressure of the left tyre.

Never use reconditioned rims because possible welds, heat treatments or brazings not performed correctly can weaken the wheels and cause following damages or failures. Deflate the tyres before their disassembly.

Before taking out possible jammed objects from the rims, it is necessary to deflate the tyres. Inflate tyres by means of a pistol complete with extension and pressure switch of control.

2.9

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 replacement.

Solvents should be checked that they are suitable for the cleaning of components and also that they do not risk the personal safety of the user.

Dirt from oil or grease and scattered tools or faulty pieces are dangerous for persons, because they can generate slipping or falls.

For the machine cleaning, use a jet of warm water or steam under pressure and commercial detergents.

Never use fuel, petroleum or solvents, because the first ones leave an oily layer that favours the sticking of dust, while solvents (even if weak) damage the paint and favour the formation of rust.

Never use water jets or steam on sensors, connectors or other electric components.

Prevent that the water jet penetrates inside the cab.

SECTION 00 - INTRODUCTION 2.10 WASTE DISPOSAL Improperly disposing of waste can threaten the environment.

Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country.

Hereunder are listed some products of the machine requiring disposal:  lubricating oil;  brake system oil;  coolant mixture, condensation rests and pure antifreeze;  fuel;  oil and fuel filter elements;  air filter elements;  battery.

Also polluting 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 into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service centre to recover and recycle used air conditioning refrigerants. Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your Dealer.

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12

SECTION 00 - INTRODUCTION

3.

TECHNICAL SPECIFICATIONS

3.1

MAIN COMPONENTS

1.

2.

3.

4.

5.

6.

7.

8.

Wheel loader bucket Tilt dumping cylinder Lifting cylinder Fuel tank Cab Hydraulic oil tank Air filter Diesel engine

9.

10.

11.

12.

13.

14.

15.

16.

Hydraulic pumps Battery Rear axle Transmission Steering cylinder Front axle Working attachment Attachment quick coupler

SECTION 00 - INTRODUCTION 3.2

13

DIMENSIONS AND PERFORMANCE WITH BUCKET

BUCKET - DIMENSIONS A Total length B Cab height C Bucket width D Wheel width E Dumping height F Dumping reach G Maximum height of bucket pin H Dumping depth I Wheel base J Track K Clearance from ground to axle L Rear overhang M Tyre width (*) R Tyre radius (*) W Clearance from ground to drive shaft Operating weight (with standard bucket)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lb)

21E 5360 (211.02) 2710 (107.70) 1900 (74.80) 1841 (72.48) 2525 (99.40) 825 (32.50) 3240 (127.55) 93 (3.66) 2182 (85.90) 1480 (58.26) 330 (13) 1203 (47.36) 361 (14.21) 483 (19.01) 400 (15.74)

121E 5490 (216.14) 2790 (109.84) 2050 (80.70) 1910 (75.19) 2550 (100.39) 785 (30.90) 3267 (128.62) 96 (3.77) 2250 (88.60) 1526 (60.07) 330 (13) 1267 (49.88) 384 (15.11) 508 (19.99) 415 (16.33)

221E 5590 (220.07) 2790 (109.84) 2100 (88.70) 1910 (75.19) 2570 (101.18) 845 (33.26) 3360 (132.28) 107 (4.21) 2350 (92.51) 1526 (60.07) 330 (13) 1267 (49.88) 384 (15.11) 508 (19.99) 415 (16.33)

321E 5650 (222.44) 2790 (109.84) 2100 (82.70) 1954 (76.92) 2616 (102.99) 890 (35.03) 3440 (135.43) 106 (4.17) 2350 (92.51) 1570 (61.81) 330 (13) 1267 (49.88) 384 (15.11) 508 (19.99) 415 (16.33)

4615 (10153) 4920 (10824)

5430 (11946)

5770 (12695)

(*) these dimensions apply when considering 12.5-20 tyres for 21E and 14.5-20 tyres for 121E - 221E - 321E

BUCKET - PERFORMANCE Standard bucket capacity Tensile force Dumping load - ISO axis Dumping load - turned by 40° ISO Bucket width Lifting capacity at ground

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m (ft ) kg (lb) kg (lb) kg (lb) mm (in) mm (in)

21E 0.7 (24.7)

121E 0.8 (28.2)

221E 1 (35.3)

321E 1.1 (38.8)

3800 (8360) 3345 (7359) 2945 (6500) 1900 (74.80) 4260 (167.71)

4550 (10010) 3495 (7689) 3100 (6820) 2050 (80.70) 5520 (217.32)

4410 (10010) 4245 (9339) 3630 (7986) 2100 (88.70) 4410 (173.62)

5100 (11220) 4420 (9724) 3755 (8261) 2100 (88.70) 6060 (238.58)

14 3.3

SECTION 00 - INTRODUCTION DIMENSIONS AND PERFORMANCE WITH FORKS

BUCKET WITH FORKS - DIMENSIONS Total length with forks mm (in) Width of fork support mm (in) Fork weight kg (lb) A Clearance from ground mm (in) B Height with maximum outreach mm (in) C Maximum height mm (in) D Outreach at ground mm (in) E Maximum outreach mm (in) F Outreach at maximum height mm (in) G Outreach of coupler pin of bucket mm (in) with forks H Coupler pin switch and centre of mm (in) gravity R Tyre radius (*) mm (in) Payload on level ground kg (lb) Payload on rough ground kg (lb) Operating weight kg (lb)

21E 1200 (47.24) 1450 (57.08) 336 (741) 100 (3.93) 1311 (51.61) 2960 (116.53) 771 (30.35) 1335 (52.55) 600 (23.62) 1630 (64.17)

121E 1200 (47.24) 1450 (57.08) 336 (741) 100 (3.93) 1336 (52.59) 2987 (117.59) 731 (28.77) 1315 (51.77) 580 (22.83) 1630 (64.17)

340 (13.38)

340 (13.38)

221E 321E 1200 (47.24) 1200 (47.24) 1450 (57.08) 1450 (57.08) 336 (741) 336 (741) 100 (3.93) 100 (3.93) 1393 (54.84) 1393 (54.84) 3080 (121.25) 3160 (124.40) 731 (28.77) 798 (31.41) 1340 (52.75) 1390 (54.72) 610 (24.01) 587 (23.11) 1650 (64.96) 1700 (66.92) 340 (13.38)

340 (13.38)

543 (21.37) 562 (22.12) 562 (22.12) 562 (22.12) 1640 (3608) 1780 (3916) 2120 (4664) 2215 (4873) 1230 (2706) 1335 (2937) 1590 (3498) 1660 (3652) 4655 (10241) 4895 (10769) 5370 (11814) 5690 (12518)

(*) this dimension applies when considering 12.5-20 tyres for 21E and 14.5-20 tyres for 121E - 221E - 321E

LIFTING LOADS At L1 = 500 mm (19.68 in) At L2 = 800 mm (31.49 in) At L3 = 1000 mm (39.37 in) At L4 = 1200 mm (47.24 in)

kg (lb) kg (lb) kg (lb) kg (lb)

21E 1600 (3520) 1400 (3080) 1250 (2750) 1000 (2200)

121E 1700 (3740) 1500 (3300) 1250 (2750) 1000 (2200)

221E 1950 (4290) 1550 (3410) 1250 (2750) 1000 (2200)

321E 2250 (4950) 1550 (3410) 1250 (2750) 1000 (2200)

SECTION 00 - INTRODUCTION 3.4

15

WEIGHTS 21E

121E

221E

Engine

kg (lb)

Front axle

kg (lb)

230 (506)

Rear axle (gearbox included) and travel motor

kg (lb)

312 (686)

Cab

kg (lb)

470 (1034)

Variable-displacement pump

kg (lb)

30 (66)

Hydraulic motor

kg (lb)

35 (77)

Lifting equipment

kg (lb)

Lifting cylinder

kg (lb)

30 (66)

Cylinder for quick coupler

kg (lb)

12 (26)

Counterweight

kg (lb)

3.5

300 (660) 318 (700) 251 (552)

420 (942)

393 (865)

315 (693)

600 (1320)

415 (913)

650 (1433)

760 (1676)

NOISE 21E

External noise level LWA Internal noise level LpA

3.6

321E

121E 221E 321E 98 dB (A) 100 dB (A) 75 dB (A)

DIESEL ENGINE 21E

Iveco model

121E

221E

F5C E9454 C* A F5C E9454 D* A F5C E9454 A* A F5C E9454 B* A

Operation

4-stroke diesel engine

Number of cylinders

4

Bore

mm (in)

99 (3.89)

Stroke

mm (in)

104 (4.09)

cm3 (in3)

3202 (195.36)

Total displacement Maximum torque (at 1400 rpm) Power ISO 9249 Rated rpm

Nm kW/CV rpm

Ignition order

220 (162.26)

260 (191.76)

275 (202.82)

310 (228.64)

40 / 54

48 / 64

55 / 74

61 / 82

2300

2300

2500

2500

1,3,4,2

Compression ratio Weight

321E

17 ± 0.5 : 1 kg (lb)

300 (660)

16

SECTION 00 - INTRODUCTION

TIGHTENING TORQUES Component

Tightening torque (Nm) (lbf·ft)

Oil pan plug

50 (36.87)

1/8 G plug (crankcase)

40 (29.50)

3/8 G plug (crankcase)

15 (11.06)

Water drain plug (crankcase)

40 (29.50)

Inspection covers

25 (18.43)

Timing gearbox cover

25 (18.43)

Timing gearbox

25 (18.43)

Flywheel case (M8)

35 (25.81)

Flywheel case (M12)

120 (88.50)

Cylinder head - 1st phase (M12)

65 (47.94)

Cylinder head - 2nd phase (M12)

90 (66.38)

Cylinder head - 3rd phase (M12)

60 (44.25)

Rocker shaft assy

25 (18.43)

Head cover

25 (18.43)

Valve adjusting nut

20 (14.75)

Suction manifold

25 (18.43)

Exhaust manifold

15 (11.06)

Heat exchanger

25 (18.43)

Drive shaft pulley

350 (258.14)

Flywheel

30 (22.12)

Injectors (screw)

25 (18.43)

Injectors (nut)

30 (22.12)

Fuel filter

25 (18.43)

Oil filter

25 (18.43)

Oil pump

25 (18.43)

Water pump

25 (18.43)

Alternator

50 (36.87)

Fuel pump

25 (18.43)

Sensors (oil pressure, water temperature, etc.)

25 (18.43)

SECTION 00 - INTRODUCTION 3.7

17

BRAKES SYSTEM

BRAKE PEDAL VALVE Allowable service pressure .................................................................................................... 175 bar (2538 psi) Adjusted pressure ...................................................................................................................... 55 bar (797 psi) Pressure of brake on disc .......................................................................................................... 55 bar (797 psi) Accumulator charging valve Preloading pressure............................................................................................................... 175 bar (2537 psi) “Cut-in” pressure .................................................................................................................... 120 bar (1740 psi) “Cut-off” pressure................................................................................................................... 150 bar (2175 psi) PRESSURE SWITCHES Brake light pressure switch Infeed pressure ........................................................................................................................... 3.5 bar (51 psi) Function ..........................................................................................................................................when closing Brake accumulator charge pressure switch Infeed pressure ........................................................................................................................ 80 bar (1160 psi) Function ........................................................................................................................................... bidirectional

18 3.8

SECTION 00 - INTRODUCTION STEERING SYSTEM

System pressure .................................................................................................................... 175 bar (2537 psi) POWER STEERING 21E - 121E - 221E

321E

OSPC200LS

OSPC315LS

Model Displacement

cm3/rev (in3/rev)

200 (12.20)

315 (19.22)

Rated oil flow

l/min (gal/min)

20 (5.30)

32 (8.40)

kg (lb)

5.8 (13)

6.2 (14)

bar (psi)

240 (3840)

240 (3840)

Weight Relief valve adjustment Tightening torques Component

Tightening torque (Nm) (lbf·ft)

Steering wheel nut

55 (40.56)

Steering column bracket

23 (16.97)

End cover

30 (22.12)

Connector

45 (33.19)

Adaptors

55 (40.56)

Check valve

30 (22.12)

STEERING CYLINDER 21E

121E

Quantity

221E

321E

1

Ø rod

mm (in)

32 (1.25)

40 (1.57)

Ø piston

mm (in)

70 (2.75)

80 (3.14)

Stroke

mm (in)

300 (11.81)

300 (11.81)

3.9

HYDRAULIC SYSTEM

PRESSURE ADJUSTMENT Working attachment Primary safety pressure ......................................................................................................... 250 bar (3625 psi) Secondary safety pressure - tilt dumping cylinder bottom side.............................................. 280 bar (4059 psi) Secondary safety pressure - tilt dumping cylinder rod side.................................................... 250 bar (3625 psi) Secondary safety pressure - boom cylinder bottom side ....................................................... 280 bar (4059 psi)

SECTION 00 - INTRODUCTION

19

VARIABLE-DISPLACEMENT PUMP 21E System

121E

221E

321E

Pump with adjustment depending on engine rpm AV4VG40DA1D2 A4VG56DA1D2 A4VG56DA1D2 A4VG71DA1D2 / 32R / 32R / 32R / 32R

Model Displacement

cm3/rev (in3/rev)

40 (2.44)

56.0 (3.41)

56.0 (3.41)

71.0 (4.33)

Power

kW (hp)

35.7 (46.1)

38.0 (51)

48.3 (61.8)

52.8 (70.8)

Transmission through Service revolutions (= engine rated speed)

diesel engine direct drive, i = 1.0 rpm

2300

2300

2500

2500

Maximum oil delivery

l/min (gal/min)

88.8 (23.40)

131.3 (34.60)

136.0 (35.80)

173.4 (45.70)

Supply pressure (rotation speed at full load)

bar (psi)

25 (362)

27 (391)

27 (391)

27 (391)

Adjustment start

bar (psi)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

Adjustment end

bar (psi)

400 (5801) (at 1800 rpm)

400 (5801) (at 1900 rpm)

400 (5801) (at 1900 rpm)

400 (5801) (at 1900 rpm)

Pressure cut-off

bar (psi)

High-pressure relief valves - opening -

bar (psi)

Hydraulic motor adjustment bar (psi) start Voltage

430 (6234) 465 (6744)

245 (3553)

467 (6773)

467 (6773)

467 (6773)

190 (2755)

245 (3553) (190 (2755) “high speed” models)

215 (3118)

V

12

GEAR PUMP

Model Displacement

cm3/rev (in3/rev)

Maximum pressure

bar (psi)

21E

121E

221E

321E

022R0020KB

032R0020KB

028R0020KB

032R0020KB

22.5 (1.37)

32 (1.95)

28 (1.7)

32 (1.95)

270 (3914)

20

SECTION 00 - INTRODUCTION

HYDRAULIC CYLINDERS 21E

121E

221E

321E

Lifting cylinder Quantity

1

Ø rod

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

Ø piston

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

Stroke

mm (in)

721 (28.38)

728 (28.66)

718 (28.26)

730 (28.74)

Tilt dumping cylinder Quantity

1

Ø rod

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

Ø piston

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

Stroke

mm (in)

459 (18.07)

454 (17.87)

490 (19.29)

490 (19.29)

Quick coupler cylinder Quantity

1

Ø rod

mm (in)

25 (0.98)

25 (0.98)

25 (0.98)

25 (0.98)

Ø piston

mm (in)

40 (1.57)

40 (1.57)

40 (1.57)

40 (1.57)

Stroke

mm (in)

60 (2.36)

60 (2.36)

60 (2.36)

60 (2.36)

ACCUMULATORS BRAKE ACCUMULATOR Capacity ............................................................................................................................. 0.32 litres (0.10 gal) Maximum pressure................................................................................................................ 210 bar (3045 psi) Service temperature..................................................................................... -10 °C / +80 °C (+14 °F / +176 °F) Filling gas .............................................................................................................................................. nitrogen Filling gas overpressure .............................................................................................. 25 ± 1 bar (362 ± 15 psi) Weight ............................................................................................................................................. 1.3 kg (3 lb) QUICK COUPLER CYLINDER ACCUMULATOR Capacity ............................................................................................................................... 0.6 litres (0.15 gal) Maximum pressure................................................................................................................ 330 bar (4784 psi) Service temperature..................................................................................... -10 °C / +80 °C (+14 °F / +176 °F) Filling gas .............................................................................................................................................. nitrogen Precharge pressure..................................................................................................... 50 ± 1 bar (724 ± 15 psi) Weight ............................................................................................................................................. 3.3 kg (7 lb) RIDE CONTROL ACCUMULATOR Capacity ............................................................................................................................. 0.75 litres (0.20 gal) Maximum pressure................................................................................................................ 330 bar (4784 psi) Service temperature..................................................................................... -10 °C / +80 °C (+14 °F / +176 °F) Filling gas .............................................................................................................................................. nitrogen Filling gas overpressure .............................................................................................. 25 ± 1 bar (362 ± 15 psi) Weight ................................................................................................................................................ 4 kg (9 lb)

SECTION 00 - INTRODUCTION

21

TRAVEL MOTOR 21E

Type Displacement Qmax / Qmin Maximum speed Delivery pressure Service pressure Pressure increasing spring Voltage

121E 221E 321E A6VM80HA1U1 / 63W A6VM107HA1U1 / 63W 80 / 18.8 80 / 23.7 cm3 80 / 24.8 107 / 34.5 3 (6.52 / 2.10) (4.88 / 1.14) (4.88 / 1.44) (4.88 / 1.51) (in ) rpm 4352 5289 5289 4811 bar 25 25 25 25 (psi) (362) (362) (362) (362) bar 245 190 245 215 (psi) (3552) (2755) (3552) (3117) bar 10 10 10 10 (psi) (145) (145) (145) (145) V 12

TRAVEL MOTOR “HIGH SPEED” 121E

Type Displacement Qmax / Qmin Maximum speed Delivery pressure Service pressure Pressure increasing spring Voltage

cm3 (in3) rpm bar (psi) bar (psi) bar (psi) V

221E 321E A6VM80HA1R1 / 63W 80 / 26.5 (4.88 / 1.62) 80 / 29.2 (4.88 / 1.78) 80 / 35.4 (4.88 / 2.16) 4770 4770 4770 25 25 25 (362) (362) (362) 190 190 215 (2755) (2755) (3117) 10 10 10 (145) (145) (145) 12

3.10 ELECTRICAL SYSTEM (EUROPE MODELS) STANDARD ELECTRICAL SYSTEM Service voltage ............................................................................................................................................ 12 V Battery (quantity 1) Capacity (20 h)........................................................................................................................................... 95 Ah Discharge current....................................................................................................................................... 900 A Weight (with electrolyte).................................................................................................................. 25 kg (55 lb) ELECTRICAL SYSTEM WITH COLD START DEVICE Service voltage ............................................................................................................................................ 12 V Battery (quantity 2) Capacity (20 h)......................................................................................................................................... 155 Ah Discharge current..................................................................................................................................... 1050 A Weight (with electrolyte)............................................................................................................. 45,4 kg (100 lb)

3.11 ELECTRICAL SYSTEM (NORTH AMERICA MODELS) Service voltage ............................................................................................................................................ 12 V Battery Capacity (20 h)........................................................................................................................................... 95 Ah Critical current............................................................................................................................................ 900 A Weight............................................................................................................................................. 25 kg (55 lb)

22

SECTION 00 - INTRODUCTION

3.12 BUCKETS 21E SAE capacity

m3 3

(ft )

121E

221E

321E

0.65 0.70 0.80 0.80 0.90 0.90 1.00 1.00 1.10 1.20 (22.95) (24.72) (28.25) (28.25) (31.78) (31.78) (35.31) (35.31) (38.84) (42.37)

Width

mm 1800 1900 1900 2050 2050 2050 2100 2100 2100 2100 (in) (70.86) (74.80) (74.80) (80.70) (80.70) (80.70) (82.67) (82.67) (82.67) (82.67)

Weight

kg 250 (lb) (550)

265 (583)

295 (650)

315 (693)

335 (737)

335 (737)

365 (803)

365 (803)

370 (814)

3.13 AXLES FRONT AXLE Model Differential type Bevel gear reduction ratio Reduction gear ratio Total reduction ratio Input rotation direction Bevel gear play Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings) Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings) Dynamic load Static load Service brake torque Parking brake torque Maximum service pressure

21E 28.16 (CA147195) limited slip 2.90 / 1 6.00 / 1 17.45 / 1 clockwise 0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in) P = 9.2 ÷ 13.7 daN (20.68 ÷ 30.79 lbf) T= (P+3.1)+(P+4.7) daN T= (P+0.96)+(P+10.56) lbf 55000 Nm (40565 lbf·ft) 137500 Nm (101415 lbf·ft) 980 Nm (722 lbf·ft) 780 Nm (575 lbf·ft) 55 bar (797 psi)

“STANDARD” and “HIGH SPEED” FRONT AXLE 121E - 221E - 321E Model Differential type

28.25 (CA4092945) limited slip

Bevel gear reduction ratio

3.66 /1

Reduction gear ratio

6.00 / 1

Total reduction ratio

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

Maximum service pressure

55 bar (797 psi)

410 (902)

SECTION 00 - INTRODUCTION

23

REAR AXLE 21E

121E - 221E

321E

Model

CA147194+CA150145 28.16 + TB150

CA147189+CA150146 28.20 + TB150

CA147186+CA150147 28.20 + TB150

Differential type

CA147194: standard CA150145: limited slip

CA147189: standard CA150146: limited slip

CA147186: standard CA150147: limited slip

Bevel gear reduction ratio

2.91 / 1

3.66 / 1

3.66 / 1

Reduction gear ratio

6.00 / 1

6.00 / 1

6.00 / 1

Transmission box reduction ratio

2.257 / 1

2.257 / 1

2.053 / 1

Total reduction ratio

39.38 / 1

49.65 / 1

45.156 / 1

Input rotation direction Bevel gear play

counterclockwise 0.18 ÷ 0.23 mm (0.007 ÷ 0.0090 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings) Ring gear-pinion bearing total preload T= (P+3.1)+(P+4.7) daN (measured on D = T= (P+6.96)+(P+10.56) lbf 34.8 mm (1.37 in) without seal rings)

0.17 ÷ 0.24 mm (0.006 ÷ 0.0094 in) P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

“HIGH SPEED” REAR AXLE 121E - 221E - 321E Model Differential type Dry weight

CA147187 28.20 + TB138.5 limited slip /

Bevel gear reduction ratio

3.66 /1

Reduction gear ratio

6.00 / 1

Transmission box reduction (1°)

2.75 / 1

Total reduction (1°)

60.5 / 1

Transmission box reduction (2°)

1.163 / 1

Total reduction (2°)

25.28 / 1

Input rotation direction Bevel gear play

counterclockwise 0.17 ÷ 0.24 mm (0.0066 ÷ 0.0094 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

24

SECTION 00 - INTRODUCTION

TIGHTENING TORQUES Component Wheel nuts Cardan shaft Front axle fastening Front axle fastening (pin retainer)

Tightening torque (Nm) (lbf·ft) 550 (405.65) 34 (25.07) 350 (258.14) 79 (58.26)

Rear axle fastening

350 (258.14)

Fastening of variable-displacement pump to engine

250 (184.40)

Fastening of travel motor to transmission

725 (534.73)

Counterweight

390 (287.64)

Engine supports

140 (103.25)

Cab elastic supports

240 (177.01)

SECTION 00 - INTRODUCTION

25

3.14 SUPPLY CHART

Component to refill Suggested product Window washer tank Cooling system

Fuel system

Engine (without filter)

Brake system

Oil tank Hydraulic system

Front axle: - differential - side gearboxes Rear axle: - differential - side gearboxes - gear box Air conditioning system: - coolant - oil (compressor) Greasing of grease nipples

CASE Standard

International Viscosity Standard

Quantity (litres) 21E

121E

Water and alcohol

-

-

-

2.2

AKCELA Premium Anti-freeze antifreeze 50% water 50%

MS 1710

CUNA NC 956-16

-

24

Decanted and filtered diesel fuel

-

-

-

100

SAE 15W40

15

-

Oil AKCELA ENGINE or oil AKCELA N. 1 ENGINE

MS 1120

API CF-4 MIL-L-2104 F LEVEL

221E

321E

MS 1121

API CF-4/CH-4 ACEA E7/E5

see Hydraulic system

-

-

-

AKCELA AW HYDRAULIC FLUID 68 HV (-30 to +40 °C)

MS 1216

ISO VG 68 DIN 51524

-

56

67

67

74

AKCELA HYDRAULIC EXCAVATORS FLUID (-10 to +50 °C)

MS 1216

ISO VG 46 DIN 51524

-

56

67

67

74

AKCELA HYDRAULIC EXCAVATORS FLUID BIO biodegradable oil (special equipment)

MS 1216

ISO VG 46 DIN 51524

-

56

67

67

74

7.5 2x0.7

8 2x0.6

8 2x0.6

8 2x0.6

7.5 2x0.7 0.75

8 2x0.7 0.75

8 2x0.7 0.75

8 2x0.7 0.75

SAE 80W-90

AKCELA GEAR 135 H EP LS Oil

-

R 134a PAG SP 20

-

-

-

1.1 -

AKCELA MULTIPURPOSE GREASE 251H EP Multi purpose grease

-

NLGI2

-

-

API GL5

26 NOTES:

SECTION 00 - INTRODUCTION

SECTION 10 - ENGINE 1. DIESEL ENGINE .......................................................................................................................................... 1 2. FUEL SYSTEM ............................................................................................................................................. 2 3. COLD START DEVICE (NORTH AMERICA) ............................................................................................... 5

SECTION 10 - ENGINE

SECTION 10 - ENGINE

1.

DIESEL ENGINE

Refer to the REPAIR MANUAL of the IVECO ENGINE Print number 87736548A

1

2

2.

SECTION 10 - ENGINE

FUEL SYSTEM

The fuel system consists simply of a tank (3) ensuring fuel supply to diesel engine (1) by means of pipes (2).

SECTION 10 - ENGINE 2.1

FUEL TANK

System capacity: 95 litres

1.

2.

3.

4.

5.

6.

7.

8.

9.

Fuel tank Screw Washer Washer Nut Washer Nut Washer Screw

10.

11.

12.

13.

14.

15.

16.

17.

18.

Plate Ring Sleeve Plug Gauge Washer Screw Rod Rod

3

4 2.2

SECTION 10 - ENGINE FUEL

Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher, oil change intervals should be reduced. The following fuel specifications / standards are approved:  DIN EN 590  BS 2869  ASTM D 975-96; 1-D and 2-D  NATO Code F-54 / F-34 / F-44 and XF 63 Exhaust emission values which may be determined in the case of type approval tests always refer to the fuels prescribed by the authorities for the type approval test.

WINTER-GRADE FUEL Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency.

If the ambient temperature is less than 0 °C (+32 °F) use winter-grade fuel, suitable down to -15 °C (+5 °F) should be used; this fuel is available at the filling stations well in advance of the cold season.

Diesel fuel containing additives (Super diesel) is often available, for use down to -20 °C (-4 °F) approximately.  At temperatures below -15 °C (+5 °F) or -20 °C (-4 °F), add “Diesel art P/N 2421LT” to diesel fuel.

Use 250 ml of product for 50/60 l of diesel fuel.

S CAUTION Diesel fuels must never be mixed with gasoline.

SECTION 10 - ENGINE

3.

COLD START DEVICE (NORTH AMERICA)

The engine can be provided with an optional heating device for starting at particularly low temperatures.

1. Heater 2. Cable

5

6 NOTES:

SECTION 10 - ENGINE

SECTION 25 - FRONT AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 4 3. TECHNICAL SPECIFICATIONS................................................................................................................... 5 4. OIL CHANGE.............................................................................................................................................. 10 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 13 5.1 DISC BRAKE ASSY (21E)................................................................................................................... 13 5.2 BRAKE CALIPER ................................................................................................................................ 20 5.3 REDUCTION GEAR (21E)................................................................................................................... 25 5.4 REDUCTION GEAR (121E, 221E, 321E)............................................................................................ 28 5.5 WHEEL HUB (21E).............................................................................................................................. 31 5.6 WHEEL HUB (121E, 221E, 321E) ....................................................................................................... 40 5.7 WHEEL SHAFT (121E, 221E, 321E)................................................................................................... 46 5.8 BRAKE AND WHEEL SHAFT (121E, 221E, 321E “STANDARD” and “HIGH SPEED”) ..................... 50 5.9 DIFFERENTIAL SUPPORT ................................................................................................................. 58 5.10 DIFFERENTIAL ASSY....................................................................................................................... 66 5.11 PINION............................................................................................................................................... 73 6. TROUBLESHOOTING................................................................................................................................ 79 7. SPECIAL TOOLS........................................................................................................................................ 82

SECTION 25 - FRONT AXLES

SECTION 25 - FRONT AXLES

1

The wheel loaders can be equipped with different types of front axles: 21E

121E

221E

321E

CA147195



/

/

/

CA4092945 (“STANDARD” and “HIGH SPEED” versions)

/







1.

REMOVAL AND INSTALLATION

CA147195 (21E)

1.

2.

3.

4.

5.

Front axle Plate Screw Nut Locknut

6.

7.

8.

9.

10.

Brake tie-rod Nut Cup Wheel Cardan shaft

2

SECTION 25 - FRONT AXLES

CA409294S (121E, 221E, 321E)

5 4 11

1

6

5 4 10 12

2 3

3

2 9 8 7 CWL00001

1.

2.

3.

4.

5.

6.

Front axle Plate Screw Nut Locknut Brake tie-rod

7.

8.

9.

10.

11.

12.

Nut Cup Wheel Cardan shaft Pipe Pipe

SECTION 25 - FRONT AXLES REMOVAL Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Remove the cups (8) and unscrew nuts (7) from both sides.

Remove the two wheels (9).

Disconnect the cardan joint (10).

Position the fork-lift truck laterally with the forks under front axle (1), lift the front axle and support it.

Release the tie-rod (6) from the brake disc.

Disconnect the pipes (11) and (12) of the multi-plate brake (121E, 221E, 321E).

Unscrew and remove the nuts (4) and (5).

Remove the screws (3) and the plates (2).

Lower the forks and remove the front axle (1).

INSTALLATION The assembly of the front axle is to be carried out in the reverse order.

Tighten the nuts (4) and (5) to the prescribed torque of 350 Nm (258.14 lbf·ft) and the wheel nuts (7) to the prescribed torque of 500 Nm (368.78 lbf·ft).

Fill oil in the hubs and in the axle reduction gears (see Operator’s manual).

Bleed air from the multi-plate brake (121E, 221E, 321E).

Adjust the parking brake.

3

4

2.

SECTION 25 - FRONT AXLES

DIMENSIONS

CA147195 (21E)

CA4092945 “STANDARD” and “HIGH SPEED” version (121E, 221E, 321E)

SECTION 25 - FRONT AXLES

3.

5

TECHNICAL SPECIFICATIONS

FRONT AXLE CA147195 (21E) Model Differential type Dry weight

28.16 limited slip 230 kg (506 lb)

Bevel gear reduction ratio

2.90 / 1

Reduction gear ratio

6.00 / 1

Total reduction ratio

17.45 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T = (P + 3.1) ÷ (P + 4.7) daN T = (P + 6.96) ÷ (P + 10.56) lbf

Maximum service pressure

55 bar (797 psi)

Differential oil capacity

7.5 litres (2 gal)

Reduction gear oil capacity (each side)

0.7 litres (0.18 gal)

6

SECTION 25 - FRONT AXLES

FRONT AXLE “STANDARD” and “HIGH SPEED” version CA4092945 (121E, 221E, 321E) Model Differential type Dry weight

28.25 limited slip -

Bevel gear reduction ratio

3.66 / 1

Reduction gear ratio

6.00 / 1

Total reduction ratio

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf

Maximum service pressure

55 bar (797 psi)

Differential oil capacity

8 litres (2.10 gal)

Reduction gear oil capacity (each side)

0.6 litres (0.20 gal)

SECTION 25 - FRONT AXLES

7

TIGHTENING TORQUES CA147195

CWL00007

8

SECTION 25 - FRONT AXLES

TIGHTENING TORQUES CA4092945

CWL00008

SECTION 25 - FRONT AXLES

9

BRAKE DISC THICKNESS

New friction disc thickness = 11.7 ± 0.05 mm (0.46 ± 0.001 in)

LIMITED SLIP DIFFERENTIAL DISCS THICKNESS

New counterdisc thickness = 1.5 ± 0.03 mm (0.059 ± 0.001 in) Worn counterdisc minimum thickness = 1.4 mm (0.055 in) Disc ref. CA110643 - q.ty 10

New friction disc thickness = 1.6 ± 0.03 mm (0.062 ± 0.001 in) Worn disc minimum thickness = 1.45 mm (0.057 in) Disc ref. CA110644 - q.ty 8

Disc ref. CA110642 - q.ty 2 New friction disc thickness = 2.8 ± 0.03 mm (0.11 ± 0.001 in) Worn disc minimum thickness = 2.7 mm (0.10 in)

10

4.

SECTION 25 - FRONT AXLES

OIL CHANGE

CWL00006

Oil filler and level plug

1

Oil drain plug

2

Air breather valve

3

Filler, level and drain plug for reduction gear oil

4

SECTION 25 - FRONT AXLES

Before draining the oil from the central axle body, operate the relevant air breather valve (3) to eliminate any possible internal pressure.

To drain the oil from the central axle body, unscrew the level plug (1) first, then the drain plug (2).

Drain the oil completely.

Clean the drain plug (2) and screw it back in.

Always operate the relevant air breather valve (3) to eliminate any possible internal pressure.

Unscrew the oil filler plug (1) and fill in specified oil up to the level hole.

Wait for the oil to flow into the axle, then check the level and top up, if necessary.

Screw in the filler plug (1) again.

Before draining the oil from the reduction gear, turn the gear so that the plug (4) is in the highest possible position [position A].

Partially unscrew the plug to release any possible internal pressure.

Rotate the reduction gear with the plug (4) oriented downwards [position B].

Remove the plug and drain the oil completely.

11

12

SECTION 25 - FRONT AXLES

Rotate the reduction gear until the hole of the plug (4) is in horizontal position.

Fill in. The oil level should be flush with the hole.

Tighten the plug (4) again.

SECTION 25 - FRONT AXLES

5.

DISASSEMBLY AND ASSEMBLY

Some of the following pictures could not show exactly the installed axle, but the procedure is the same.

5.1

DISC BRAKE ASSY (21E)

DISASSEMBLY Remove the breather valve (1). Loosen the screw (14). Remove the connector (13) and the breather pipe (3) from the brake caliper (5).

13

14

SECTION 25 - FRONT AXLES

Loosen and remove the screws (4).

Remove the brake caliper (5) from the support (10) and from the brake disc (7).

Remove the elastic ring (6).

Remove the brake disc (7).

SECTION 25 - FRONT AXLES

Remove the elastic ring (8).

Loosen and remove the screws (9).

Remove the brake caliper support (10).

Only if necessary remove the dowel pin (11).

15

16

SECTION 25 - FRONT AXLES

Remove the seal ring (12).

NOTE: destructive operation for the seal ring.

ASSEMBLY Assemble the seal ring (12) into the brake caliper support (10).

Before matching worked surfaces, make sure they are perfectly clean. Degrease and clean with appropriate detergents. Spread a film of prescribed sealant on the contact surface of the brake caliper support and the differential support (2).

NOTE: check that the dowel pin (11) is in its seat.

Assemble the brake caliper support (10) with the screws (9).

Tighten the screws (9) to the prescribed torque of 50 Nm (36.87 lbf·ft).

SECTION 25 - FRONT AXLES

Insert the elastic ring (8) on the pinion end.

Install the brake disc (7).

Assemble the elastic ring (6).

Assemble the brake caliper (5) on the support and on the brake disc (7).

17

18

SECTION 25 - FRONT AXLES

Apply some Loctite 242 on the thread of the screws (4).

Screw in and tighten the screws (4) to the prescribed torque of 169 Nm (124.64 lbf·ft).

Apply some Loctite 242 on the thread of the fitting (13). Screw in and tighten the connector (13) to the prescribed torque of 12 Nm (8.85 lbf·ft).

Loosen the screw (14).

Assemble the breather pipe (3), the connector (13) and the breather valve (1).

SECTION 25 - FRONT AXLES

Screw in and tighten the screw (14) to the prescribed torque of 50 Nm (36.87 lbf·ft).

Check the brake caliper correct operation by blowing air at 5 bar (73 psi) pressure into the proper port (a1).

S WARNING Never activate the parking brake lever (a2) during brake caliper assembly.

19

20

SECTION 25 - FRONT AXLES

5.2

BRAKE CALIPER

OPERATION s

The parking brake assembly is a ball and ramp, sliding caliper brake designed for use primarily as a parking brake, with some secondary braking capability. The brake has an open caliper design to facilitate changing linings, along with a retraction spring to reduce parasitic drag. It is sealed from the environment to provide a long and trouble free service life.

14

9 16

5

8

10

7

14 11

17

12

13 1

15

2 4

3

6

CWL00004

1.

2.

3.

4.

5.

6.

7.

8.

9.

Lever Bolt Boot Cam Torque plate Lining and carrier assy Torque plate Ball retainer Sleeve

10.

11.

12.

13.

14.

15.

16.

17.

Spring-flat Garlock thrust bearing Hex nut Jam nut Seal sleeve Seal Washer hardened Washer

SECTION 25 - FRONT AXLES

21

PARTS LIST

13

17

12

11

16

1 3

15

8

4

4

9 5 9

14 14 6

10

6 7 2

CWL00005

22

SECTION 25 - FRONT AXLES

MOUNTING PROCEDURE Insert mounting bolts through sleeves (9) and thread brake mounting locking nuts as far as possible on mounting bolts. This is not required if brake assembly comes with the sleeve/bolt sub-assy (9).

Position the brake over disc and align with mounting holes in mounting bracket.

BALL AND CAM REPLACEMENT Remove both adjustment nuts (12 - 13), thrust, stainless steel and hardened washers (11, 17 - 16), lever (1), and boot (3) from adjustment bolt (2).

Remove outer cam (4) and ball/retainer assembly (8) from adjustment bolt (2).

Thread mounting bolts into mounting bracket, adjusting bolts until a 0.580 - 1.524 mm (0.020 - 0.060 in) gap exists between the sleeves (9) and the locking nuts. Tighten the locking nuts to 101.6 to 115 mm (75 to 85 lbf-ft) of torque against the bracket.

Use a screwdriver, or similar tool, to gently pry inner cam (4) protrusions on back of cam, loose from torque plate (5), and remove from adjusting bolt (2). remove seal (15) from adjusting bolt (2).

Refer to adjustment procedure to set clearance of installed brake assembly.

Install the new seal (15) on the adjusting bolt (2), inserting through inner cam (4) until seal (15) bottoms out on torque plate (5).

ADJUSTMENT PROCEDURE Loosen two adjustment nuts (12 - 13) (one full nut and one jam nut except when using a 12.7 mm (0.50 in) thick disc which requires two jam nuts).

Tighten inner nut (12) until firm contact is made with the disc by the linings. Torque to 11.3 Nm (8.33 lbf-ft).

Make certain lever (1) is in proper operating position for application.

Back off inner nut (12) 4 to 5 flats and check that disc is free to move.

Tighten outer nut (13) against inner nut (12) to lock adjustment bolt (2) in place. Torque to 61 to 74.5 mm (45 to 55 lbf-ft).

NOTE: prior to the installation of the cams (4), it is recommended that grease be applied to ramp areas of the cams.

Install new inner cam (4) on adjusting bolt (2), taking care to orient protrusions into holes in torque plate (5).

Install ball/retainer assembly (8) onto adjusting bolt (2), orienting balls into pockets of inner cam (4). Install outer cam (4) onto adjusting bolt (2), orienting pockets onto balls of ball/retainer assembly (8). Install boot (3) over cam assembly.

Install lever (1), using protrusions on back of outer cam (4) and holes in lever (1) to orient lever to proper operating position. nstall remaining washers and nuts (11,17,16,12 13) and follow adjustment procedure in section “ADJUSTMENT PROCEDURE”.

NOTE: make sure to orient coated face of thrust washer (11) toward stainless steel washer (17).

SECTION 25 - FRONT AXLES LINING REPLACEMENT Replace both linings when either has worn to 2.2 mm (0.090 in). Remaining.

Loosen two adjustment nuts (12 - 13) enough to slide each torque plate (5 - 7) away from disc far enough to provide clearance to remove old carrier lining assemblies (6) and install new ones. (It may be necessary to remove one or both nuts).

Collapse lining retraction spring (10) and remove from brake head assembly.

Slide torque plates (5 - 7) away from disc, move carrier - lining assemblies (6) out of pockets, and remove from the brake head assembly from the side.

NOTE: prior to the installation of the new linings, it is recommended that a coating of grease must be applied to the interface of the sleeve (9) and the torque plates (5) & (7). After grease has been applied, slide torque plates back and forth on sleeve as far as possible to insure that the grease has been introduced into the bores of the torque plates.

Install new carrier & lining assemblies (6) in each torque plate (5 - 7).

23

Install lining retention spring (10) into brake head assembly. be sure spring's "feet" are positioned properly in holes in both lining carrier assemblies (6).

Adjust brake per section “ADJUSTMENT PROCEDURE”.

SLEEVE SEAL REPLACEMENT Loosen the two locking nuts on the mounting bolts and remove the sleeve/bolt subassembly (9) from the brake. remove sleeve seals (14).

Insert new sleeve seals (14) between the torque plates (5 - 7) and align with the sleeve bores.

NOTE: prior to the installation of the mounting bolt sleeve assembly, it is recommended that grease must be applied to the sleeves and the bores of the torque plates.

Insert sleeve/bolt sub-assembly (9) through the front torque plate (5), sleeve seal (14), and back torque plate (7).

Mount brake per paragraph “MOUNTING PROCEDURE”. and adjust per section “ADJUSTMENT PROCEDURE”.

24 5.3

SECTION 25 - FRONT AXLES REDUCTION GEAR (21E)

DISASSEMBLY Unscrew and remove the plug (2).

Drain the oil completely from the reduction gear.

SECTION 25 - FRONT AXLES

Unscrew and remove the two screws (3) of the planetary carrier cover (1).

Remove the planetary carrier cover (1) and collect the relevant O-ring (5).

Position the planetary gear carrier (1) onto a workbench and check its wear conditions.

If necessary, replace the gears as follows:  remove the elastic rings (10) from each pin (4);  remove the triangular plate (9);  take out the gears (8) from the pins;  collect the bearings (7) checking their conditions;  collect the washers (6).

ASSEMBLY Collect all reduction gear parts: the planetary gear carrier (1), the washers (6), the gears (8) and the bearings (7), the triangular plate (9) and the elastic rings (10) of each pin.

NOTE: with new gears, it is advisable to assemble new bearings.

25

26

SECTION 25 - FRONT AXLES

Position the planetary gear carrier (1) on a workbench.

Insert the washers (6) and the gears (8) into the planetary gear carrier pins.

Insert the bearings (7) into the gears (8).

NOTE: thoroughly grease the bearings.

Assemble the triangular plate (9) and the elastic rings (10).

Insert a new O-ring (5) onto the planetary gear carrier (1).

Assemble the planetary gear carrier (1) to the wheel hub.

Screw in and tighten the screws (3) to the prescribed torque of 25 Nm (18.43 lbf·ft).

Top up the oil on the wheel hub.

Screw in the plug (2) onto the planetary gear carrier (1) and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

SECTION 25 - FRONT AXLES 5.4

REDUCTION GEAR (121E, 221E, 321E)

DISASSEMBLY Unscrew and remove the plug (2).

Drain the oil completely from the reduction gear.

27

28

SECTION 25 - FRONT AXLES

Unscrew and remove the screws (3) of the planetary carrier cover (1).

Remove the planetary carrier cover (1) and collect the relevant O-ring (4).

Position the planetary gear carrier (1) onto a workbench and check its wear conditions.

If necessary, replace the gears as follows:  remove the elastic rings (10) from each pin (5);  remove the washers (9);  take out the gears (7) from the pins (5);  collect the bearings (6) and (8) checking their condition.

ASSEMBLY Collect all reduction gear parts: the planetary gear carrier (1), the elastic rings (10), the washers (9), the gears (7) and the relevant bearings (6) and (8).

NOTE: with new gears, it is advisable to assemble new bearings.

SECTION 25 - FRONT AXLES

Position the planetary gear carrier (1) on a workbench.

NOTE: thoroughly grease the bearings.

Insert the bearings (6) and (8) into the gears (7).

Insert the gears (7) into the pins (5) of the planetary gear carrier (1).

Assemble the washers (9) and the elastic rings (10) onto the pins of the planetary gear carrier (1).

Insert a new O-ring (4) onto the planetary gear carrier (1).

Assemble the planetary gear carrier (1) to the wheel hub.

Screw in and tighten the screws (3) to the prescribed torque of 25 Nm (18.43 lbf·ft).

Top up the oil on the wheel hub.

Screw in the plug (2) on the planetary gear carrier (1). Tighten to prescribed torque 60 Nm (44.25 lbf·ft).

29

30 5.5

SECTION 25 - FRONT AXLES WHEEL HUB (21E)

DISASSEMBLY Before disassembling the wheel hub, secure it with a belt or a rope to a hoist or other support, to prevent it from accidentally falling down, which could injury the operator and damage the wheel hub.

Unscrew and remove the screws (1) of the ring gear carrier.

SECTION 25 - FRONT AXLES

In order to extract the ring gear carrier from its housing, use at least two of the just removed screws (1) and screw them in the threaded holes they were extracted from.

Remove the ring gear carrier (2) together with the ring gear (3).

Only if necessary, remove the bushings (4) of the ring gear carrier.

Remove the snap ring (5).

31

32

SECTION 25 - FRONT AXLES

Slide out the wheel hub (6), using levers and a hammer to facilitate the operation.

NOTE: recuperate the bearing (7).

Position the wheel hub (6) on a flat surface and extract the seal ring (8).

NOTE: destructive operation for the seal ring.

Take out the bearing cups (7) and (9) with a driver and a hammer.

To unscrew and replace the worn stud bolts (10) of the wheel hub, use a nut and a locknut. Warm up the screwed part, if necessary.

SECTION 25 - FRONT AXLES

Remove the bearing (9).

Extract the short half axle (11).

Loosen and remove the screws (12).

S WARNING Do not drop the wheel shaft and, if necessary, hold it by means of a rope.

Remove the wheel shaft (13) and collect the relevant O-ring (14).

33

34

SECTION 25 - FRONT AXLES

Take out the seal ring (16) from the wheel shaft (13).

NOTE: destructive operation for the seal ring.

Position the wheel shaft (13) on a flat surface and extract the bushing (15) using a hammer and the driver 380002226.

Extract the long half shaft (17).

Remove the sleeve (18). If necessary, remove the elastic ring (19) from inside the sleeve.

ASSEMBLY Assemble the bushing (15) into the wheel shaft (13) with the driver 380002831 and a hammer.

SECTION 25 - FRONT AXLES

Turn the wheel shaft (13).

Fit the seal ring (16) onto the wheel shaft (13).

Check that the elastic ring (19) is assembled to the sleeve (18).

Fasten the sleeve (18) to the long half shaft (17).

Insert the long half shaft (17) in the axle beam (20).

Assemble a new O-ring (14).

Assemble the wheel shaft (13) and fasten it with the screws (12). Tighten the screws (12) to the prescribed torque of 190 Nm (140.13 lbf·ft).

35

36

SECTION 25 - FRONT AXLES

The special operation “Set Right” of the bearings does not require preload or backlash adjustment.

Anyway, before assembling new components, check the indicated dimensions.

A = 11.975 ÷ 12.025 mm (0.471 ÷ 0.473 in) B = 52.229 ÷ 52.279 mm (2.056 ÷ 2.058 in) C = 20.000 ÷ 20.100 mm (0.78 ÷ 0.79 in)

Heat the bearing (9) to 80 ÷ 100 °C (176 ÷ 212 °F).

Assemble the bearing on the wheel shaft.

S WARNING Wear safety gloves.

Apply the prescribed sealant on the stud bolt threads (10) and tighten them to the prescribed torque of 70 Nm (51.62 lbf·ft) using two nuts (nut and locknut).

Position the wheel hub (6) on a workbench and assemble the bearing cups (7) and (9).

Fit the seal ring (8) onto the wheel hub (6).

SECTION 25 - FRONT AXLES

Insert the wheel hub (6) on the wheel shaft.

Heat the bearing (7) to 80 ÷ 100 °C (176 ÷ 212 °F) and assemble it.

S WARNING Wear safety gloves.

Position the ring gear carrier (2) on a workbench and assemble the bushings (4) at surface level.

At least two bushings (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.

Preassemble the ring gear carrier (2) and the ring gear (3) with the snap ring (5).

Assemble the ring gear carrier assy (2) and the ring gear (3) on the wheel hub using the two projecting bushings (4) as dowel pins.

37

38

SECTION 25 - FRONT AXLES

Assemble the bushings (4) and completely insert them.

Apply some Loctite 242 on the thread of the screws (1).

Screw in the screws (1) and tighten them to the prescribed torque of 120 Nm (88.51 lbf·ft).

Install the short half axle (11).

SECTION 25 - FRONT AXLES 5.6

WHEEL HUB (121E, 221E, 321E)

DISASSEMBLY Unscrew and remove the screws (1) of the ring gear carrier.

39

40

SECTION 25 - FRONT AXLES

In order to extract the ring gear carrier from its housing, use at least two of the just removed screws (1) and screw them in the threaded holes they were extracted from.

Remove the ring gear carrier (2) together with the ring gear (3).

Only if necessary, remove the bushings (4) of the ring gear carrier.

Remove the snap ring (5).

SECTION 25 - FRONT AXLES

Slide out the wheel hub (6), using levers and a hammer to facilitate the operation.

NOTE: recuperate the bearing (7).

Position the wheel hub (6) on a flat surface and extract the seal ring (8).

NOTE: destructive operation for the seal ring.

Take out the bearing cups (7) and (9) with a driver and a hammer.

To unscrew and replace the worn stud bolts (10) of the wheel hub, use a nut and a locknut. Warm up the screwed part, if necessary.

41

42

SECTION 25 - FRONT AXLES

Remove the bearing (9).

ASSEMBLY The special operation “Set Right” of the bearings does not require preload or backlash adjustment.

Anyway, before assembling new components, check the indicated dimensions.

A= 08.450 ÷ 08.500 mm (0.332 ÷ 0.334 in) B = 54.775 ÷ 54.825 mm (2.156 ÷ 2.158 in) C = 23.070 ÷ 23.172 mm (0.908 ÷ 0.912 in)

Heat the bearing (9) to 80 ÷ 100 °C (176 ÷ 212 °F).

Assemble the bearing on the wheel shaft.

S WARNING Wear safety gloves.

Apply some Loctite 242 on the stud bolt threads (10) and tighten them to the prescribed torque of 70 Nm (51.62 lbf·ft) using two nuts (nut and locknut).

SECTION 25 - FRONT AXLES

Position the wheel hub (6) on a workbench and assemble the bearing cups (7) and (9).

Fit the seal ring (8) onto the wheel hub (6).

Insert the wheel hub (6) on the wheel shaft.

Heat the bearing (7) to 80 ÷ 100 °C (179 ÷ 212 °F) and assemble it.

S WARNING Wear safety gloves.

Position the ring gear carrier (2) on a workbench and assemble the bushings (4) at surface level.

At least two bushings (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.

Preassemble the ring gear carrier (2) and the ring gear (3) with the snap ring (5).

43

44

SECTION 25 - FRONT AXLES

Assemble the ring gear carrier assy (2) and the ring gear (3) on the wheel hub using the two projecting bushings (4) as dowel pins.

Assemble the bushings (4) and completely insert them.

Apply some Loctite 242 on the thread of the screws (1).

Screw in the screws (1) and tighten them to the prescribed torque of 95 Nm (70.06 lbf·ft).

SECTION 25 - FRONT AXLES 5.7

WHEEL SHAFT (21E)

DISASSEMBLY Extract the short half axle (1).

45

46

SECTION 25 - FRONT AXLES

Loosen and remove the screws (19).

S WARNING Do not drop the wheel shaft and, if necessary, hold it by means of a rope.

Remove the wheel shaft (2).

Remove the seal ring (6).

Turn the wheel shaft upside down. Position the wheel shaft on a flat surface and extract the bushing (5) using a hammer and the driver 380002229.

SECTION 25 - FRONT AXLES

Extract the long half shaft (17).

Remove the sleeve (15). If necessary, remove the elastic ring (16) from inside the sleeve.

ASSEMBLY Install the bushing (5) onto the wheel shaft.

Turn the wheel shaft upside down and install the seal ring (6).

Check that the elastic ring (16) is assembled to the sleeve (15).

Assemble the sleeve (15) to the long half shaft (17).

Insert the long half shaft (17) in the axle beam (18).

47

48

SECTION 25 - FRONT AXLES

Before matching worked surfaces, make sure they are perfectly clean. Degrease and clean with appropriate detergents. Spread a film of sealant on contact surface between the axle beam and the wheel shaft.

NOTE: check that the pins (10) remain in their housings.

Assemble the wheel shaft (2) and fasten it with the screws (19). Tighten the screws (19) to the prescribed torque of 190 Nm (140.13 lbf·ft).

Remove the short half axle (1) from the wheel shaft (2).

SECTION 25 - FRONT AXLES 5.8

BRAKE AND WHEEL SHAFT (121E, 221E, 321E “STANDARD” and “HIGH SPEED”)

49

50

SECTION 25 - FRONT AXLES

DISASSEMBLY Extract the short half axle (1).

Loosen and remove the breather valve (20).

Loosen and remove the screws (19).

S WARNING Do not drop the wheel shaft and, if necessary, hold it by means of a rope.

Remove the wheel shaft (2) paying attention not to drop the brake disc (13) and the gear (15).

Remove the counterdisc (14).

SECTION 25 - FRONT AXLES

Remove the brake disc (13) and the gear (15).

If necessary, remove the elastic ring (16) from inside the gear (15).

Loosen and remove the screw of the self-adjust kit (11) and of the brake piston return kit (12).

Take out the relevant components.

Check the operating condition and wear of kit components (11) and (12).

To extract the brake piston (8) use the hydraulic connection applying the lowest oil or air pressure necessary to dislodge the piston.

S WARNING This operation must be performed with extreme care.

51

52

SECTION 25 - FRONT AXLES

Remove the O-rings (7) and (9) from the brake piston (8).

With a hammer and a driver remove the three pins of the self-adjust kit (9) from the brake piston (8).

Remove the seal ring (6).

Turn the wheel shaft upside down. Position the wheel shaft on a flat surface and extract the bushing (5).

SECTION 25 - FRONT AXLES

Extract the long half shaft (17) from the axle beam (18).

ASSEMBLY Install the bushing (5) onto the wheel shaft.

Turn the wheel shaft upside down and install the seal ring (6).

Assemble the split pin of the self-adjust kit (11) in the brake piston.

53

54

SECTION 25 - FRONT AXLES

Clean the piston and the O-ring seat.

Grease the O-ring seat.

Grease and install the O-rings (7) and (9).

Position a flat disc on the piston. With a lever anchored to an eyebolt, exert just enough pressure to insert the piston into the wheel shaft.

S WARNING Pay attention not to damage the O-rings.

Remove the components of the self-adjust kit (11) and piston return kit (12) and assemble them on the piston.

Tighten the screws of the kits to the prescribed torque of 10 Nm (7.37 lbf·ft).

SECTION 25 - FRONT AXLES

Assemble the counterdisc (14).

Insert the long half shaft (17) in the axle beam (18).

Check that the elastic ring (16) is assembled to the gear (15).

Install the brake disc (13).

S WARNING The pin (10) of the brake disc (13) must be oriented downwards.

Before matching worked surfaces, make sure they are perfectly clean. Degrease and clean with appropriate detergents. Spread a film of sealant on contact surface between the axle beam and the wheel shaft.

NOTE: check that the pins (10) remain in their housings.

55

56

SECTION 25 - FRONT AXLES

Install the wheel shaft (2) and fasten it with the screws (19). Tighten the screws (19) to the prescribed torque of 190 Nm (140.13 lbf·ft).

Screw in and tighten the breather valve (20) to the prescribed torque of 12 Nm (8.85 lbf·ft).

Insert the short half axle (1).

SECTION 25 - FRONT AXLES 5.9

DIFFERENTIAL SUPPORT

DISASSEMBLY Loosen and remove the screws (2).

57

58

SECTION 25 - FRONT AXLES

To extract the differential support (1), tighten two screws in the threaded holes of the differential support.

Then hold the differential support (1) with a rope or other appropriate means and remove it.

Loosen and remove the screws (6) to extract the 2 ring nut retainers (5).

Before removing the screws, mark both half collars and the differential support with permanent reference marks, in order not to invert them during reassembly. Also mark the area between the ring nuts (3) and (7) and the differential support (1).

Loosen the adjusting ring nuts (3) and (7) with the wrench 380002827 (a1).

SECTION 25 - FRONT AXLES

Loosen and remove the 4 screws (11) and both half collars (10).

Check that the bushings (9) remain in their housings.

Remove the differential assy (13).

Remove the bearings (4) and (8) from the differential assy.

ASSEMBLY Assemble the bearings (4) and (8) on the differential assy (1).

S WARNING Do not invert the bearing cups if the bearings are replaced.

59

60

SECTION 25 - FRONT AXLES

Assemble the differential assy complete with bearings (13) on the differential support (1).

S WARNING Check the correct mounting side of the ring gear.

Move the differential assy so as to place the ring gear in contact with the pinion.

Check that all bushings (9) are in their relevant seats and position both half collars (10) by means of the previously traced reference marks.

Fasten both half collars (10) with the screws (11).

Assemble the adjusting ring nuts (3) and (7) to the differential support.

Tighten the two ring nuts (3) and (7) with the wrench 380002827 (a1) until backlash is eliminated and slightly load the differential bearings.

Check that the differential bearings are well settled; if necessary, hit them with a rubber hammer.

Position a magnetic-base dial gauge on the differential support, so that the feeler touches the surface of one tooth of the ring gear at a 90° angle.

SECTION 25 - FRONT AXLES

Holding the pinion, move the ring gear alternatively and note the backlash between the pinion and the ring gear, measured with the dial gauge.

Repeat the operation on two or more points (teeth), rotating the crown gear, so that to obtain an average value.

Check if the measured backlash value is within the requested range: 0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in) Carry out the adjustment by means of the adjusting ring nuts with the wrench 380002827.

Adjust the ring nuts (3) and (7), remembering that:  (A) if the measured backlash is greater than the given tolerance range, unscrew the ring nut (3) and screw in the ring nut (7) by the same measure;  (B) if the measured backlash is less than the given tolerance range, unscrew the ring nut (7) and screw in the ring nut (3) by the same measure.

After pinion-ring gear backlash adjustment, check that there is a minimum preload on the differential box bearings.

Repeat the whole sequence of the above mentioned operations until the indicated conditions are reached.

61

62

SECTION 25 - FRONT AXLES

Once the pinion-ring gear backlash has been adjusted, measure the total preload (T) of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on the pinion end. The measured value should be within the following range: T = (P + 3.1) ÷ (P + 4.7) daN T = (P + 6.96) ÷ (P + 10.56) lbf where P is the effectively measured pinion preload.

S WARNING All preloads must be measured without seal ring.

If the measurement is not within the requested range, accurately check the assembly of each single component and operate on the adjusting ring nuts (3) and (7) of the differential support:  if the total preload is lower than the given range, screw in both ring nuts (3) and (7) by the same measure, keeping the value of the pinion-ring gear (A) backlash unchanged;  if the total preload is higher than the given range, loosen both ring nuts (3) and (7) by the same measure, keeping the value of the pinion-ring gear (B) backlash unchanged.

Once the adjustment is complete, screw in and tighten the screws (11) to the prescribed torque of 266 Nm (196.19 lbf·ft).

Check total preload of bearings.

SECTION 25 - FRONT AXLES

Once all the adjustment operations have been completed, assemble the ring nut retainers (5) and the relevant screws (6), tightening them to the prescribed torque of 13 Nm (9.58 lbf·ft).

Before coupling the surfaces, make sure that they are perfectly clean, degrease and clean them with appropriate detergents.

Spread an adhesive film on the contact surface between the axle beam and the differential support.

NOTE: check that the pins (12) remain in their housings.

Position the differential support (1) on the axle beam and tighten the screws (2) to the prescribed torque of 169 Nm (124.64 lbf·ft).

63

64

SECTION 25 - FRONT AXLES

BEVEL GEAR CHECK To check the contact marks of the bevel gear teeth, paint the bevel gears with red lead paint.

Check the contact marks of the ring gear teeth and on both sides.

OK -> Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular.

Z -> Excessive contact on the tooth tip: Bring the pinion closer to the ring gear and then move the ring gear away from the pinion in order to adjust the backlash.

X -> Excessive contact at the tooth base: Move the pinion away from the ring gear and then approach the ring gear to the pinion in order to adjust the backlash.

Movements to correct: 1 -> move the pinion for type X contact adjustment.

2 -> move the pinion for type Z contact adjustment.

SECTION 25 - FRONT AXLES 5.10 DIFFERENTIAL ASSY

DISASSEMBLY Use a puller to remove the bearing (3).

65

66

SECTION 25 - FRONT AXLES

Use a puller to remove the bearing (24).

Loosen and remove all screws (1) from the ring gear (2).

S WARNING This will make both differential half boxes free, so take care not to loose the internal components.

Remove the ring gear (2) by using a hammer.

Check the reference marks that will be useful during assembly.

Separate the two differential half boxes (4) and (23).

SECTION 25 - FRONT AXLES

Remove the discs (5) and (6).

Remove the gear (8) and the shim (7).

Remove the shafts (9) and (14), the gears (10), (13), (15) and (17) and the spherical washers (11), (12), (16) and (18).

Remove the gear (19) and the shim (20).

67

68

SECTION 25 - FRONT AXLES

Remove the discs (21) and (22).

ASSEMBLY Apply a thin layer of grease on the differential half boxes (4) and (23).

Apply a thin layer of Molicote G-n plus on the gears (10), (13), (15) and (17) and on the gears (8) and (19).

Assemble discs (21) and (22).

SECTION 25 - FRONT AXLES

Assemble the gear (19) and the shim (20).

Position the shaft (9), the gears (15) and (17) and the spherical washers (16) and (18).

Position the shaft (14), the gears (10) and (13) and the spherical washers (11) and (12).

Assemble the gear (8) and the shim (7).

69

70

SECTION 25 - FRONT AXLES

Assemble discs (5) and (6).

Assemble the two differential half boxes (4) and (23).

S WARNING Carefully check that the reference marks of both differential half boxes are aligned.

Assemble the ring gear (2) by using a hammer.

Apply some Loctite 242 on the thread of the screws (1).

SECTION 25 - FRONT AXLES

Screw in and tighten the screws (1) to the prescribed torque of 95 Nm (70.06 lbf·ft).

Install the bearing (3).

Install the bearing (24).

71

72

SECTION 25 - FRONT AXLES

5.11 PINION

DISASSEMBLY Position the differential assy in a vice.

Loosen the ring nut (10) with the wrenches 380002828 and 380002830.

NOTE: this operation irreparably damages the ring nut (10).

SECTION 25 - FRONT AXLES

Tap the shaft end with a rubber hammer to extract the pinion (1).

S WARNING Prevent letting the pinion fall down.

Remove the shims (4) and (6), the spacer (5), the bearing (8) and the washer (9).

Take out the bearing cups (3) and (8).

Remove the bearing (3) from the pinion (1) using a puller.

Collect the shim (2).

73

74

SECTION 25 - FRONT AXLES

Check the conditions of all parts.

S WARNING The ring nut (10) and the spacer (5) must be replaced by reassembly.

ASSEMBLY Fit the bearing cups (3) and (8).

Prepare the kit consisting of the special tools called “false pinion” (a1) 380002219 and “false differential box” 380000407 (a2) and 380002214 (a3) and a depth gauge (a4).

Insert the bearings (3) and (8) into their housings.

Assemble the “false pinion” 380002219 and the ring nut (10).

Tighten without exceeding the ring nut, until the backlash is eliminated.

SECTION 25 - FRONT AXLES

Assemble the special tools “false differential box” 380000407 + 380002214 to the supports of the differential assy (7) and block by means of the half collar screws.

Mounting diagram of the tools of the “false differential box” on the seats of the differential support bearings.

Use a depth gauge to measure the dimension “X” (distance between the axis of the differential bearings and the leaning point of the pinion head or bearing base).

In order to determine the value (S) of the shim to be placed between pinion and bearing, subtract the value (V) stamped on the pinion head (V = prescribed bevel distance) from the measured value (X).

S = X - V mm (in)

Select the shim (2) with a value (S) among the range of available shims.

75

76

SECTION 25 - FRONT AXLES

Remove the “false differential box” special tool from the differential supports (7).

Remove the ring nut (10), the “false pinion” and the bearings (3) and (8).

After choosing and inserting the appropriate shim (2) with the chamfer oriented towards the gear, insert the bearing (3) into the pinion (1) using a press, making sure it is well set.

Insert the shims (4) and (6) and a new collapsible spacer (5).

NOTE: always use a new spacer (5).

Insert the pinion assy (1) into the differential support box (7) and the bearing (8).

It is recommended to contrast the hammering force with a resisting action, e.g. a mallet.

Insert the washer (9) and screw in a new ring nut (10) on the pinion.

SECTION 25 - FRONT AXLES

Screw in the ring nut (10) using the wrenches 380002828 and 380002830 for ring nut and pinion retainer.

S WARNING The torque setting is given by the measure of the preload on the bearings; gradually tighten the ring nut (10).

NOTE: if it is overtight, the collapsible spacer should be replaced and the procedure repeated. When you check the preload, it is advisable to slightly beat both pinion ends with a soft hammer, so as to help setting the bearings.

Carry out the preload measurement (P) of the bearings, using a dynamometer whose cord is wound on the splined end of the pinion (1).

The adjustment is carried out by increasing the ring nut torque gradually, being careful not to exceed.

S WARNING All preloads must be measured without seal ring.

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.79 lbf)

Once the prescribed preload value is achieved, caulk the ring nut (10) using a hammer and a punch.

77

78

6.

SECTION 25 - FRONT AXLES

TROUBLESHOOTING PROBLEMS

CAUSE

1

2

3

Wheel vibration; front tyre resistance; half shaft breakage.







Steering is difficult; the vehicle goes straight while it is turning.







No differential action; jams during steering.



Excessive noise of transmission.





Uneven wear of tyre.





Friction noise.



Vibration during forward run, intermittent noise.



1. Incorrect installation or defective axle Correct the installation or repair or replace the differential in case it does not survive any one of the test phases.

2. Overload or incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tyres If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with bigger radius will have to support all the work.

Replace the tyre or adjust pressure to have same radius on both tyres.

4. Broken axle beam It is not advisable to operate the vehicle with a broken axle beam. It is acceptable to move the vehicle (engine off unloaded) a few metres away only.

5. Bent axle beam Replace the axle beam.

6. Blocked differential Anomalous operation of the differential or breakage or blockage of the control device. Verify assembly and all components.

Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.



4

5

7

8

9

10 11































6



























7. Incorrect wheel adjustment Verify group integrity and wheel side bearings.

Adjusting according.

8. Spoiled or worn out axle parts Check the conditions of ring gear, of the pinion, of the bearings, etc.

Replace whenever necessary.

9. Contamination in the axle box or incorrect assembly of parts Look for foreign particles. Check assembly of the various parts of the axle.

10.Incorrect adjustment of bevel gear set: transmission components worn out (transmission gears, U joints, etc.)

Replace or adjust as required.

11.Incorrect use of the product See the vehicle producer’s instructions once again.

SECTION 25 - FRONT AXLES

FAULT

CAUSE

79

ACTION

Break towards the external end Excessive gear load compared to the of the ring gear tooth. one expected.

Gear adjustment wrong (excessive backlash).

Pinion nut loose.

Replace bevel gear.

Carefully observe the recommended operations for the adjustment of ring gear and pinion backlash and for tooth mark detection.

Break towards the internal end Crash load. of the ring gear tooth.

Gear adjustment wrong (insufficient backlash).

Pinion nut loose.

Replace bevel gear.

Carefully observe the recommended operations for the adjustment of ring gear and pinion backlash and for tooth mark detection.

Pinion teeth or ring gear teeth worn or scored.

Insufficient oil.

Contaminated oil.

Incorrect oil or with poor additives.

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Replace bevel gear.

Replace worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Use proper oil, fill up to the right level and change at recommended intervals.

Ring gear teeth or pinion teeth Prolonged operation at high temperaoverheated. Check if gear ture.

Incorrect oil. teeth have faded.

Oil level low.

Contaminated oil.

Replace bevel gear.

Use proper oil, fill up to the right level and change at recommended intervals.

Drive pinion teeth pitted.

Extremely intense use.

Insufficient oil.

Replace bevel gear.

Use proper oil, fill up to the right level and change at recommended intervals.

Bent axle beam body.

Machine overloaded.

Damaged vehicle.

Crash load.

Replace the axle beam body.

Bearings worn or pitted.

Insufficient oil.

Contaminated oil.

Extremely intense use.

Normal wear.

Pinion nut loose.

Replace bearings.

Use proper oil, fill up to the right level and change at recommended intervals.

Gaskets leak oil.

Prolonged operation at excessive oil temperature.

Oil gasket wrongly installed.

Gasket edge cut or scored.

Contaminated oil.

Replace the gasket and matching surface if damaged.

Use proper lubricant, fill up to right level and replace at recommended intervals.

Excessive wear of input flange Intense use. spline.

Pinion nut loose.

Pinion axial backlash.

Replace the flange.

Check that the pinion spline is not excessively worn out.

80

SECTION 25 - FRONT AXLES

FAULT

CAUSE

ACTION

Intense use.

Pinion gear tooth fatigue break. Check if the fracture line Continuous overload. is with wavy or clearly delineated (stop line).

Replace bevel gear.

Break of pinion and ring gear teeth.

Check and/or replace other differential components.

Crash load of differential components.

Splines of planetary gear worn Intense use. (excessive backlash).

Replace differential gear assy.

Replace axle beam, if necessary.

Surfaces of bearing worn or scratched.

Replace all scratched washers and those with a 0.1 mm (0.003 in) thickness lower than the new ones.

Use proper oil, fill up to the right level and change at recommended intervals.

Insufficient oil.

Incorrect oil.

Contaminated oil.

Inner diameter of pinion Intense use. tapered roller bearing worn out. Excessive pinion end play.

Insufficient oil.

Contaminated oil.

Replace bearing.

Check pinion axial backlash.

Use proper oil, fill up to the right level and change at recommended intervals.

Bent or broken axle beam.

Intense vehicle operation, overload.

Replace the axle beam.

Broken axle beam at wheel flange.

Wheel support loosen.

Axle beam body bent.

Replace the axle beam.

Check bending of axle beam body.

Ensure that wheel support is not worn out or wrongly adjusted.

SECTION 25 - FRONT AXLES

7.

81

SPECIAL TOOLS

Drivers and buffers for the assembly of gaskets, bearings and bushings must be used with the interchangeable handle 380002211; its use is recommended together with a safety handle for hand protection.

P/N CNH

NAME

21E

121E

221E

321E

380000407

False differential box

•

•

•

•

380002212

Key - Pinion nut

•

•

•

•

380002214

False differential tool

•

•

•

•

380002219

False pinion

•

•

•

•

380002827

Key - Differential ring nut

•

•

•

•

380002828

Key - Pinion nut

•

•

•

•

380002830

Key - Pinion support

•

•

•

•

380002831

Driver - Axle beam bushing

•

/

/

/

82 NOTES:

SECTION 25 - FRONT AXLES

SECTION 27 - REAR AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 3 3. TECHNICAL SPECIFICATIONS................................................................................................................... 7 4. OIL CHANGE.............................................................................................................................................. 14 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 18 5.1 MOTOR TB150 .................................................................................................................................... 18 5.2 MOTOR TB138.5 “HIGH SPEED” ....................................................................................................... 21 5.3 TRANSMISSION BOX TB150 ............................................................................................................. 25 5.4 TRANSMISSION TB138.5 “HIGH SPEED” ......................................................................................... 34 5.5 REDUCTION GEAR (21E)................................................................................................................... 54 5.6 REDUCTION UNIT (121E, 221E, 321E).............................................................................................. 57 5.7 WHEEL HUB (21E).............................................................................................................................. 61 5.8 WHEEL HUB (121E, 221E, 321E) ....................................................................................................... 70 5.9 WHEEL SHAFT (121E, 221E, 321E)................................................................................................... 76 5.10 DIFFERENTIAL SUPPORT ............................................................................................................... 80 5.11 DIFFERENTIAL ASSY....................................................................................................................... 88 5.12 LIMITED SLIP DIFFERENTIAL ASSY............................................................................................... 94 5.13 PINION............................................................................................................................................. 101 6. TROUBLESHOOTING.............................................................................................................................. 107 7. SPECIAL TOOLS...................................................................................................................................... 110

SECTION 27 - REAR AXLES

SECTION 27 - REAR AXLES

1

It is possible to install different types of rear axles:

Standard differential STANDARD Limited slip differential “HIGH SPEED”

1.

1.

2.

3.

4.

5.

6.

Limited slip differential

21E

121E

221E

321E

CA147194



/

/

/

CA147189

/





/

CA147186

/

/

/



CA150145



/

/

/

CA150146

/





/

CA150147

/

/

/



CA147187

/







REMOVAL AND INSTALLATION

Rear axle Screw Nut Pin Hose Wheel

7.

8.

9.

10.

11.

12.

Nut Cup Hose Cardan shaft Hose Hose

2

SECTION 27 - REAR AXLES

NOTE: the drawing shows a standard rear axle, the procedure for the high speed rear axle is the same.

REMOVAL Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Remove the cups (8) and unscrew nuts (7) from both sides.

Remove the two wheels (6).

Disconnect the cardan shaft (10).

Position the fork-lift truck laterally with the forks under the rear axle (1), lift the rear axle and support it.

Disconnect the hoses (5) and (9).

Disconnect the hoses (11) and (12) from the hydraulic motor.

Unscrew and remove the screw (2) and the nut (3).

Slide out the pin (4).

Lower the forks and remove the rear axle (1).

INSTALLATION The assembly of the rear axle is to be carried out in the reverse order.

Fill in oil in the reduction gears, in the transmission box and in the axle body.

Lubricate the axle floating.

SECTION 27 - REAR AXLES

2.

DIMENSIONS

CA147194 - CA150145 (21E)

3

4

SECTION 27 - REAR AXLES

CA147189 - CA150146 (121E, 221E)

SECTION 27 - REAR AXLES CA147186 - CA150147 (321E)

5

6

SECTION 27 - REAR AXLES

CA147187 (121E, 221E, 321E) “HIGH SPEED”

SECTION 27 - REAR AXLES

3.

7

TECHNICAL SPECIFICATIONS

REAR AXLES CA147194 - CA150145 (21E) (*) These two axles differ for the type of differential installed: CA147194: standard differential CA150145: limited slip differential Model Differential type Dry weight

28.16 - TB150 * 255 kg (561 lb)

Bevel gear reduction ratio

2.91 / 1

Reduction gear ratio

6.00 / 1

Transmission box reduction ratio

2.257 / 1

Total reduction ratio

39.38 / 1

Input rotation direction

counterclockwise

Bevel gear play

0.18 ÷ 0.23 mm (0.007 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.79 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T = (P + 3.1) ÷ (P + 4.7) daN T = (P + 6.70) ÷ (P + 10.56) lbf

Differential oil capacity

7.5 litres (2 gal)

Reduction gear oil capacity (each side)

0.7 litres (0.18 gal)

Transmission box oil capacity

0.75 litres (0.19 gal)

8

SECTION 27 - REAR AXLES

REAR AXLES CA147189 - CA150146 (121E, 221E) (*) These two axles differ for the type of differential installed: CA147189: standard differential CA150146: limited slip differential Model Differential type Dry weight

28.20 - TB150 * 251 kg (552 lb)

Bevel gear reduction ratio

3.66 / 1

Reduction gear ratio

6.00 / 1

Transmission box reduction ratio

2.257 / 1

Total reduction ratio

49.65 / 1

Input rotation direction

counterclockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf

Differential oil capacity

8 litres (2.10 gal)

Reduction gear oil capacity (each side)

0.7 litres (0.18 gal)

Transmission box oil capacity

0.75 litres (0.19 gal)

SECTION 27 - REAR AXLES

9

REAR AXLES CA147186 - CA150147 (321E) (*) These two axles differ for the type of differential installed: CA147186: standard differential CA150147: limited slip differential Model Differential type Dry weight

28.20 - TB150 * 276 kg (607 lb)

Bevel gear reduction ratio

3.66 / 1

Reduction gear ratio

6.00 / 1

Transmission box reduction ratio

2.053 / 1

Total reduction ratio

45.166 / 1

Input rotation direction

counterclockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf

Differential oil capacity

8 litres (2.10 gal)

Reduction gear oil capacity (each side)

0.7 litres (0.18 gal)

Transmission box oil capacity

0.75 litres (0.19 gal)

10

SECTION 27 - REAR AXLES

REAR AXLE “HIGH SPEED” CA147187 (121E, 221E, 321E) Model

28.20 - TB138.50

Differential type

limited slip

Dry weight

...... kg (lb)

Bevel gear reduction ratio

3.66 / 1

Reduction gear ratio

6.00 / 1

Transmission box reduction 1st gear

2.75 / 1

Total reduction 1st gear

60.5 / 1

Transmission box reduction 2nd gear

1.163 / 1

Total reduction 2nd gear

25.28 / 1

Input rotation direction

counterclockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf

Differential oil capacity

8 litres (2.10 gal)

Reduction gear oil capacity (each side)

0.7 litres (0.18 gal)

Transmission box oil capacity

0.75 litres (0.19 gal)

SECTION 27 - REAR AXLES TIGHTENING TORQUES

11

12

SECTION 27 - REAR AXLES

SECTION 27 - REAR AXLES

13

LIMITED SLIP DIFFERENTIAL DISCS THICKNESS

New counterdisc thickness = 1.5 ± 0.03 mm (0.059 ± 0.001 in) Worn counterdisc minimum thickness = 1.4 mm (0.055 in) Disc ref. CA110643 - q.ty 10

New friction disc thickness = 1.6 ± 0.03 mm (0.062 ± 0.001 in) Worn disc minimum thickness = 1.45 mm (0.057 in) Disc ref. CA110644 - q.ty 8

Disc ref. CA110642 - q.ty 2 New friction disc thickness = 2.8 ± 0.03 mm (0.11 ± 0.001 in) Worn disc minimum thickness = 2.7 mm (0.10 in)

14

4.

SECTION 27 - REAR AXLES

OIL CHANGE

Oil filler and level plug

1

Oil drain plug

2

Filler, level and drain plug for reduction gear oil

3

Air breather valve

4

Oil filler and level plug of transmission box

5

Transmission box oil drain plug

6

Transmission box air breather

7

Greasing points

8

SECTION 27 - REAR AXLES

Before draining the oil from the central axle body, operate the relevant air breather valve (4) to eliminate any possible internal pressure.

To drain the oil from the central axle body, unscrew the level plug (1) first, then the drain plug (2).

Drain the oil completely.

Clean the drain plug (2), screw it back in and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

Unscrew the oil filler plug (1) and fill in specified oil up to the level hole.

Wait for the oil to flow into the axle, then check the level and top up, if necessary.

Screw the filler plug (1) back in and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

Before draining the oil from the reduction gear, turn the gear so that the plug (3) is in the highest possible position [position A].

Partially unscrew the plug to release any possible internal pressure.

Rotate the reduction gear with the plug (3) oriented downwards [position B].

Remove the plug and drain the oil completely.

15

16

SECTION 27 - REAR AXLES

Rotate the reduction gear until the hole of the plug (3) is in horizontal position.

Fill in oil. The oil level should be flush with the hole.

Screw the plug back in and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

Always operate the relevant air breather valve (4) to eliminate any possible internal pressure before loosening the oil drain plug (6).

To drain the oil from the transmission box, loosen the plug (6). Let the oil drain completely, clean the plug (6), screw it in and tighten it to the prescribed torque of 70 Nm (51.62 lbf·ft).

Always operate the relevant air breather valve (4) to eliminate any possible internal pressure before loosening the oil filler plug (5).

Fill with oil up to the plug hole (5).

Wait for the oil to flow into the box, then check the level and top up, if necessary.

Check that the oil level in the transmission box is approximately 20 mm (0.78 in) from the output axle. If necessary, top up with oil to respect the previous reference measure.

Screw the filler plug (5) back in and tighten it to the prescribed torque of 70 Nm (51.62 lbf·ft).

SECTION 27 - REAR AXLES

Only for “HIGH SPEED” axle Always operate the relevant air breather valve (7) to eliminate any possible internal pressure before loosening the oil drain plug (6).

To drain the oil from the transmission box, loosen the plug (6). Let the oil drain completely, clean the plug (6), screw it in and tighten it to the prescribed torque of 70 Nm (51.62 lbf·ft).

Always operate the relevant air breather valve (7) to eliminate any possible internal pressure before loosening the oil filler plug (5).

Fill with oil up to the level plug hole (5).

Wait for the oil to flow into the box, then check the level and top up, if necessary.

Check that the oil level in the transmission box is approximately 67 mm (2.63 in) from the output axle. If necessary, top up with oil to respect the previous reference measure.

Screw the filler plug (5) back in and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

17

18

5.

SECTION 27 - REAR AXLES

DISASSEMBLY AND ASSEMBLY

Some of the following pictures could not show exactly the installed axle, but the procedure is the same.

5.1

MOTOR TB150

DISASSEMBLY

S WARNING Before performing any operation on the axle, drain the oil.

Support the motor with a rope or other appropriate means.

Loosen and remove the screws (2).

Remove the motor (1) from the transmission box (7).

SECTION 27 - REAR AXLES

Remove the O-ring (3).

Loosen and remove the screw (6) and the washer (5). Remove the gear (4) from the motor (1).

ASSEMBLY Assemble the gear (4) onto the motor (1).

Apply some Loctite 242 on the thread of the screw (6).

Screw in and tighten the screw (6) to the prescribed torque.

Assemble the new O-ring (3).

19

20

SECTION 27 - REAR AXLES

Assemble the motor (1) onto the transmission box and fasten it with the screws (2).

Tighten the screws (2) to the prescribed torque of 280 Nm (206.51 lbf·ft).

SECTION 27 - REAR AXLES 5.2

MOTOR TB138.5 “HIGH SPEED”

DISASSEMBLY

S WARNING Before performing any operation on the axle, drain the oil.

Support the motor with a rope or other appropriate means.

Loosen and remove the screws (2).

Remove the motor (1) from the transmission box (6).

21

22

SECTION 27 - REAR AXLES

Remove the O-ring (3).

Remove the gear (4) from the transmission box (6).

Use a puller to remove the bearing (5).

Use a puller to remove the bearing cup (5) from the transmission box (6).

SECTION 27 - REAR AXLES ASSEMBLY Assemble the bearing cup (5) onto the transmission box (6).

Heat the bearing (5) to 80 ÷ 100 °C (176 ÷ 212 °F).

Assemble the bearing (5) on the gear (4) with a soft hammer.

S WARNING Wear safety gloves.

Assemble the gear (4) on the transmission box (6).

Assemble the new O-ring (3).

23

24

SECTION 27 - REAR AXLES

Assemble the motor (1) onto the transmission box (6) and fasten it with the screws (2).

Tighten the screws (2) to the prescribed torque of 280 Nm (206.51 lbf·ft).

SECTION 27 - REAR AXLES 5.3

TRANSMISSION BOX TB150

DISASSEMBLY Loosen and remove the screws (14).

Remove the transmission box (4).

S WARNING Support the transmission box with a rope or other appropriate means.

Remove the O-ring (13).

25

26

SECTION 27 - REAR AXLES

Position the transmission box (4) on a workbench.

Remove the elastic ring (12) from the shaft (1).

Remove the shaft (1) from the transmission box (4) with a hammer and a driver.

Remove the protection (2) from the shaft (1), if necessary.

NOTE: destructive operation for the protection (2).

Unscrew and remove the screws (11) of the flange (10).

In order the remove the flange (10) from its seat, screw in two M8 screws in the extraction holes.

Remove the O-ring (7).

SECTION 27 - REAR AXLES

Place the flange on an appropriate support.

Remove the bearing (8) from the flange (5).

Remove the bearing (8) and the shims (9).

Take out the gear (6).

Remove the seal ring (3).

NOTE: destructive operation for the seal ring.

Remove the bearing (5) from the transmission box (4).

27

28

SECTION 27 - REAR AXLES

ASSEMBLY Install the bearing (5) into the transmission box.

Turn the transmission box (4) upside down and install the seal ring (3).

NOTE: lubricate seal ring with grease.

Install the protection (2) on the shaft (1).

Assemble the shaft (1) on the transmission box (4).

SECTION 27 - REAR AXLES

Turn the transmission box upside down. Assemble the gear (6) on the shaft (1).

Assemble the bearing (8).

Assemble the elastic ring (12) onto the shaft (1).

Clean the transmission box (4) surface.

Measure dimension A on the bearing (8).

29

30

SECTION 27 - REAR AXLES

Clean the surface of the flange (5).

Measure the dimension B on the flange (5).

Measure the dimension C on the flange (5).

SECTION 27 - REAR AXLES

To determine the dimension (S) of the shim required between the bearing (8) and the flange (5), calculate: S = [A - (C - B) - 0.1] mm S = [A - (C - B) - 0.003] in where 0.1 mm (0.003 in) is the final backlash between the bearing (8) and the flange (5).

Select the shim (9) with a value (S) among the range of available shims.

Slightly grease the seats of the shims (9). Assemble the shims (9) on the flange (5).

31

32

SECTION 27 - REAR AXLES

Grease the O-ring (7) and install it on the flange (5).

Before matching worked surfaces, make sure they are perfectly clean, if not, clean with proper detergents.

Spread a film of sealant on the contact surface of the transmission box (4) and of the flange (5).

Assemble the flange (5) to the transmission box (4) with a soft hammer.

Apply some Loctite 242 on the thread of the screws (11).

Screw in and tighten the screws (11) to the prescribed torque of 23 Nm (16.97 lbf·ft).

S WARNING Do not damage the O-ring during assembly operations.

Install the new O-ring (13).

S WARNING Support the transmission box with a rope or other appropriate means.

Assemble the transmission box (4) on the axle (15).

Apply some Loctite 242 on the thread of the screws (14). Tighten the screws (14) to the prescribed torque of 70 Nm (51.62 lbf·ft).

SECTION 27 - REAR AXLES

Top up the oil in the transmission box.

Assemble the filler and level plug (A) and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

33

34 5.4

SECTION 27 - REAR AXLES TRANSMISSION TB138.5 “HIGH SPEED”

SECTION 27 - REAR AXLES DISASSEMBLY Loosen and remove the screws (1).

Remove the transmission box (33).

S WARNING Support the transmission box with a rope or other appropriate means.

Remove the O-ring (2).

Remove the sleeve (47).

Remove the O-ring (46) from the sleeve (47).

Remove the O-ring (41).

35

36

SECTION 27 - REAR AXLES

Unscrew the piston (45).

Remove the piston (45), the spring seat (44) and the spring (43).

Remove the spring seat (42). Loosen and remove the fitting (40) and the O-ring (38).

Unscrew and remove the screws (4) of the flange (5).

SECTION 27 - REAR AXLES

In order the remove the flange (5) from its seat, screw in two M8 screws in the extraction holes.

Remove the O-ring (6).

Remove the bearing cup (12) by means of a puller.

Remove the 2 seal rings (3).

NOTE: destructive operation for the seal rings.

37

38

SECTION 27 - REAR AXLES

Loosen and remove the screw (7).

Remove the gear assy.

Use a buffer to remove the gear (8).

Use a buffer to remove the splined sleeve (10).

SECTION 27 - REAR AXLES

Remove the shim (15).

Remove the splined sleeve (10), the bearing (14), the shim (13) and the bearings (12).

Remove the O-ring (9). If necessary, remove the elastic ring (11) from the splined sleeve (10).

Remove the bearing (18).

39

40

SECTION 27 - REAR AXLES

Remove the elastic ring (17).

Remove the fork assy (23).

Remove the gear (20) and the ring (19).

Loosen and remove the screw (25).

SECTION 27 - REAR AXLES

Remove the shim (24) and the shaft (21). Remove the fork (23) and both shims (22).

Remove the gear (27).

Remove the bearing (29).

Remove the elastic rings (26) and (28).

41

42

SECTION 27 - REAR AXLES

Remove the bushing (30).

Remove the shaft (37) using a soft hammer.

Remove the bearing (31) and the shim (32).

Remove the seal ring (36) with a puller.

NOTE: destructive operation for the seal ring.

SECTION 27 - REAR AXLES

Remove the elastic ring (35).

Remove the bearing (34).

43

44

SECTION 27 - REAR AXLES

ASSEMBLY Install the bearing (34).

Install the elastic ring (35).

Turn the transmission box (33) upside down and install the seal ring (36).

NOTE: lubricate seal ring with grease.

Insert the shaft (37).

Install the shaft (37) on the transmission box (33).

SECTION 27 - REAR AXLES

Assemble the shim (32) and the bearing (31) on the shaft (37).

Install the bearing (31) on the shaft (37).

Insert the bushing (30) on the shaft (37).

Insert the elastic rings (26) and (28) on the gear seats (27).

45

46

SECTION 27 - REAR AXLES

Install the bearing (29) into the gear (27).

Assemble the gear (27) - bearing (29) assy on the shaft (37).

Correctly position the gear (27) - bearing (29) assy.

Insert the 2 shims (22) on the fork (23). Assemble the shaft (21) on the fork (23). Insert the washer (24) on the screw (25).

Apply some Loctite 242 on the thread of the screw (25).

Screw in and tighten the screw (25).

SECTION 27 - REAR AXLES

Install the gear (20) on the shaft (37).

Insert the ring (19) on the fork (23).

Assemble the assy on the transmission box and on the gear (20).

Install the elastic ring (17) on the gear seat (16).

Assemble the bearing (18) on the gear (16).

47

48

SECTION 27 - REAR AXLES

Check that the elastic ring (11) is already assembled on the splined sleeve (10).

Install the O-ring (9) on the splined sleeve (10).

Install the bearing (12) on the splined sleeve (10).

Insert the shim (13).

Install the bearing (14) on the splined sleeve (10).

S WARNING The following operations must be carried out in quick sequence to exploit the heat expansion of bearing (18) and gear (16).

Heat the bearing (18) to 80 ÷ 100 °C (176 ÷ 212 °F) for 15 minutes.

Install the bearing (18) into the gear (16).

SECTION 27 - REAR AXLES

Insert the shim (15) on the splined sleeve (10).

Install the gear (16) on the splined sleeve (10).

Assemble the gear - splined sleeve assy on the shaft (37).

Assemble the gear (8) on the screw (7).

Apply some Loctite 242 on the thread of the screw (7).

49

50

SECTION 27 - REAR AXLES

Screw in and tighten the screw (7) to the prescribed torque of 140 Nm (103.25 lbf·ft).

Install the bearing cup (12) on the flange (5).

Turn the flange (5) upside down and install the two seal rings (3).

NOTE: lubricate the seal rings with grease.

Grease the O-ring (6).

Assemble the O-ring (6) on the flange (5).

Before matching worked surfaces, make sure they are perfectly clean, if not, clean with proper detergents.

Spread a film of sealant on the contact surface of the transmission box (33) and of the flange (5).

Assemble the flange (5) to the transmission box (33) with a soft hammer.

SECTION 27 - REAR AXLES

Apply some Loctite 242 on the thread of the screws (4). Tighten the screws (4) to the prescribed torque of 23 Nm (16.97 lbf·ft).

Assemble two new O-rings (39) and (38) on the fitting (40).

Apply some Loctite 242 on the thread of the fitting (40).

Screw in the fitting (40) and tighten it to the prescribed torque of 125 Nm (92.20 lbf·ft).

51

52

SECTION 27 - REAR AXLES

Install the spring seat (42), the spring (43) and the spring seat (44) on the shaft (21).

Apply some Loctite 242 on the thread of the shaft (21).

Install the piston (45) onto the shaft (21).

Tighten the piston (45) to the prescribed torque of 140 Nm (103.26 lbf·ft).

Assemble a new O-ring (41) in the fitting (40).

Assemble a new O-ring (46) in the sleeve (47).

SECTION 27 - REAR AXLES

Assemble the sleeve (47) and tighten it to the prescribed torque of 125 Nm (92.20 lbf·ft).

S WARNING Do not damage the O-ring during assembly operations.

Install the new O-ring (2).

S WARNING Support the transmission box with a rope or other appropriate means.

Assemble the transmission box (33) on the axle.

Apply some Loctite 242 on the thread of the screws (1). Tighten the screws (1) to the prescribed torque of 123 Nm (90.72 lbf·ft).

Top up the oil in the transmission box.

Screw in the filler and level plug (A) and tighten it to the prescribed torque of 70 Nm (51.62 lbf·ft).

53

54 5.5

SECTION 27 - REAR AXLES REDUCTION GEAR (21E)

DISASSEMBLY Unscrew and remove the plug (2).

Drain the oil completely from the reduction gear.

SECTION 27 - REAR AXLES

Unscrew and remove the screws (3) of the planetary carrier cover (1).

Remove the planetary carrier cover (1) and collect the relevant O-ring (5).

Position the planetary gear carrier (1) onto a workbench and check its wear conditions.

If necessary, replace the gears as follows:  remove the elastic rings (10) from each pin (4);  remove the triangular plate (9);  take out the gears (8) from the pins;  collect the bearings (7) checking their conditions;  collect the washers (6).

ASSEMBLY Collect all reduction gear parts: the planetary gear carrier (1), the washers (6), the gears (8) and the bearings (7), the triangular plate (9) and the elastic rings (10) of each pin.

NOTE: with new gears, it is advisable to assemble new bearings.

55

56

SECTION 27 - REAR AXLES

Position the planetary gear carrier (1) on a workbench.

Insert the washers (6) and the gears (8) into the planetary gear carrier pins.

Insert the bearings (7) into the gears (8).

NOTE: thoroughly grease the bearings.

Assemble the triangular plate (9) and the elastic rings (10).

Insert a new O-ring (5) onto the planetary gear carrier (1).

Assemble the planetary gear carrier (1) to the wheel hub.

Screw in and tighten the screws (3) to the prescribed torque of 25 Nm (18.43 lbf·ft).

Top up the oil on the wheel hub.

Screw in the plug (2) onto the planetary gear carrier (1) and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

SECTION 27 - REAR AXLES 5.6

REDUCTION UNIT (121E, 221E, 321E)

DISASSEMBLY Unscrew and remove the plug (2).

Drain the oil completely from the reduction gear.

57

58

SECTION 27 - REAR AXLES

Unscrew and remove the screws (3) of the planetary carrier cover (1).

Remove the planetary carrier cover (1) and collect the relevant O-ring (4).

Position the planetary gear carrier (1) onto a workbench and check its wear conditions.

If necessary, replace the gears as follows:  remove the elastic rings (10) from each pin (5);  check the washers (9);  take out the gears (7) from the pins (5);  collect the bearings (6) and (8) checking their condition.

SECTION 27 - REAR AXLES ASSEMBLY Collect all reduction gear parts: the planetary gear carrier (1), the elastic rings (10), the washers (9), the gears (7) and the bearings (6) and (8).

NOTE: with new gears, it is advisable to assemble new bearings.

Position the planetary gear carrier (1) on a workbench.

NOTE: thoroughly grease the bearings.

Insert the bearings (6) and (8) into the gears (7).

Insert the gears (7) into the pins (5) of the planetary gear carrier (1).

Assemble the washers (9) and the elastic rings (10) onto the pins of the planetary gear carrier (1).

Insert a new O-ring (4) onto the planetary gear carrier (1).

Assemble the planetary gear carrier (1) to the wheel hub.

Screw in the screws (3) and tighten them to the prescribed torque of 25 Nm (18.43 lbf·ft).

59

60

SECTION 27 - REAR AXLES

Top up the oil on the wheel hub.

Screw in the plug (2) onto the planetary gear carrier (1) and tighten it to the prescribed torque of 60 Nm (44.25 lbf·ft).

SECTION 27 - REAR AXLES 5.7

WHEEL HUB (21E)

DISASSEMBLY Before disassembling the wheel hub, secure it with a belt or a rope to a hoist or other support, to prevent it from accidentally falling down, which could injury the operator and damage the wheel hub.

Unscrew and remove the screws (1) of the ring gear carrier.

61

62

SECTION 27 - REAR AXLES

In order to extract the ring gear carrier from its housing, use at least two of the just removed screws (1) and screw them in the threaded holes they were extracted from.

Remove the ring gear carrier (2) together with the ring gear (3).

Only if necessary, remove the bushings (4) of the ring gear carrier.

Remove the snap ring (5).

SECTION 27 - REAR AXLES

Slide out the wheel hub (6), using levers and a hammer to facilitate the operation.

NOTE: recuperate the bearing (7).

Position the wheel hub (6) on a flat surface and extract the seal ring (8).

NOTE: destructive operation for the seal ring.

Take out the bearing cups (7) and (9) with a driver and a hammer.

To unscrew and replace the worn stud bolts (10) of the wheel hub, use a nut and a locknut. Warm up the screwed part, if necessary.

63

64

SECTION 27 - REAR AXLES

Remove the bearing (9).

Extract the short half axle (11).

Loosen and remove the screws (12).

S WARNING Do not drop the wheel shaft and, if necessary, hold it by means of a rope.

Remove the wheel shaft (13) and collect the relevant O-ring (14).

SECTION 27 - REAR AXLES

Take out the seal ring (16) from the wheel shaft (13).

NOTE: destructive operation for the seal ring.

Position the wheel shaft (13) on a flat surface and extract the bushing (15) using a hammer and the driver 320002226.

Extract the long half shaft (17).

Remove the sleeve (18). If necessary, remove the elastic ring (19) from inside the sleeve.

65

66

SECTION 27 - REAR AXLES

ASSEMBLY Assemble the bushing (15) into the wheel shaft (13) with the driver 380002831 and a hammer.

Turn the wheel shaft (13) upside down and install the seal ring (16).

Check that the elastic ring (19) is assembled to the sleeve (18).

Fasten the sleeve (18) to the long half shaft (17).

Insert the long half shaft (17) in the axle beam (20).

Assemble a new O-ring (14).

SECTION 27 - REAR AXLES

Assemble the wheel shaft (13) and fasten it with the screws (12). Tighten the screws (12) to the prescribed torque of 304 Nm (224.21 lbf·ft).

The special operation “Set Right” of the bearings does not require preload or backlash adjustment.

Anyway, before assembling new components, check the indicated dimensions.

A = 11.975 ÷ 12.025 mm (0.471 ÷ 0.473 in) B = 52.229 ÷ 52.279 mm (2.056 ÷ 2.058 in) C = 20.000 ÷ 20.100 mm (0.787 ÷ 0.791 in)

Heat the bearing (9) to 80 ÷ 100 °C (176 ÷ 212 °F).

Assemble the bearing on the wheel shaft.

S WARNING Wear safety gloves.

Apply the prescribed sealant on the stud bolt threads (10) and tighten them to the prescribed torque of 70 Nm (51.62 lbf·ft) using two nuts (nut and locknut).

67

68

SECTION 27 - REAR AXLES

Position the wheel hub (6) on a workbench and assemble the bearing cups (7) and (9) using a press or a hammer.

Fit the seal ring (8) onto the wheel hub (6).

Insert the wheel hub (6) on the wheel shaft.

Heat the bearing (7) to 80 ÷ 100 °C (176 ÷ 212 °F) and assemble it.

S WARNING Wear safety gloves.

Position the ring gear carrier (2) on a workbench and assemble the bushings (4) at surface level.

At least two bushings (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.

Preassemble the ring gear carrier (2) and the ring gear (3) with the snap ring (5).

SECTION 27 - REAR AXLES

Assemble the ring gear carrier assy (2) and the ring gear (3) on the wheel hub using the two projecting bushings (4) as dowel pins.

Install the bushings (4) and completely insert them.

Apply some Loctite 242 on the thread of the screws (1).

Screw in the screws (1) and tighten them to the prescribed torque of 120 Nm (80.50 lbf·ft).

Install the short half axle (11).

69

70 5.8

SECTION 27 - REAR AXLES WHEEL HUB (121E, 221E, 321E)

DISASSEMBLY Unscrew and remove the screws (1) of the ring gear carrier.

SECTION 27 - REAR AXLES

In order to extract the ring gear carrier from its housing, use at least two of the just removed screws (1) and screw them in the threaded holes they were extracted from.

Remove the ring gear carrier (2) together with the ring gear (3).

Only if necessary, remove the bushings (4) of the ring gear carrier.

Remove the snap ring (5).

71

72

SECTION 27 - REAR AXLES

Slide out the wheel hub (6), using levers and a hammer to facilitate the operation.

NOTE: recuperate the bearing (7).

Position the wheel hub (6) on a flat surface and extract the seal ring (8).

NOTE: destructive operation for the seal ring.

Take out the bearing cups (7) and (9) with a driver and a hammer.

To unscrew and replace the worn stud bolts (10) of the wheel hub, use a nut and a locknut. Warm up the screwed part, if necessary.

SECTION 27 - REAR AXLES

Remove the bearing (9).

ASSEMBLY The special operation “Set Right” of the bearings does not require preload or backlash adjustment.

Anyway, before assembling new components, check the indicated dimensions.

A= 08.450 ÷ 08.500 mm (0.332 ÷ 0.334 in) B = 54.775 ÷ 54.825 mm (2.156 ÷ 2.158 in) C = 23.072 ÷ 23.173 mm (0.908 ÷ 0.912 in)

Heat the bearing (9) to 80 ÷ 100 °C (176 ÷ 212 °F).

Assemble the bearing on the wheel shaft.

S WARNING Wear safety gloves.

Apply some Loctite 242 on the stud bolt threads (10) and tighten them to the prescribed torque of 70 Nm (51.62 lbf·ft) using two nuts (nut and locknut).

73

74

SECTION 27 - REAR AXLES

Position the wheel hub (6) on a workbench and assemble the bearing cups (7) and (9) using a press or a hammer.

Fit the seal ring (8) onto the wheel hub.

Insert the wheel hub (6) on the wheel shaft.

Heat the bearing (7) to 80 ÷ 100 °C (176 ÷ 212 °F) and assemble it.

S WARNING Wear safety gloves.

Position the ring gear carrier (2) on a workbench and assemble the bushings (4) at surface level.

At least two bushings (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.

Preassemble the ring gear carrier (2) and the ring gear (3) with the snap ring (5).

SECTION 27 - REAR AXLES

Assemble the ring gear carrier assy (2) and the ring gear (3) on the wheel hub using the two projecting bushings (4) as dowel pins.

Install the bushings (4) and completely insert them.

Apply some Loctite 242 on the thread of the screws (1).

Screw in the screws (1) and tighten them to the prescribed torque of 120 Nm (88.50 lbf·ft).

75

76 5.9

SECTION 27 - REAR AXLES WHEEL SHAFT (121E, 221E, 321E)

DISASSEMBLY Extract the short half axle (1).

SECTION 27 - REAR AXLES

Loosen and remove the screws (10).

S WARNING Do not drop the wheel shaft and, if necessary, hold it by means of a rope.

Remove the wheel shaft (2) and the O-ring (3).

Extract the seal ring (5).

NOTE: destructive operation for the seal ring.

Turn the wheel shaft upside down. Position the wheel shaft on a flat surface and extract the bushing (4) using a hammer and the driver.

77

78

SECTION 27 - REAR AXLES

Extract the long half shaft (8).

Remove the sleeve (6). If necessary, remove the elastic ring (7) from inside the sleeve.

ASSEMBLY Install the bushing (4) onto the wheel shaft.

Turn the wheel shaft upside down and install the seal ring (5).

Check that the elastic ring (7) is assembled to the sleeve (6).

Assemble the sleeve (6) to the long half shaft (8).

Insert the long half shaft (8) in the axle beam (9).

SECTION 27 - REAR AXLES

Before matching worked surfaces, make sure they are perfectly clean. Degrease and clean with appropriate detergents.

Install the O-ring (3).

Assemble the wheel shaft (2) and fasten it with the screws (10). Tighten the screws (10) to the prescribed torque of 304 Nm (224.21 lbf·ft).

Remove the short half axle (1) from the wheel shaft (2).

79

80

SECTION 27 - REAR AXLES

5.10 DIFFERENTIAL SUPPORT

DISASSEMBLY Unscrew and remove the screws (17) of the cover (16).

Remove the bushings (15) from the axle beam only if the wear conditions require it.

NOTES: this is a destructive operation for the bushings.

S WARNING Do not damage the bushings seat.

SECTION 27 - REAR AXLES

Drain the oil completely from the differential.

Loosen and remove the screws (2).

To extract the differential support (1), tighten two screws in the threaded holes of the differential support.

Then hold the differential support (1) with a rope or other appropriate means and remove it.

Loosen and remove the screws (6) to extract the 2 ring nut retainers (5).

Before removing the screws, mark both half collars and the differential support with permanent reference marks, in order not to invert them during reassembly. Also mark the area between the ring nuts (3) and (7) and the differential support (1).

81

82

SECTION 27 - REAR AXLES

Loosen the adjusting ring nuts (3) and (7) with the wrench 380002827 (a1).

Loosen and remove the 4 screws (11) and both half collars (10).

Check that the bushings (9) remain in their housings.

Remove the differential assy (13).

Remove the bearings (4) and (8) from the assy.

SECTION 27 - REAR AXLES ASSEMBLY Assemble the bearings (4) and (8) on the differential assy (13).

S WARNING Do not invert the bearing cups if the bearings are replaced.

Assemble the differential assy complete with bearings (13) on the differential support (1).

S WARNING Check the correct mounting side of the ring gear.

Move the differential assy so as to place the ring gear in contact with the pinion.

Check that all bushings (9) are in their relevant seats and position both half collars (10) by means of the previously traced reference marks.

Fasten both half collars (10) with the screws (11).

Assemble the adjusting ring nuts (3) and (7) to the differential support.

Tighten the ring nuts (3) and (7) with the wrench 380002827 (a1) until backlash is eliminated and slightly load the differential bearings.

Check that the differential bearings are well settled; if necessary, slightly hit them with a rubber hammer.

83

84

SECTION 27 - REAR AXLES

Position a magnetic-base dial gauge on the differential support, so that the feeler touches the surface of one tooth of the ring gear at a 90° angle.

Holding the pinion, move the ring gear alternatively and note the backlash between the pinion and the ring gear, measured with the dial gauge.

Repeat the operation on two or more points (teeth), rotating the crown gear, so that to obtain an average value.

Check if the measured backlash value is within the requested range: 0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in) Carry out the adjustment by operating on the ring nuts with tool 380002827.

Adjust the ring nuts (3) and (7), remembering that:  (A) if the measured backlash is greater than the given tolerance range, unscrew the ring nut (3) and screw in the opposite ring nut (7) by the same measure;  (B) if the measured backlash is less than the given tolerance range, unscrew the ring nut (7) and screw in the opposite ring nut (3) by the same measure.

After pinion-ring gear backlash adjustment, check that there is a minimum preload on the differential box bearings.

Repeat the whole sequence of the above mentioned operations until the indicated conditions are reached.

SECTION 27 - REAR AXLES

Once the pinion-ring gear backlash has been adjusted, measure the total preload (T) of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on the pinion end. The measured value should be within the following range: T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf where P is the effectively measured pinion preload.

S WARNING All preloads must be measured without seal ring.

If the measurement is not within the requested range, accurately check the assembly of each single component and operate on the adjusting ring nuts (3) and (7) of the differential support:  if the total preload is lower than the given range, screw in both ring nuts (3) and (7) by the same measure, keeping the value of the pinion-ring gear (A) backlash unchanged;  if the total preload is higher than the given range, loosen both ring nuts (3) and (7) by the same measure, keeping the value of the pinion-ring gear (B) backlash unchanged.

Once the adjustment is complete, screw in and tighten the screws (11) to the prescribed torque of 266 Nm (196.19 lbf·ft).

Check total preload of bearings.

85

86

SECTION 27 - REAR AXLES

Once all the adjustment operations have been completed, assemble the ring nut retainers (5) and the relevant screws (6), tightening them to the prescribed torque of 13 Nm (9.58 lbf·ft).

Before coupling the surfaces, make sure that they have been perfectly cleaned with appropriate detergents. Spread an adhesive film on the contact surface between the axle beam and the differential support.

NOTE: check that the pins (12) remain in their housings.

Position the differential support (1) on the axle beam and tighten the screws (2) to the prescribed torque of 169 Nm (124.64 lbf·ft).

Install the new bushings (15) into the hole of the axle beam.

Position the cover (16) fastening it with the screws (17).

Tighten the screws (17) to the prescribed torque of 50 Nm (36.87 lbf·ft).

SECTION 27 - REAR AXLES BEVEL GEAR CHECK To check the contact marks of the bevel gear teeth, paint the bevel gears with red lead paint.

Check the contact marks of the ring gear teeth and on both sides.

OK -> Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular.

Z -> Excessive contact on the tooth tip: Bring the pinion closer to the ring gear and then move the ring gear away from the pinion in order to adjust the backlash.

X -> Excessive contact at the tooth base: Move the pinion away from the ring gear and then approach the ring gear to the pinion in order to adjust the backlash.

Movements to correct: 1 -> move the pinion for type X contact adjustment.

2 -> move the pinion for type Z contact adjustment.

87

88

SECTION 27 - REAR AXLES

5.11 DIFFERENTIAL ASSY

DISASSEMBLY Use a puller to remove the bearing (3).

SECTION 27 - REAR AXLES

Use a puller to remove the bearing (20).

Loosen and remove all screws (1) from the ring gear (2).

S WARNING This will make both differential half boxes free, so take care not to loose the internal components.

Remove the ring gear (2) by using a hammer.

Check the reference marks that will be useful during assembly.

Separate the two differential half boxes (4) and (19).

89

90

SECTION 27 - REAR AXLES

Remove the gear (5) and the shim (6).

Remove the shafts (8) and (12), the gears (7), (9), (13) and (15) and the spherical washers (10), (11), (14) and (16).

Remove the gear (17) and the shim (18).

ASSEMBLY Apply a thin layer of grease on the differential half boxes (4) and (19).

SECTION 27 - REAR AXLES

Apply a thin layer of Molicote G-n plus paste on the gears (7), (9), (13) and (15), and on gears (6) and (17).

Assemble the gear (17) and the shim (18).

Position the shaft (8), the gears (7) and (9) and the spherical washers (20) and (11).

Position the shaft (12), the gears (13) and (15) and the spherical washers (14) and (16).

91

92

SECTION 27 - REAR AXLES

Assemble the gear (6) and the shim (5).

Assemble the two differential half boxes (4) and (19).

S WARNING Carefully check that the reference marks of both differential half boxes are aligned.

Assemble the ring gear (2) by using a hammer.

Apply some Loctite 242 on the thread of the screws (1).

SECTION 27 - REAR AXLES

Screw in and tighten the screws (1) to the prescribed torque of 95 Nm (70.06 lbf·ft).

Install the bearing (3).

Install the bearing (20).

93

94

SECTION 27 - REAR AXLES

5.12 LIMITED SLIP DIFFERENTIAL ASSY

DISASSEMBLY Use a puller to remove the bearing (3).

SECTION 27 - REAR AXLES

Use a puller to remove the bearing (24).

Loosen and remove all screws (1) from the ring gear (2).

S WARNING This operation also frees both differential half boxes; take care not to loose the external components.

Remove the ring gear (2) by using a hammer.

Check the reference marks that will be useful during assembly.

Separate the two differential half boxes (4) and (23).

95

96

SECTION 27 - REAR AXLES

Remove the discs (5) and (6).

Remove the gear (8) and the shim (7).

Remove the shafts (9) and (14), the gears (10), (13), (15) and (17) and the spherical washers (11), (12), (16) and (18).

Remove the gear (19) and the shim (20).

SECTION 27 - REAR AXLES

Remove the discs (21) and (22).

ASSEMBLY Apply a thin layer of grease on the differential half boxes (4) and (23).

Apply a thin layer of Molicote G-n plus paste on the gears (10), (13), (15) and (17), and on gears (8) and (19).

Assemble discs (21) and (22).

97

98

SECTION 27 - REAR AXLES

Assemble the gear (19) and the shim (20).

Position the shaft (9), the gears (15) and (17) and the spherical washers (16) and (18).

Position the shaft (14), the planetary gears (10) and (13) and the spherical washers (11) and (12).

Assemble the gear (8) and the shim (7).

SECTION 27 - REAR AXLES

Assemble discs (5) and (6).

Assemble the two differential half boxes (4) and (23).

S WARNING Carefully check that the reference marks of both differential half boxes are aligned.

Assemble the ring gear (2) by using a hammer.

Apply some Loctite 242 on the thread of the screws (1).

99

100

SECTION 27 - REAR AXLES

Screw in and tighten the screws (1) to the prescribed torque of 95 Nm (70.06 lbf·ft).

NOTE: fix differential box in the vice.

Install the bearing (3).

Install the bearing (24).

SECTION 27 - REAR AXLES 5.13 PINION

DISASSEMBLY Position the differential assy in a vice.

Loosen the ring nut (10) with the wrenches 380002828 and 380002830.

NOTE: this operation irreparably damages the ring nut (10).

101

102

SECTION 27 - REAR AXLES

Tap the shaft end with a rubber hammer to extract the pinion (1).

S WARNING Prevent letting the pinion fall down.

Remove the shims (4) and (6), the spacer (5), the bearing (8) and the washer (9).

Take out the bearing cups (3) and (8).

Remove the bearing (3) from the pinion (1) using a puller.

Collect the shim (2).

SECTION 27 - REAR AXLES

Check the conditions of all parts.

S WARNING The ring nut (10) and the spacer (5) must be replaced by reassembly.

ASSEMBLY Fit the bearing cups (3) and (8).

Prepare the kit consisting of the special tools called “false pinion” (a1) 380002219 and “false differential box” 380000407 (a2) and 380002214 (a3) and a depth gauge (a4).

Insert the bearings (3) and (8) into their housings.

Assemble the “false pinion” and the ring nut (10).

Tighten without exceeding the ring nut, until the backlash is eliminated.

103

104

SECTION 27 - REAR AXLES

Assemble the special tools “false differential box” 380000407 + 380002211 to the supports of the differential assy (7) and block by means of the half collar screws.

Mounting diagram of the tools of the “false differential box” on the seats of the differential support bearings.

Use a depth gauge to measure the dimension “X” (distance between the axis of the differential bearings and the leaning point of the pinion head or bearing base).

In order to determine the value (S) of the shim to be placed between pinion and bearing, subtract the value (V) stamped on the pinion head (V = prescribed bevel distance) from the measured value (X).

S = X - V mm (in)

Select the shim (2) with a value (S) among the range of available shims.

SECTION 27 - REAR AXLES

Remove the “false differential box” special tool from the differential supports (7).

Remove the ring nut (10), the “false pinion” and the bearings (3) and (8).

After choosing and inserting the appropriate shim (2) with the chamfer oriented towards the gear, insert the bearing (3) into the pinion (1) using a press, making sure it is well set.

Insert the shims (4) and (6) and a new collapsible spacer (5).

NOTE: always use a new spacer (5).

Insert the pinion assy (1) into the differential support box (7) and the bearing (8).

It is recommended to contrast the hammering force with a resisting action, e.g. a mallet.

Insert the washer (9) and screw in a new ring nut (10) on the pinion.

105

106

SECTION 27 - REAR AXLES

Screw in the ring nut (10) using the wrenches 380002828 and 380002830 for ring nut and pinion retainer.

S WARNING The torque setting is given by the measure of the preload on the bearings; gradually tighten the ring nut (10).

NOTE: if it is overtight, the collapsible spacer should be replaced and the procedure repeated. When you check the preload, it is advisable to slightly beat both pinion ends with a soft hammer, so as to help setting the bearings.

Carry out the preload measurement (P) of the bearings, using a dynamometer whose cord is wound on the splined end of the pinion (1).

The adjustment is carried out by increasing the ring nut torque gradually, being careful not to exceed.

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

S WARNING All preloads must be measured without seal ring.

Once the prescribed preload value is achieved, caulk the ring nut (10) using a hammer and a punch.

SECTION 27 - REAR AXLES

6.

107

TROUBLESHOOTING PROBLEMS

CAUSE

1

2

3

Wheel vibration; front tyre resistance; half shaft breakage.







Steering is difficult; the vehicle goes straight while it is turning.







No differential action; jams during steering.



Excessive noise of transmission.





Uneven wear of tyre.





Friction noise.



Vibration during forward run, intermittent noise.



1. Incorrect installation or defective axle Correct the installation or repair or replace the differential in case it does not survive any one of the test phases.

2. Overload or incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tyres If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with bigger radius will have to support all the work.

Replace the tyre or adjust pressure to have same radius on both tyres.

4. Broken axle beam It is not advisable to operate the vehicle with a broken axle beam. It is acceptable to move the vehicle (engine off unloaded) a few metres away only.

5. Bent axle beam Replace the axle beam.

6. Blocked differential Anomalous operation of the differential or breakage or blockage of the control device. Verify assembly and all components.

Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.



4

5

7

8

9

10 11































6



  







 









7. Incorrect wheel adjustment Verify group integrity and wheel side bearings.

Adjusting according.

8. Spoiled or worn out axle parts Check the conditions of ring gear, of the pinion, of the bearings, etc.

Replace whenever necessary.

9. Contamination in the axle box or incorrect assembly of parts Look for foreign particles. Check assembly of the various parts of the axle.

10. Incorrect adjustment of bevel gear set: transmission components worn out (transmission gears, U joints, etc.)

Replace or adjust as required.

11. Incorrect use of the product See the vehicle producer’s instructions once again.

108

SECTION 27 - REAR AXLES

FAULTS CHECK AND EXAMINATION This chapter offers a descriptive and explanatory outline of fault that can be commonly found on axles or troubles that can take place. This outline also suggests repair procedures.

FAULT

CAUSE

ACTION

Break towards the external end Excessive gear load compared to the of the ring gear tooth. one expected.

Gear adjustment wrong (excessive backlash).

Pinion nut loose.

Replace bevel gear.

Carefully observe the recommended operations for the adjustment of ring gear and pinion backlash and for tooth mark detection.

Break towards the internal end Crash load. of the ring gear tooth.

Gear adjustment wrong (insufficient backlash).

Pinion nut loose.

Replace bevel gear.

Carefully observe the recommended operations for the adjustment of ring gear and pinion backlash and for tooth mark detection.

Ring gear teeth or pinion teeth Insufficient oil. damaged or scored.

Contaminated oil.

Incorrect oil or with poor additives.

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Replace bevel gear.

Replace worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Use proper lubricant, fill up to right level and replace at recommended intervals.

Ring gear teeth or pinion teeth Prolonged operation at high temperaoverheated. Check if gear ture. teeth have faded.

Incorrect oil.

Oil level low.

Contaminated oil.

Replace bevel gear.

Use proper oil, fill up to the right level and change at recommended intervals.

Drive pinion teeth pitted.

Extremely intense use.

Insufficient lubrication.

Replace bevel gear.

Use proper oil, fill up to the right level and change at recommended intervals.

Bent axle beam body.

Machine overloaded.

Damaged vehicle.

Crash load.

Replace the axle beam body.

Bearings worn or pitted.

Insufficient oil.

Contaminated oil.

Extremely intense use.

Normal wear.

Pinion nut loose.

Replace bearings.

Use proper oil, fill up to the right level and change at recommended intervals.

Gaskets leak oil.

Prolonged operation at excessive oil temperature.

Oil gasket wrongly installed.

Gasket edge cut or scored.

Contaminated oil.

Replace the gasket and matching surface if damaged.

Use proper lubricant, fill up to right level and replace at recommended intervals.

SECTION 27 - REAR AXLES

FAULT

CAUSE

109

ACTION

Excessive wear of input flange Intense use. spline.

Pinion nut loose.

Pinion axial backlash.

Replace the flange.

Check that the pinion spline is not excessively worn out.

Replace bevel gear.

Intense use.

Pinion gear tooth fatigue break. Check if the fracture line Continuous overload. is with wavy or clearly delineated (stop line).

Replace bevel gear.

Break of pinion and ring gear teeth.

Check and/or replace other differential components.

Crash load of differential components.

Splines of planetary gear worn Intense use. (excessive backlash).

Replace differential gear assy.

Replace axle beam, if necessary.

Surfaces of bearing worn or scratched.

Replace all scratched washers and those with a 0.1 mm (0.003 in) thickness lower than the new ones.

Use proper oil, fill up to the right level and change at recommended intervals.

Insufficient oil.

Incorrect oil.

Contaminated oil.

Inner diameter of pinion Intense use. tapered roller bearing worn out. Excessive pinion end play.

Insufficient oil.

Contaminated oil.

Replace bearing.

Check pinion axial backlash.

Use proper oil, fill up to the right level and change at recommended intervals.

Bent or broken axle beam.

Intense vehicle operation, overload.

Replace the axle beam.

Broken axle beam at wheel flange.

Wheel support loosen.

Axle beam body bent.

Replace the axle beam.

Check bending of axle beam body.

Ensure that wheel support is not worn out or wrongly adjusted.

110

7.

SECTION 27 - REAR AXLES

SPECIAL TOOLS

Drivers and buffers for the assembly of gaskets, bearings and bushings must be used with the interchangeable handle 380002211; its use is recommended together with a safety handle for hand protection.

P/N CNH

NAME

21E

121E

221E

321E

380000407

False differential box

•

•

•

•

380002212

Key - Pinion nut

•

•

•

•

380002214

False differential tool

•

•

•

•

380002219

False pinion

•

•

•

•

380002827

Key - Differential ring nut

•

•

•

•

380002828

Key - Pinion nut

•

•

•

•

380002830

Key - Pinion support

•

•

•

•

380002831

Driver - Axle beam bushing

/

•

•

•

SECTION 33 - BRAKE SYSTEM 1. BRAKE SYSTEM DIAGRAM ........................................................................................................................ 1 1.1 STANDARD DIAGRAM (21E)................................................................................................................ 1 1.2 “HIGH SPEED” DIAGRAM (121E, 221E, 321E) .................................................................................... 2 2. TECHNICAL SPECIFICATIONS................................................................................................................... 3 2.1 BRAKE PEDAL VALVE ......................................................................................................................... 3 2.2 PRESSURE SWITCHES ....................................................................................................................... 3 3. OPERATION................................................................................................................................................. 4 3.1 SERVICE BRAKE OPERATION............................................................................................................ 6 3.2 PARKING BRAKE OPERATION ........................................................................................................... 8 4. BRAKE PEDAL VALVE ................................................................................................................................ 9 5. PRESSURE SWITCHES ............................................................................................................................ 11 6. BRAKE ACCUMULATOR ........................................................................................................................... 12 6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 12 7. CHECKS AND ADJUSTMENTS................................................................................................................. 13 7.1 SERVICE BRAKE SYSTEM PRESSURE CHECK.............................................................................. 13 7.2 ACCUMULATOR PRESSURE CHECK............................................................................................... 14 7.3 PEDAL ANGLE ADJUSTMENT........................................................................................................... 15 7.4 “INCHING” VALVE ADJUSTMENT...................................................................................................... 16 8. TROUBLESHOOTING................................................................................................................................ 17

SECTION 33 - BRAKE SYSTEM

SECTION 33 - BRAKE SYSTEM

1.

BRAKE SYSTEM DIAGRAM

1.1

STANDARD DIAGRAM (21E)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Diesel engine Gear pump Priority valve Accumulator charging valve Accumulator charge pressure switch Accumulator Brake valve Braking alarm pressure switch Brake light pressure switch

10.

11.

12.

13.

14.

15.

16.

17.

18.

Oil tank “Inching” valve To the working hydraulic system To the steering valve and brake valve Oil tank breather valve To the variable-displacement pump Front axle Brake disc Rear axle

1

2 1.2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

SECTION 33 - BRAKE SYSTEM “HIGH SPEED” DIAGRAM (121E, 221E, 321E)

Diesel engine Gear pump Priority valve Accumulator charging valve Accumulator charge pressure switch Accumulator Brake valve Braking alarm pressure switch Brake light pressure switch Oil tank “Inching” valve To the working hydraulic system

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

To the steering valve Oil tank breather valve To the variable-displacement pump Emergency steering Emergency steering pressure switch “High speed” pressure switch “High speed” valve Front axle Brake caliper Brake disc Rear axle

SECTION 33 - BRAKE SYSTEM

2.

3

TECHNICAL SPECIFICATIONS

The caliper brake on the input disc of the front axle operates on the rear axle through the cardan shaft. The brake pedal activation reduces the oil flow towards the transmission and applies hydraulic pressure to the brake when the pedal is operated. The oil flow to the transmission is reduced and an additional oil flow is supplied to the hydraulic working and steering systems.

Braking surface of the service brake....................................................................................45.81 cm2 (7.10 in2) Braking surface of the parking brake ...................................................................................45.81 cm2 (7.10 in2) Brake pressure................................................................................................................. 5500 kPa (797.70 psi)

2.1

BRAKE PEDAL VALVE

Allowable service pressure .................................................................................................... 175 bar (2538 psi) Adjusted pressure ...................................................................................................................... 55 bar (797 psi) Pressure of brake on disc .......................................................................................................... 55 bar (797 psi) ACCUMULATOR CHARGING VALVE Precharge pressure ............................................................................................................... 175 bar (2537 psi) “Cut-in” pressure .................................................................................................................... 120 bar (1740 psi) “Cut-off” pressure................................................................................................................... 150 bar (2175 psi) BRAKE ACCUMULATOR Capacity ...............................................................................................................................0.32 litres (0.10 gal) Service pressure .................................................................................................................... 210 bar (3045 gal) Maximum temperature .................................................................................. -10 °C / +80 °C (+14 °F / +176 °F) Filling gas............................................................................................................................................... nitrogen Filling gas overpressure............................................................................................... 25 ± 1 bar (362 ± 15 psi) Weight.............................................................................................................................................. 1.3 kg (3 lb)

2.2

PRESSURE SWITCHES

STOP LIGHT PRESSURE SWITCH Infeed pressure ........................................................................................................................... 3.5 bar (51 psi) Function ..........................................................................................................................................when closing BRAKE ACCUMULATOR CHARGE PRESSURE SWITCH Infeed pressure ........................................................................................................................ 80 bar (1160 psi) Function ........................................................................................................................................... bidirectional

4

SECTION 33 - BRAKE SYSTEM

3.

OPERATION

(21E)

1.

2.

3.

4.

Front axle Rear axle Brake pedal valve Disc brake

On the 21E version, the service brake is installed on the front axle (1) acting as a hydraulically actuated disc brake.

The hydraulic pressure of the brake, coming from the brake pedal valve (3), reaches the disc brake (4) through the hose (5).

The disc brake also has the function of a parking brake, which is operated through the activation of the lever (8) and by means of the tie-rod (6).

The cardan shaft (7) transmits the braking effect to the rear axle (2).

5.

6.

7.

8.

Hose Tie-rod Cardan shaft Parking brake lever

SECTION 33 - BRAKE SYSTEM

5

“STANDARD” AND “HIGH SPEED” VERSION

8

9

5

10

6 3

1

2

11

4 8

5 CWL00003

1.

2.

3.

4.

5.

6.

Front axle Rear axle Brake pedal valve Disc brake Tie-rod Cardan shaft

On the “standard” and “high speed” version there are two hydraulically actuated service brakes. In the hubs of the front axle (1) there are two hydraulic disc brakes (7), which operate as main brake. The disc brake (4) assists the disc brakes (7).

7.

8.

9.

10.

11.

Brake disc Tube T-connector Hose Parking brake lever

6 3.1

SECTION 33 - BRAKE SYSTEM SERVICE BRAKE OPERATION

21E

The pump (2) delivers oil to the brake pedal valve (7) through the priority valve (3). By means of the accumulator charging valve (4), the accumulator (6) is filled with oil.

When the accumulator pressure reaches 150 bar, the accumulator charge is disconnected and oil delivered to the brake valve is returned to the tank (10).

By activating the brake pedal valve (7), the oil is delivered from the accumulator to the service brake on the front axle (1). The brake pressure is limited from pedal brake valve at a maximum value of 55 bar (797 psi).

If the accumulator pressure lowers below 100 bar (1450 psi), the accumulator charging valve activates again the accumulator filling (6).

121E 221E 321E CWL00018a

SECTION 33 - BRAKE SYSTEM If the accumulator pressure drops below 80 bar, the accumulator charge pressure switch (5) activates the lamp on the instrument panel and the cab acoustic alarm. If the accumulator pressure drops below 80 bar (1160 psi), the hydraulic transmission is disconnected, until brake pressure is high enough again.

If a braking pressure higher than 3.5 bar (51 psi) is generated, the brake light pressure switch (9) activates.

If the brake pedal (11) is released, the pressure can discharge into the oil tank (10).

On port F1 of the brake pedal valve (7), the “high speed” version is equipped with a further pressure switch, activating when pressure reaches 40 bar (580 psi). Only with machine shut off and when activating the brake valve with force, the gear in the rear axle can change between standard speed and high speed.

AUXILIARY BRAKE When the pedal brake valve is activated, also the “inching” valve (8), incorporated in the brake pedal valve, activates at the same time.

During the braking phase, the “inching” valve sets the pump to the neutral position, and this interrupts the transmission.

A great advantage of this so-called “inching” consists in the fact that, when the travel pump returns, most of the engine power can be made available to the working attachment.

7

8 3.2

SECTION 33 - BRAKE SYSTEM PARKING BRAKE OPERATION

To activate the parking brake, operate the lever (1), pulling it upwards.

Lower the lever to release the parking brake.

With the parking brake engaged, the lamp (2) on the front instrument turns on.

Lamp (2) is off when parking brake is deactivated.

The parking brake acts on the disc brake of the front axle by means of a tie-rod.

The tie-rod operates a caliper which blocks or releases the disc, which is fastened to the transmission.

By pulling the parking brake lever, the switch (3), located under the lever, activates and disconnects the transmission. a = maximum resting position 6.0 mm (0.236 in) b = engagement point 5.5 mm (0.216 in)

SECTION 33 - BRAKE SYSTEM

4.

BRAKE PEDAL VALVE

This valve allows using, with a limited number of outer connections, a small quantity of energy of the machine’s hydraulic system, then leaving the complete system delivery available for other operations. This operation is performed through a load valve sucking oil automatically, to fill the accumulators.

Its technical specifications have as a result an increase of braking power and a reduction of pressure on pedal. The braking pressure is adjusted by modules connected to braking circuits.

 = working angle (maximum 16°) 1. “Inching” valve 2. Pedal support 3. Brake module 4. Shut-off flange 5. Pedal

IP. “Inching” connection IS. Discharge N’. Discharge (plugged) N. Discharge R. Accumulator T1. Brakes T’1.Accumulator charge pressure switch R1. Accumulator

9

10

SECTION 33 - BRAKE SYSTEM

HYDRAULIC DIAGRAM 1.

2.

3.

4.

5.

6.

7.

Brake pedal valve “Inching” valve Accumulator Accumulator charge pressure switch Braking alarm pressure switch Brake light pressure switch “High speed” pressure switch

SECTION 33 - BRAKE SYSTEM

5.

11

PRESSURE SWITCHES

STOP LIGHT PRESSURE SWITCH Infeed pressure ........................................................................................................................... 3.5 bar (51 psi) Function ..........................................................................................................................................when closing Connection..............................................................................................................................................M10 x 1 The light pressure switch is mounted on connection F1 of the brake pedal valve and turns on the stop lights.

ACCUMULATOR CHARGE PRESSURE SWITCH Infeed pressure ........................................................................................................................ 80 bar (1160 psi) Function ........................................................................................................................................... bidirectional Connection..............................................................................................................................................M14 x 1 The pressure switch for the accumulator pressure operates when the accumulator pressure drops below 80 bar.

BRAKING ALARM PRESSURE SWITCH Infeed pressure ........................................................................................................................... 3.5 bar (51 psi) Function ..........................................................................................................................................when closing Connection..............................................................................................................................................M10 x 1 “STANDARD” and “HIGH SPEED” PRESSURE SWITCH Infeed pressure .......................................................................................................................... 40 bar (580 psi) Function ..........................................................................................................................................when closing Connection..............................................................................................................................................M10 x 1

12

6.

SECTION 33 - BRAKE SYSTEM

BRAKE ACCUMULATOR

As regards their operation, the accumulators are identical, they are membrane-type and ensure a certain number of activations of the connected users in case of hydraulic pressure lack.

The membrane accumulator consists of a pressureresistant steel container, inside which a membrane made of elastic material is assembled as separating element.

The membrane is locked with a ring nut between the body lower and upper part. In the membrane central lower section is dived a metallic disc preventing its slipping out from fluid inlet port.

Without hydraulic pressure, the membrane, loaded on the gas side to precharge pressure (P0), leans against the inner surface of the accumulator and the poppet stops the liquid flow.

With hydraulic pressure applied, the precharge pressure is exceeded by compressing nitrogen, the poppet is lifted and liquid flows into the accumulator. The useful quantity of liquid results from the difference between gas volume and minimum and maximum service pressure.

6.1

TECHNICAL SPECIFICATIONS

Capacity ...................................0.32 litres (0.10 gal) Allowable service overpressure ... 210 bar (3045 psi) Admissible service temperature .............................. ........ from -10 °C to 80 °C (from +14 °F to +176 °F) Filling gas ................................................... nitrogen Filling gas overpressure ..... 25 ± 1 bar (362 ± 15 psi) Weight .................................................. 1.3 kg (3 lb)

SECTION 33 - BRAKE SYSTEM

7.

CHECKS AND ADJUSTMENTS

During all check and adjustment operations on the brake system, the hydraulic oil temperature must be of about 65 °C (149 °F), to achieve a reproducible value for oil viscosity.

Carry out service work only after the machine and the articulated joint have been secured. The accumulators contain nitrogen under high pressure.

Even after releasing pressure from the hydraulic system, the nitrogen in the accumulators remains under pressure. The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

Never perform mechanical work on the accumulators, never weld or solder them.

The inspection and maintenance operations must only be performed by qualified personnel and before beginning to release pressure from the hydraulic system.

Before disassembling an accumulator, wear safety goggles and protection gloves, only fill the accumulator with nitrogen and never use compressed air nor oxygen.

Immediately report any defects or damage to the After-sales service.

7.1

SERVICE BRAKE SYSTEM PRESSURE CHECK

S WARNING Repair operations on the brakes must be performed only by personnel specially trained to carry out operations on the braking system.

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Place some wedges under the wheels to prevent the machine from moving.

Block the articulated joint.

Relieve the braking pressure.

To remove the braking pressure, depress the brake pedal 10-15 times. The brake system is depressurized when the pedal can be depressed without resistance.

Remove the plug (1) from the joint (2) of the brake valve (3) and connect the pressure gauge (4).

(Measuring range up to 200 bar (2900 psi)).

13

14

SECTION 33 - BRAKE SYSTEM

Check that the parking brake is activated and that the travel lever is in neutral position.

Start the engine and wait until the required minimum braking pressure is achieved, that is when lamp (5) goes out and when the acoustic warning signal stops sounding.

Check the braking pressure. The pressure gauge (4) must indicate a pressure of 55 ± 5 bar (797 ± 73 psi).

Contact the After-sales service in case the following conditions occur:  lamp does not go out;  the acoustic warning signal continues to sound;  the braking pressure is below 55 bar (797 psi) or higher than 60 bar (870 psi).

PRESSURE ADJUSTMENT The adjustment of the brake pressure is carried out by means of the setscrew (7), located in the lower part of the brake valve.

Connect a pressure gauge (range 250 bar (3625 psi)) to the brake line. Then depress the brake pedal.

To decrease the brake pressure, tighten setscrew (7).

To increase the brake pressure, unscrew the setscrew (7).

After that, the setscrew must be secured with the locknut (6).

7.2

ACCUMULATOR PRESSURE CHECK

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

Block the articulated joint.

Relieve the braking pressure.

To this purpose, depress brake pedal 10-15 times.

The brake system is depressurized when the pedal can be depressed without marked resistance.

Remove the plug (1) from the coupler (2) of the joint (3).

SECTION 33 - BRAKE SYSTEM Screw in the pressure gauge (4) (measuring range up to 200 bar (2900 psi)) on the coupler (2).

Start the engine and wait until the accumulator pressure is reached, the lamp (5) turns off and the acoustic warning signal stops sounding.

Check the braking pressure.

The pressure gauge must indicate a pressure of 150 ± 10 bar (2175 ± 145 psi).

In the event this value is not achieved, please contact our After-sales service.

After the accumulator has reached the charging pressure, stop the engine and leave the starter switch key in position 1.

Depress the brake pedal repeatedly to limit stop and observe the pressure gauge.

Each time the brake pedal is pressed, the pressure drops.

When the acoustic warning signal is not heard and the lamp (5) does not turn on, despite a repeated activation of the brake pedal (minimum 3 times), the accumulator pressure is sufficient.

Once check is complete, relieve the brake pressure.

Remove the pressure gauge (4) and tighten the plug (1) again.

7.3

PEDAL ANGLE ADJUSTMENT

The adjustment of brake pedal position as resting position is obtained with front positioning screw (1).

Once the pedal angle adjustment has been performed, the resting position has to be adjusted by means of back screw (2).  = working angle 16°

15

16 7.4

SECTION 33 - BRAKE SYSTEM “INCHING” VALVE ADJUSTMENT

On the pump, to the measuring port for high travel pressure (PHD), connect a pressure gauge with a measuring range of 600 bar (8702.2 psi). Connect another pressure gauge with a measuring range of 60 bar (870.2 psi) to the measuring port (Pin) on the same pump.

Then drive the wheel loader in road gear against a wall or into a mound of earth. The engine speed is kept constant so that also the measured travelling high pressure (PHD) remains constant.

To prevent the transmission under load to switch over to the low speed, the setscrew for adjustment start located on the travel motor must be loosened by about 3 turns.

Now, generate a brake pressure (PBL) of 5 bar (72.5 psi).

By means of the setscrew (1), it is necessary to adjust the “inching” valve so that the high travel pressure (PHD) starts decreasing when the braking pressure (PBL > in) reaches 5 bar (72.5 psi).

Once the adjustment is complete, the “inching” valve must be blocked again by means of the nut (2).

If the “inching” start is correctly adjusted, the “inching” must end when the activated braking pressure (Pin) reaches 13 bar (189 psi). This means that, with this pressure, only the supply pressure must be detected on the measuring port for high travel pressure (PHD).

SECTION 33 - BRAKE SYSTEM

8.

17

TROUBLESHOOTING FAULT

CAUSE

ACTION

Abrupt braking.

Pressure setting incorrect.

Decrease pressure by handling on the setscrew under the pedal. During operation, pressure has to be checked with a pressure gauge.

Insufficient braking action.

Pressure setting incorrect.

Increase the pressure with the setscrew under the pedal. During operation, pressure has to be checked with a pressure gauge. WARNING: the admissible braking pressures must not be exceeded.

Delayed braking action and release of brake.

Insufficient charging and discharging speed of the brakes.

Make sure the diameter of the lines in the brake system is not too small with respect to their length and the oil volume.

Fill the system with hydraulic oil of prescribed viscosity.

Viscosity of hydraulic oil too high.

Brakes remain engaged.

Incorrect discharging of the brake system.

Brake pedal does not return to original position.

The system is not completely released and the residual pressure continues to act on the brakes.

Check that the stop screw of the pedal leaves some clearance between pedal return and actuating piston.

Remove obstacles under the pedal, if any.

The brake lamp on the instrument panel remains permanently off or on.

Check the pressure switch setting.

Adjust the pressure switch on the charging valve to a value below minimum pressure of the accumulators, but high enough to ensure 3 or 4 braking cycles after lighting up of the lamp.

Inconstant brake pressure.

The minimum pressure of the accu- Check the correct setting of accumumulator is lower than the brake max- lator pressure. If necessary, correct imum pressure. the value on the setscrew of the accumulator charging valve.

18

SECTION 33 - BRAKE SYSTEM

FAULT

CAUSE

ACTION

Accumulators are permanently recharged.

Not enough or too much nitrogen in accumulators.

After removing the oil from the accumulators, check the nitrogen pressure in the accumulators with a suitable instrument. Refill the accumulators in strict observance of the manufacturer’s operating instructions. The nitrogen pressure can be checked by measuring the pressure of the residual oil ejected.

Feeding pump always under pressure.

Pump worn out.

Repair or replace pump.

The accumulators do not recharge.

A foreign body clogs the priority valve.

Check the hydraulic connection and the accumulator’s charging valve.

Bleed air from the supply pump circuit.

Knocks are felt at pedal.

Abrupt pressure variations on the release side.

Discharge flow of brake too high.

Choose a larger diameter for the discharge lines.

SECTION 35 - HYDRAULIC SYSTEM 1. HYDRAULIC DIAGRAMS ............................................................................................................................. 1 1.1 HYDRAULIC DIAGRAM FOR 21E ........................................................................................................ 1 1.2 HYDRAULIC DIAGRAM FOR 21E WITH OPTIONAL OUTFITS........................................................... 3 1.3 HYDRAULIC DIAGRAM FOR 121E ...................................................................................................... 5 1.4 HYDRAULIC DIAGRAM FOR 121E WITH OPTIONAL OUTFITS......................................................... 7 1.5 HYDRAULIC DIAGRAM FOR 221E ...................................................................................................... 9 1.6 HYDRAULIC DIAGRAM FOR 221E WITH OPTIONAL OUTFITS....................................................... 11 1.7 HYDRAULIC DIAGRAM FOR 321E .................................................................................................... 13 1.8 HYDRAULIC DIAGRAM FOR 321E WITH OPTIONAL OUTFITS....................................................... 15 2. TRANSMISSION......................................................................................................................................... 17 2.1 HYDRAULIC DIAGRAM ...................................................................................................................... 17 2.2 OPERATION........................................................................................................................................ 18 2.3 ADJUSTMENTS .................................................................................................................................. 20 3. VARIABLE-DISPLACEMENT PISTON PUMP ........................................................................................... 22 3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 23 3.2 MAIN VALVES ..................................................................................................................................... 24 3.3 DISASSEMBLY.................................................................................................................................... 32 3.4 ASSEMBLY.......................................................................................................................................... 51 4. GEAR PUMP .............................................................................................................................................. 58 4.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 58 4.2 COMPONENTS ................................................................................................................................... 59 4.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 60 5. PRIORITY VALVE ...................................................................................................................................... 63 5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 63 6. TRAVEL MOTOR........................................................................................................................................ 64 6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 64 6.2 MAIN COMPONENTS ......................................................................................................................... 66 6.3 OPERATION........................................................................................................................................ 67 6.4 REMOVAL ........................................................................................................................................... 70 6.5 DISASSEMBLY AND ASSEMBLY....................................................................................................... 71 7. ONE-WAY DISTRIBUTOR VALVE............................................................................................................. 85 8. HYDRAULIC OIL TANK.............................................................................................................................. 86 8.1 OIL FILTER.......................................................................................................................................... 87 9. TROUBLESHOOTING................................................................................................................................ 88

SECTION 35 - HYDRAULIC SYSTEM

SECTION 35 - HYDRAULIC SYSTEM

1.

HYDRAULIC DIAGRAMS

1.1

HYDRAULIC DIAGRAM FOR 21E

1

2 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle Brake pedal valve Brake pedal valve accumulator Brake light pressure switch Accumulator charge pressure switch Braking alarm pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Dumping cylinder Lifting cylinder 3rd function cylinders Emergency steering Emergency steering pressure switch

SECTION 35 - HYDRAULIC SYSTEM 1.2

HYDRAULIC DIAGRAM FOR 21E WITH OPTIONAL OUTFITS

3

4 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle Brake pedal valve Brake pedal valve accumulator Brake light pressure switch Accumulator charge pressure switch Braking alarm pressure switch Emergency steering Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Load-holding valve Accumulator Return-to-dig valve Dumping cylinder Lock valve Lifting cylinder Lock valve 3rd function cylinders Emergency steering pressure switch

SECTION 35 - HYDRAULIC SYSTEM 1.3

HYDRAULIC DIAGRAM FOR 121E

5

6 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle Brake pedal valve Brake pedal valve accumulator Brake light pressure switch Accumulator charge pressure switch Braking alarm pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Dumping cylinder Lifting cylinder 3rd function cylinders Emergency steering Emergency steering pressure switch

SECTION 35 - HYDRAULIC SYSTEM 1.4

HYDRAULIC DIAGRAM FOR 121E WITH OPTIONAL OUTFITS

7

8 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle “High speed” valve Brake pedal valve Brake pedal valve accumulator Brake light pressure switch “High speed” pressure switch Accumulator charge pressure switch Braking alarm pressure switch Emergency steering pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Load-holding valve Accumulator Return-to-dig valve Tilt dumping cylinder Lock valve Lifting cylinder Lock valve 3rd function cylinders Emergency steering

SECTION 35 - HYDRAULIC SYSTEM 1.5

HYDRAULIC DIAGRAM FOR 221E

9

10 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle Brake pedal valve Brake pedal valve accumulator Brake light pressure switch Accumulator charge pressure switch Braking alarm pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Dumping cylinder Lifting cylinder 3rd function cylinders Emergency steering Emergency steering pressure switch

SECTION 35 - HYDRAULIC SYSTEM 1.6

HYDRAULIC DIAGRAM FOR 221E WITH OPTIONAL OUTFITS

11

12 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle “High speed” valve Brake pedal valve Brake pedal valve accumulator Brake light pressure switch “High speed” pressure switch Accumulator charge pressure switch Braking alarm pressure switch Emergency steering pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Load-holding valve Accumulator Return-to-dig valve Tilt dumping cylinder Lock valve Lifting cylinder Lock valve 3rd function cylinders Emergency steering

SECTION 35 - HYDRAULIC SYSTEM 1.7

HYDRAULIC DIAGRAM FOR 321E

13

14 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle Brake pedal valve Brake pedal valve accumulator Brake light pressure switch Accumulator charge pressure switch Braking alarm pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Dumping cylinder Lifting cylinder 3rd function cylinders Emergency steering Emergency steering pressure switch

SECTION 35 - HYDRAULIC SYSTEM 1.8

HYDRAULIC DIAGRAM FOR 321E WITH OPTIONAL OUTFITS

15

16 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

SECTION 35 - HYDRAULIC SYSTEM Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Front axle Rear axle “High speed” valve Brake pedal valve Brake pedal valve accumulator Brake light pressure switch “High speed” pressure switch Accumulator charge pressure switch Braking alarm pressure switch Emergency steering pressure switch Power steering Steering cylinder Travel motor Hydraulic oil tank Oil return filter Valve Valve One-way distributor valve Working equipment control valve Quick tool coupler cylinders Quick tool coupler cylinders valve Load-holding valve Accumulator Return-to-dig valve Tilt dumping cylinder Lock valve Lifting cylinder Lock valve 3rd function cylinders Emergency steering

SECTION 35 - HYDRAULIC SYSTEM

2.

TRANSMISSION

2.1

HYDRAULIC DIAGRAM

21E

121E 221E 321E

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Diesel engine Variable-displacement pump Cooler Gear pump Priority valve Switching valve Adjusting cylinder High pressure relief valve Relief valve Pressure cut-off valve Adjusting valve Supply pump

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Orifice Switching valve Travel motor Feed pressure valve Valve Check valve Oil tank Oil return filter Brake pedal valve “Inching” valve Adjusting cylinder

17

18 2.2

SECTION 35 - HYDRAULIC SYSTEM OPERATION

PRINCIPLE This transmission consists mainly in a variable-displacement pump (2), directly activated by the diesel engine (1) and by a motor (15) installed on the rear axle.

In neutral position (neither forward nor reverse travel is engaged), the travel pump (2) is not actuated, and therefore it does not deliver any oil to the motor (15).

Machine does not move.

By engaging the forward or reverse travel, the variable-displacement pump (2) activates and the motor (15) receives the oil delivery.

The machine sets to forward or reverse run.

The regulation pressure, shifting travel pump (2), is generated by the feed pump (12).

OPERATION The diesel engine (1) drives the variable displacement pump (2) and the supply pump (12).

The system pump (12) sucks oil through the filter of the supply circuit (18).

The feed pressure is supplied through the relevant pressure relief valve (9) at approximately 25 bar (362.6 psi).

By means of check valves, incorporated into the high pressure relief valves (8), the supply oil is delivered to each intake side (according to travel direction) of the variable-displacement pump (2), so as to compensate its leaks.

The valve (16) and the supply pressure valve (17) are conceived to dissipate the heat from the closed circuit and to ensure the minimum supply pressure.

According to the diesel engine (1) revolutions, the supply pump (12) generates a variable oil flow.

This quantity is detected through the holding pressure, on the diaphragm (13).

The higher is the holding pressure, the higher is the revolutions number of diesel engine (1) activated.

According to the holding pressure in front of the diaphragm (13), by means of the adjusting valve (11), a higher or lower regulation pressure is deviated by the supply pressure.

NOTE: the regulator valve (11) is adjusted so that with a speed of approximately 1100 rpm, you can achieve about 50 bar (725 psi) of high pressure.

The regulation pressure is present on the electromagnetically activated switching valve (6). When the operator activates the lever according to travel direction, the switching valve (6) is actuated electrically, leading the regulation pressure on the side required by the actuator cylinder (7).

The pump shifts and delivers oil under pressure to the motor (15). By activating the valve of the pedal brake (21), the “inching” valve (22), located inside it, is shifted.

According to the actuated braking pressure, the “inching” valve (22) opens a higher or lower connection between the regulation pressure and the tank.

In this way, by pressing slightly the brake pedal, the regulation pressure is decreased minimally.

When the braking pressure reaches approximately 14 bar (203 psi), the regulation pressure releases completely into the hydraulic tank. The consequence of this operation is that the moving machine is braked by means of hydrostatic transmission.

NOTE: with “inch” it is meant the lowering of the running speed (=braking), achieved reducing the regulation pressure of travel pump.

Inch is in other words the additional brake of the machine.

When the machine is moving, the travel pump (2) delivers oil under pressure to the motor (15).

When travel high pressure exceeds a value of about 430 bar (6236.6 psi), the pressure cut off (10) decreases the regulation pressure for the whole time that high pressure remains constant on set value.

Beyond the pressure cut, travel high pressure is ensured by means of two pressure limiting valves (8) that actuate though at 465 bar (6742 psi).

According to running direction (forward or backward), one or the other of the limiting valves operates.

The switching valve (14) can deliver the high travel pressure to the actuator cylinder (23).

SECTION 35 - HYDRAULIC SYSTEM In this way, the consumption of the motor (15) is increased, and consequently the transmission operates more slowly but more strongly (= creep gear).

The actuation of the switching valve (14) is done either electrically (by means of travel direction selector) or by means of travel high pressure.

If the gear change is performed depending on the high pressure, the oil pressure reaches the switching valve (14) by means of a non-return valve (18).

If, on the motor (15), the pressure is higher than 190 bar (2755.7 psi), the valve (17) engages, even if not electrically activated.

The consequence is that the high travel pressure is delivered to the actuator cylinder bottom side (23).

This means that, according to a certain resistance of travel, the machine sets automatically to the lowest gear.

This means also that the creep speed (= 1st gear level) is engaged exclusively when you wish to perform travel at a low speed.

With all other conditions is preferable the 2nd gear level.

HIGH-SPEED OPERATION The hydrostatic travel drive of the high-speed version works on the same technical principle as the travel drive of the standard version.

In the high-speed version, an additional gearbox on the rear axle is switched over hydraulically by means of switching valve (A) between standard and highspeed gear.

In the high-speed version, the axial-piston motor (B) is equipped with an additional valve for travel direction (C).

The travel direction valve (C) ensures that, even in case of change of high-pressure side (e.g. travel drive during downhill travel) the swivel angle is always determined by the preselected pressure side of the axial-piston. Undesired swivelling of the variable displacement motor towards greater displacement volumes is thus avoided.

19

20 2.3

SECTION 35 - HYDRAULIC SYSTEM ADJUSTMENTS

To carry out any check and adjustment work on transmission, the hydraulic oil temperature should be about 60 - 70 °C (140 - 158 °F).

MECHANICAL ZERO-SETTING Usually the mechanical zero-setting is not performed automatically. Check and adjustment are then necessary only if:  the pump is going to be disassembled and reassembled;  the operator claims that, although he engages the travel lever to idle, the wheel loader moves in a certain direction. In this case, it is necessary to previously check the correct operation of the travel lever and of the electromagnetically activated switching valve (6).

To check the mechanical zero-setting, it is necessary to connect a pressure gauge (measuring range up to 600 bar) to both measuring points (PHD) for high travel pressure.

S WARNING Now the machine has to be secured with proper means, so that it cannot move neither forward nor backward. The safety regulations have to be observed carefully.

By engine activation make sure that travel lever is set to idle.

Once the safety nut (A) is loose, using a 5 mm (0.196 in) Allen wrench, turn the centring rod (B) until the same pressure (in this case the supply pressure) is read on both measuring points (PHD).

Once the adjustment has been performed, the centring rod (B) has to be secured with the safety nut (A).

The zero-setting is now adjusted.

SECTION 35 - HYDRAULIC SYSTEM HIGH PRESSURE CHECK AND ADJUSTMENT The travel high pressure (PHD) is released both by high pressure relief valve (8) and cut-off valve (10).

NOTE: the maximum high pressure is obtained only by removing the consumption switching on the travel motor (15). To do this, it is necessary to loosen the setscrew for adjustment start (C) by approximately 3 turns. Once this operation has been completed, carry out again the adjustment of the hydraulic motor adjustment start. Each time that the high pressure is measured, the travel lever must be engaged on road travel.

If you prefer to avoid adjusting again the hydraulic motor regulation start, you can, in the majority of cases, also avoid a pressure drop due to the wheel slip, by applying the parking brake at travel stroke end, and avoid the transmission disengagement with parking brake switch.

21

22

3.

SECTION 35 - HYDRAULIC SYSTEM

VARIABLE-DISPLACEMENT PISTON PUMP 21E - 121E - 221E

A. B. C. D.

High pressure relief valves Regulator valve Pressure cut-off valve Pilot valve for forward, backward and reverse gear engagement

Pressure measuring points PSD Supply pressure PHD Travel high pressure Pin

Pressure Inch

321E

E. Forward - reverse - idle gear control cylinder F. Supply pressure relief valve

SECTION 35 - HYDRAULIC SYSTEM 3.1

23

TECHNICAL SPECIFICATIONS 21E

System

Power (useful)

Maximum oil delivery

321E

AV4VG40DA1D2 A4VG56DA1D2 / A4VG56DA1D2 / A4VG71DA1D2 / / 32R 32R 32R 32R cm3/rev (in3/rev)

40 (2.44)

56.0 (3.41)

56.0 (3.41)

71.0 (4.33)

kW (hp)

35.7 (46.1)

38.0 (51)

48.3 (51.6)

49.0 (65.7)

Transmission through Service revolutions (= engine rated speed)

221E

Pump with adjustment depending on engine rpm

Model Displacement

121E

diesel engine direct drive, i = 1.0 rpm l/min (gal/min)

2300

2300

2500

2500

88.8 (23.40)

131.3 (34.60)

136.0 (35.80)

173.4 (45.70)

Supply pressure (rotation speed at full load)

bar (psi)

25 (362)

27 (391)

27 (391)

27 (391)

Adjustment start

bar (psi)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

Adjustment end

bar (psi)

400 (5801) (at 1800 rpm)

400 (5801) (at 1900 rpm)

400 (5801) (at 1900 rpm)

400 (5801) (at 1900 rpm)

Pressure cut-off

bar (psi)

High-pressure relief valves - opening -

bar (psi)

465 (6744)

467 (6773)

467 (6773)

467 (6773)

Hydraulic motor adjustment start

bar (psi)

245 (3553)

190 (2755)

245 (3553) (190 (2755) “high speed” models)

215 (3118)

Voltage

V

430 (6234)

12

24 3.2

SECTION 35 - HYDRAULIC SYSTEM MAIN VALVES

HIGH PRESSURE RELIEF VALVE (A) (21E, 121E, 221E) To check the high pressure relief valves (A), first of all firmly tighten the setscrew of pressure cut-off and connect a pressure gauge (measuring range up to 600 bar (8702.2 psi))) to the relevant measuring point (PHD).

It is advisable to measure the distance “X” on the setscrew (1) first, and to note down this distance, in order to facilitate a new adjustment of the screw.

After that, once the 2nd speed has been engaged, drive the loader against a wall or an earth heap, and observe the pressure gauge. The maximum achievable pressure, both with forward and reverse run, is about 450 bar (6524 psi).

Unlocking To tow the machine, it is necessary to short-circuit (unlock) the hydraulic system of the travel motor, otherwise the transmission and the wheels remain locked.

Loosen the locknut (2) from 1 ½ to 2 turns.

Hold the locknut with a wrench and screw in the setscrew (1) with another wrench, until this one locks the locknut (2). Tighten the nut again.

Once towing is complete, loosen the locknut (2).

Loosen the setscrew (1) up to the retainer and tighten the locknut (2).

S WARNING Do not operate against the high pressure relief valves (A) longer than 5 seconds, because they could get damaged due to high temperature.

The high pressure relief valves (A) do not usually need any adjustment. If anyway the high pressure relief value has to be adjusted, disassemble the valve and loosen the stud screw (7). Then proceed with pressure adjustment by means of the piston (11). Once the adjustment is complete (1 turn corresponds to about 44 bar (638 psi)), tighten the stud bolt (7) again and reassemble the valve on the pump casing.

NOTE: after the assembly check the pressure again.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Setscrew Locknut Valve body O-ring Spring Distance sleeve Stud screw Spring Seal ring Spring seat Little piston Ring

SECTION 35 - HYDRAULIC SYSTEM HIGH PRESSURE RELIEF VALVES (A) (321E) To check the high pressure relief valves (A), first of all firmly tighten the setscrew of pressure cut-off and connect a pressure gauge (measuring range up to 600 bar (8702.2 psi)) to the relevant measuring point (PHD).

It is advisable to measure the distance “X” on the setscrew first, and to note down this distance, in order to facilitate a new adjustment of the screw.

After that, once the 2nd speed has been engaged, drive the loader against a wall or an earth heap, and observe the pressure gauge. The maximum achievable pressure, both with forward and reverse run, is about 450 bar (6524 psi).

S WARNING Do not operate against the high pressure relief valves (A) longer than 5 seconds, because they could get damaged due to high temperature.

The high pressure relief valves (A) do not usually need any adjustment.

If anyway the maximum pressure value has to be adjusted, remove the cap (2) and loosen the safety nut (3), disassemble the valve and loosen the stud screw (7).

Then proceed with the pressure adjustment by means of the setscrew (1).

Once the adjustment is complete, tighten the locknut (3) and reassemble the cap (2).

NOTE: after the locknut (3) has been tightened, check pressure again.

The high pressure adjustment, at the end of operation, has to be secured with a lead seal.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Setscrew Cup Locknut Setscrew O-ring O-ring Spring O-ring Gasket Ring O-ring O-ring Valve inner body Valve outer body Pilot piston Piston Restrictor Spring

25

26

SECTION 35 - HYDRAULIC SYSTEM

ADJUSTING VALVE (B) Adjustment start On measuring port (PHD) for forward speed connect a pressure gauge (measuring range 600 bar (8702.2 psi)). To measure the engine revolutions, you have to connect also a proper revolution counter (better if digital to be connected to injection pipes).

Once the road travel speed has been engaged, move the loader against a wall or an heap of hearth.

Now the engine revolutions hold on 1100 ± 100 rpm.

During this operation an high travel pressure (PHD), equal to 50 bar (725 psi) should be obtained.

To carry out the adjustment, it is necessary to turn the setscrew (2) after loosening the locknut (5). By loosening the setscrew (2), the adjustment start is “anticipated”; by tightening the setscrew, the adjustment start is “delayed”. Once the 50 bar (725 psi) for high pressure have been adjusted at a speed of 1100 ± 100 min, the safety nut has to be retightened (5).

S WARNING Each adjusting valve (B) for 21E, 121E, 221E and 321E has different diaphragms.

This is the reason why the regulator valves are not interchangeable between one machine model and another.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Valve body Setscrew Locknut Spacer Locknut Spring Spring seat Bushing Ring O-ring Piston Elastic ring Elastic ring Orifice Piston housing

SECTION 35 - HYDRAULIC SYSTEM Adjustment end If adjustment start (start-up begin) is correctly adjusted, the adjustment end is done automatically. As for checking and regulation begin adjustment, connect a pressure gauge for high pressure and a revolution counter.

With a certain number of revolutions, a high pressure (PHD) of 400 bar (5799 psi) is achieved.

NOTE: also the measuring has to be performed with road travel speed engaged, because otherwise the wheels will slip beforehand. To prevent the change of absorption of the motor (M), unscrew the setscrew for adjustment start (V) by about 3 turns. Once this operation has been completed, carry out again the regulation start of the hydraulic motor.

27

28

SECTION 35 - HYDRAULIC SYSTEM

PRESSURE CUT-OFF VALVE (C) As the pressure cut off involves both the forward and reverse speed, it is sufficient to check the high pressure only with forward speed.

For this operation, connect a pressure gauge (measuring range 600 bar (8702.2 psi)) to measuring port for high pressure of forward gear (PHD) and once the road travel speed has been engaged, push with the loader against a wall or an heap of earth.

NOTE: also the measuring has to be performed with road travel speed engaged, because otherwise the wheels will slip beforehand. To prevent the switching of oil absorption in the travel motor, loosen the setscrew (2) of about 3 turns. Once this operation has been completed, carry out again the regulation start of the hydraulic motor.

On the setscrew for pressure cut-off (1), the pressure cut-off can be adjusted without any disassembly. The pressure cut-off value is of 430 ± 10 bar (6234 ± 145 psi).

NOTE: before a possible disassembly of pressure cut-off valve, it is advisable to measure the gap “X” to facilitate its resetting.

SWITCHING VALVE (D) 1.

2.

3.

4.

5.

6.

7.

Valve body Little piston Distance sleeve Spring Magnet Plunger Gasket

SECTION 35 - HYDRAULIC SYSTEM ACTUATOR CYLINDER (E)

1.

2.

3.

4.

5.

6.

7.

8.

9.

O-ring Cover Piston Spring Centring rod Spring seat Elastic ring Locknut Locknut

10.

11.

12.

13.

14.

15.

16.

17.

Spring Screw Screw Distance sleeve O-ring Bushing Bushing Cylinder liner

29

30

SECTION 35 - HYDRAULIC SYSTEM

SUPPLY PRESSURE RELIEF VALVE (F) (21E, 121E, 221E) The supply pressure is checked on the measuring point (PSP) and adjusted on feed pressure relief valve (F).

The rated value of the supply pressure is: 25 ± 2 bar (362 ± 29 psi) at nmot = 2300 rpm. (21E) 27 ± 2 bar (391 ± 29 psi) at nmot = 2300 rpm. (121E, 221E)

Should it be necessary to correct the pressure value, it is only possible to operate by adding or removing a shim (3).

NOTE: during the basic adjustment (for instance after valve replacement or disassembly), first completely relieve the pressure of the valve spring, taking away all shims (3) and connect a pressure gauge (measuring range 60 bar (870 psi)) to the measuring point (PSP). Then start the engine and measure the supply pressure according to the engine rpm. If the supply pressure is too low, try to adjust it by adding proper shims (1 mm = 3.9 bar) (0.039 in = 57 psi).

1.

2.

3.

4.

5.

6.

O-ring Valve body Shim Spring Distance sleeve Piston

A. Piston side B. Sealing/Control edge C. Tank channel

SECTION 35 - HYDRAULIC SYSTEM SUPPLY PRESSURE RELIEF VALVE (F) (321E) The supply pressure is checked on the measuring point (PSP) and adjusted on feed pressure relief valve (F).

The rated value of the supply pressure is: 25 ± 2 bar (362 ± 29 psi) at nmot = 2300 rpm.

Should it be necessary to correct the pressure value, it is possible to adjust it by means of the setscrew (3) of the supply pressure relief valve (F).

By unscrewing the screw, the feed pressure is reduced; by tightening it, it increases.

NOTE: during the basic adjustment (for instance after valve replacement or disassembly), first of all relieve the pressure of the valve spring by turning the setscrew (3) to the left and connect a pressure gauge (measuring range 60 bar (870.2 psi)) on the measuring point (PSP). Then start the engine and slowly tighten the setscrew (3), until the desired supply pressure is achieved, according to the relevant engine rpm.

1.

2.

3.

4.

5.

6.

7.

Spring Valve body Setscrew Locknut Distance sleeve Piston Gasket

A. Piston side B. Sealing/Control edge C. Tank channel

31

32 3.3

SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY

GENERAL INSTRUCTIONS Disconnect and plug all different hydraulic connections.

Replace all O-rings and seal rings.

Check all seal rings and sliding and coupling surfaces for wear.

Use only original spare parts.

MAIN COMPONENTS

1. Elastic ring 2. Shim 3. Pump body

A. B. C. D. E.

Piston assy Rotary assy Solenoid valve Distributor plate Boost pump

SECTION 35 - HYDRAULIC SYSTEM SWITCHING VALVE (C)

1.

2.

3.

4.

5.

6.

7.

8.

Screw Screw O-ring O-ring O-ring Cross pin Magnet Screw

Unscrew and remove the screws (1) and (2).

9.

10.

11.

12.

13.

O-ring Spring Spring seat Valve body Spool

C. Solenoid valve

33

34

SECTION 35 - HYDRAULIC SYSTEM

Replace the O-rings (3), (4) and (5).

Only if necessary, disassemble the switching valve:  unscrew and remove the screws (8);  remove the magnet (7);  replace the O-ring (9);  remove the body (12), the spring (10) and the seat (11);  remove the spool (13).

SECTION 35 - HYDRAULIC SYSTEM BOOST PUMP (E)

1.

2.

3.

4.

5.

Screw Cover O-ring External gear Inner gear

Mark the reference position.

Loosen and remove the fixing screws (1).

6.

7.

8.

9.

E.

Distributor plate O-ring Coupling Snap ring Auxiliary pump

35

36

SECTION 35 - HYDRAULIC SYSTEM

To remove the complete cover (2), use a screwdriver.

Unscrew the nut (2) and remove the control plate (6).

Replace the O-ring (7).

If requested:  remove the snap ring (9), the coupler (8) and the gears (5) and (4) from the cover (2);  replace the O-ring (3).

SECTION 35 - HYDRAULIC SYSTEM CONTROL PLATE ASSY (D)

K. X. Z. W.

Pressure cut-off valve High pressure relief valve Supply pressure relief valve Regulator valve

Pressure cut-off valve (K) Mark dimension H1 before removing the valve.

Unscrew and remove the pressure cut-off valve (K).

1.

2.

3.

4.

5.

6.

7.

8.

Screw Distributor plate Cross pin Spacer Bushing Bushing O-ring Control valve

37

38

SECTION 35 - HYDRAULIC SYSTEM

If necessary disassemble the valve (K).

Check the conditions of the O-ring (12), of the locknut (2) and of the setscrew (1). Replace if necessary.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Setscrew Locknut Body O-ring Distance sleeve Spring Plunger Needle Spool Pin Body O-ring

High pressure relief valve (X) Mark dimension H2 before removing the valve.

Unscrew and remove the pressure relief valve (X).

If necessary disassemble the valve (X).

Check the conditions of the O-ring (12), of the locknut (1) and of the setscrew (2). Replace if necessary.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Locknut Setscrew Spring Plunger Body Spring seat O-ring Spring Needle Seat Body O-ring

SECTION 35 - HYDRAULIC SYSTEM Regulator valve (W) Loosen and remove the regulator valve (W).

Check orifice: it should not be damaged.

 If necessary disassemble the valve (W).  Check the conditions of the O-ring (3), of the locknut (1) and of the setscrew (4). Replace if necessary.

1.

2.

3.

4.

5.

Locknut Body O-ring Setscrew Pin

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Spring seat Spring Ring Seal ring Piston Ring Washer Nut Liner Disc

39

40

SECTION 35 - HYDRAULIC SYSTEM

Supply pressure relief valve (Z) Unscrew and remove the supply pressure relief valve (Z).

If necessary disassemble the valve (Z).

Check the conditions of the O-ring (5), of the locknut (8) and of the setscrew (4). Replace if necessary.

1.

2.

3.

4.

5.

6.

7.

8.

Spring Spring seat Plunger Setscrew O-ring Body O-ring Locknut

Distributor plate assy Loosen and remove the screws (1).

Mark the assembly position of the distributor plate assy.

Remove the control valve (2) and the distributor plate (8).

Replace the O-ring (7).

SECTION 35 - HYDRAULIC SYSTEM PISTON ASSY (A)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Screw Cover O-ring Ring O-ring Piston assy O-ring Ring O-ring Cover Screw Nut

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Bushing Bushing Spring seat Spring Spring Pin Disc Liner Shaft Elastic ring O-ring

41

42

SECTION 35 - HYDRAULIC SYSTEM

Loosen and remove the screws (1).

Remove the cover (2) and the ring (4).

Replace the O-rings (3) and (5).

Mark the position of the cover (10), and measure the dimension (K) of the “zero position”.

Unscrew and remove the nut (12).

SECTION 35 - HYDRAULIC SYSTEM Loosen and remove the screws (11).

Remove the cover (10) and the ring (8).

Replace the O-rings (7) and (9).

Remove the piston assy (6).

43

44

SECTION 35 - HYDRAULIC SYSTEM

If necessary disassemble the piston assy.

Fit tool device and preload the spring (16).

Remove the elastic ring (22).

Disassemble the piston assy.

SECTION 35 - HYDRAULIC SYSTEM COMPLETE ROTARY ASSY (B)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Elastic ring Seal ring Pin Plug Plug Locknut Setscrew Rotary assy Shaft Elastic ring Bearing Elastic ring Bearing cup Bearing

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Retainer Plate Retainer Swash plate Pistons Pistons holding plate Articulated joint Washer Belleville washers Cylinder Washer Spring Elastic ring

45

46

SECTION 35 - HYDRAULIC SYSTEM

Remove the elastic ring (1).

Screw in the two screws (V) into the holes of seal ring (2).

Remove the seal ring (2).

Loosen and remove the caps (4) and the pins (3).

SECTION 35 - HYDRAULIC SYSTEM Mark the position of the setscrew (7) (A).

Record setting measure.

Set the screw to disassembly position (B).

Loosen and remove the locknuts (6) and the setscrews (7).

Push off rotary assy.

Remove the drive shaft (9) and the bearing (10) with hammer strokes.

47

48

SECTION 35 - HYDRAULIC SYSTEM

Remove the swash plate (18), the bearings (14) with the relevant cups (13).

Disassemble the pistons (19), the plate (20), the articulated joint (21), the washer (22), the belleville washers (23) and the cylinder (24).

Remove the snap ring (27), the washers (25) and the spring (26) from the cylinder (24).

SECTION 35 - HYDRAULIC SYSTEM Inspections Check on shaft (9):  teeth (P);  sealing surface (Q);  splined surface (R);  bearing seat (S).

Check the swash plate (18):  the sliding surfaces of the bearings.

 the sliding surface.

Check the pistons (19):  slides (V) and than check the axial backlash.

49

50

SECTION 35 - HYDRAULIC SYSTEM

Check the plate (20) and the articulated joint (19):  contact surfaces between the plate (20) and the articulated joint (19) must allow the gliding.

Check the cylinder (24):  pistons gliding seats (Z);  cylinder inner splined surface (X).

 contact areas (Y) between cylinder (24) and control plate.

Check:  the plate seat (16) on piston.

SECTION 35 - HYDRAULIC SYSTEM 3.4

ASSEMBLY

COMPLETE ROTARY ASSY (B) Insert the bearing cups (13).

Assemble the bearings (14) and the relevant retainers (15) and (17) on the swash plate (18) by keeping them in place with a proper assembly system:  use a folded metal sheet (L);  use grease.

Assemble the assy consisting in swash plate (18), bearings (14) and bearing cups (13) into the relevant seat. Collect the assembly system, if present.

NOTE: check the correct seating of the assy into its relevant seat.

51

52

SECTION 35 - HYDRAULIC SYSTEM

Assemble the pins (3) and the caps (4).

Screw in the locknuts (6) and the setscrews (7) using the seating values marked during disassembly.

Assemble the shaft (9) complete with the bearing (11).

SECTION 35 - HYDRAULIC SYSTEM Assemble the seal ring (2).

Press-in shaft seal with bush to stop.

Assemble the elastic ring (1).

Assemble the articulated joint (21), the belleville washers (23) and the washer (22) on the cylinder (24).

Assemble the pistons (19) and the plate (20) on the cylinder (24).

Keep the assy assembled.

53

54

SECTION 35 - HYDRAULIC SYSTEM

Assemble the cylinder assy (24).

Assemble the washers (25) and the spring (26).

Install the elastic ring (27).

PISTON ASSY (A) Insert the piston assy (6).

SECTION 35 - HYDRAULIC SYSTEM Assemble the new O-rings (3) and (5) and the ring (4).

Assemble the cover (2) and fasten it with screws (1).

Assemble the new O-rings (7) and (9) and the ring (8).

Assemble the cover (10).

Screw the nut (12) considering the assembly dimension marked during disassembly.

Screw the screws (11).

OTHER ASSEMBLIES

1. Plate clockwise rotation - indexed in the direction of rotation.

2. Plate counter clockwise rotation - indexed in the direction of rotation.

55

56

SECTION 35 - HYDRAULIC SYSTEM

Press the cylinder to the bottom.

Screw up the screw.

Groove in mounting position.

Assemble the control valve plate assy complete with the new O-ring.

To seat the valve plate assy correctly, follow the mark applied during disassembly. Lock the control valve plate assy by tightening the relevant fixing screws.

Assemble the auxiliary pump assy complete with the new O-ring.

Fasten the auxiliary pump by means of the relevant fixing screws.

SECTION 35 - HYDRAULIC SYSTEM Assemble switching valve with new O-rings.

Fasten the solenoid valve by means of the relevant fixing screws.

57

58

SECTION 35 - HYDRAULIC SYSTEM

4.

GEAR PUMP

4.1

TECHNICAL SPECIFICATIONS

Model Displacement Maximum pressure

cm3/rev (in3/rev)

21E

121E

221E

321E

022R0020KB

032R0020KB

028R0020KB

032R0020KB

22.5 (1.37)

32 (1.95)

28 (1.70)

32 (1.95)

bar (psi)

270 (3914)

21E

121E

221E

321E

A

57.5

57.5

57.5

59

B

112.8

118.2

118.8

123.3

C

120

120

120

121.5

D

26

26

26

29

SECTION 35 - HYDRAULIC SYSTEM 4.2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

COMPONENTS

Elastic ring Seal ring Flange Gasket Retainer Gasket Bearing Gear Gear Bearing

11.

12.

13.

14.

15.

16.

17.

18.

19.

Cross pin Pump body Priority valve Screw Gasket Retainer Gasket Closing plate Screw

59

60 4.3

SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY

DISASSEMBLY Loosen and remove the screws (14).

Disassemble the priority valve (13).

Loosen and remove the screws (19).

Disassemble the end plate (18) and the gasket (17).

Remove the elastic ring (1).

Remove the seal ring (2).

SECTION 35 - HYDRAULIC SYSTEM Separate the pump body (12) from the flange (3).

Collect the pins (11) and the gasket (4).

If necessary, disassemble the pump body (12):  remove the retainer (5);  check the condition and remove the gasket (6);  remove the bearings (7) and the gears (8) and (9);  remove the gasket (15);  remove the retainer (16).

ASSEMBLY Repeat the operations described for disassembly in reverse order.

INSPECTIONS Check that the disassembled components are free from scales and to not show evidence of fading; after that, clean them with fuel.

NOTE: do not clean rubber components with fuel.

Pump body The pump is designed to operate efficiently when its gears rotate with the teeth tips very close to the body. Therefore a used pump shows the evidence of a contact near to the suction port. The rated length of the contact evidence is about 1/3 of the inner circumference of the body. If the evidence is longer than the half circumference, this could mean the presence of wear on a bushing of gear shaft.

The flange should show: 1. Acceptable evidence 2. Unacceptable evidence

61

62

SECTION 35 - HYDRAULIC SYSTEM

Bearing A bearing can be considered in good condition, when its inner gliding surface is not rough and the gears spacer rings are polished and free from evident scores.

Replace bearing under following conditions:  when inner gliding surface roughness is such, that it can be felt with a nail;  when the contact extends over the complete inner gliding surface;  when the roughness of side surface is such, that it can be felt with a nail;  when foreign bodies are stuck between the couplings of bearings, gears and of pump body.

Gear Replace the gear under following conditions:  the shaft surface or the gear side surface is rough and it can be felt with a nail;  teeth sides are split;  the teeth surface shows some cracks or it is worn only on one side.

NOTE: if the surface is rough or faded, also bushing or pump body could be in bad condition, it is necessary to re-check them.

SECTION 35 - HYDRAULIC SYSTEM

5.

63

PRIORITY VALVE

The priority valve (1) is installed on the gear pump.

5.1

TECHNICAL SPECIFICATIONS

Rated pressure ...................................................................................................................... 250 bar (3625 psi) Displacement rate .......................................................................................................... 84 l/min (22.10 gal/min) Pre-charge pressure .................................................................................................................... 7 bar (102 psi)

64

6.

SECTION 35 - HYDRAULIC SYSTEM

TRAVEL MOTOR

The travel motor is designed to transfer motion, by means of the speed change, to the front and rear axles.

The travel motor is conceived with tilted axle (tilted body), with variable displacement, and with a rotary assy with axial pistons.

The displacement regulator is mounted on the motor head.

The displacement can vary from maximum to minimum.

At travel thrust or during travel on slopes the engine displacement increases with consequent increase of travel force.

To achieve the maximum travel speed, the engine displacement should be at minimum value.

6.1

TECHNICAL SPECIFICATIONS 21E

121E

Type Displacement gmax / gmin Maximum speed

221E

A6VM107HA1U1 / 63W

A6VM80HA1U1 / 63W cm3 (in3) rpm

321E

80 / 18.8 (4.88 / 1.14)

80 / 23.7 (4.88 / 1.44)

80 / 24.8 (4.88 / 1.51)

107 / 34.5 (6.52 / 2.10)

4352

5289

5289

4811

Delivery pressure

bar (psi)

25 (362)

25 (362)

25 (362)

25 (362)

Service pressure

bar (psi)

245 (3552)

190 (2755)

245 (3552)

215 (3117)

10 (145)

10 (145)

10 (145)

10 (145)

Pressure increasing spring bar (psi) Voltage

V

12

“HIGH SPEED” 121E Type Displacement Qmax / Qmin Maximum speed

221E

321E

A6VM80HA1R1 / 63W cm3 (in3) rpm

80 / 26.5 (4.88 / 1.61)

80 / 29.2 (4.88 / 1.78)

80 / 35.4 (4.88 / 2.16)

4770

4770

4770

Delivery pressure

bar (psi)

25 (362)

25 (362)

25 (362)

Service pressure

bar (psi)

190 (2755)

190 (2755)

215 (3117)

Pressure increasing spring

bar (psi)

10 (145)

10 (145)

10 (145)

Voltage

V

12

SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM ù

65

66 6.2

SECTION 35 - HYDRAULIC SYSTEM MAIN COMPONENTS

1. Rotary assy 2. Regulator assy 3. Qmin setscrew of swivel angle limitation; not adjustable 4. Qmax setscrew of swivel angle limitation 5. Setscrew 6. Solenoid valve 7. Travel direction valve

M1 Measuring point of regulation start PHD Measuring point of high travel pressure

SECTION 35 - HYDRAULIC SYSTEM 6.3

67

OPERATION

ROTARY ASSY The rotary assy consists of: control plate (1), seven pistons (2), driving shaft (3), cylinder block (4), spring (5), central pivot (6), bearings (7), seal ring (8).

The hydraulic oil pressure is applied to the piston by means of the control plate (1), and the pistons, under the oil thrust, perform the extension stroke and, being bound to the driving shaft, convert their motion into a rotary motion of the driving shaft.

The cylinders block turns with the pistons that by carrying out in sequence the extension stroke, generate an output torque on drive shaft.

The oil, after pistons displacement, is discharged on pistons return line during the retraction stroke.

The cylinders block can vary its tilting with relation to the shaft axis from 5° to 25°. When the tilting angle is changed, also the piston stroke changes and as a consequence the generated torque.

The output torque of the drive shaft depends on the hydraulic pressure and on the tilting of cylinders block, while the rotating speed depends on the oil flow and on the tilting of cylinders block; so if the cylinders block tilting is reduces, as a consequence the speed increases and the tractive force decreases, on the contrary, by increasing the angle the speed decreases and the traction force increases.

68

SECTION 35 - HYDRAULIC SYSTEM

REGULATOR ASSY The motor is equipped with an automatic capacity regulator according to the service pressure. The control takes service pressure from port (A) or (B) and checks the position of the tilted shaft and then the motor displacement from a minimum position (minimum torque - maximum speed) to a maximum displacement (maximum torque - minimum speed).

In detail the delivery pressure is connected with the control spool opposite to the setting spring.

When the pressure exceeds the spring setting, the spool shifts and sets in contact input pressure with actuator cylinder. This latter by shifting varies the engine displacement from minimum to maximum.

By varying the displacement, the pressure decreases and the balance is re-established.

The regulator is equipped with an additional control for the control plate drive at maximum displacement, by means of a power control pressure at input (X).

This outer pilot control is performed through the electric energizing of solenoid (D2) controlling the travel speed variation.

If normal speed (hare) is selected though the steering column, solenoid valve (D2) is not energized, and power control pressure does not reach the travel motor.

If, instead low speed (tortoise) is selected, solenoid valve (D2) energizes and allows the passage of power control pressure reaching input (X) of travel motor. This power control pressure is applied to the displacement control valve together with the service pressure, and generates the axle shifting to maximum displacement.

Under this condition, with additional pilot control engaged, the rotation speed of the motor will be lower than the engine rotation speed under normal condition.

1. Control block 2. Cover 3. Piston

4. Positioning pin 5. Slide

SECTION 35 - HYDRAULIC SYSTEM

69

CHECKING AND ADJUSTING HYDRAULIC MOTOR ADJUSTMENT START (ABSORPTION SWITCHING) On measuring ports (M1) and (PHD) of forward speed connect some pressure gauges with a measuring range 600 bar (8699 psi). Once the road travel speed has been engaged, move the loader against a wall or an heap of earth. At this point accelerate slowly the engine, keeping a watch on both pressure gauges.

The start regulation is reached when on measuring port (M1) is detected the first pressure increase. The high travel pressure (PHD) detected at the same time on the other pressure gauge, represents the adjusted value for regulation start. If this value is too low (regulation start too early), unscrew setscrew (5) counterclockwise. In this way you allow an higher preload of the spring for regulation start.

If this value is too high (regulation start delayed), screw up setscrew clockwise. The hydraulic motor adjustment stops when both pressure gauges indicate nearly the same pressure, that should be of about 10-20 bar (145-290 psi) beyond the adjustment start.

NOTE: high travel pressure, allowing to adjust the adjustment start of hydraulic motor, can be read also on measuring port (PHD*).

70 6.4

SECTION 35 - HYDRAULIC SYSTEM REMOVAL

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Disconnect the hoses (1).

Support the motor (2) with a rope.

Loosen and remove the screws (3).

Remove the motor (2).

SECTION 35 - HYDRAULIC SYSTEM 6.5

DISASSEMBLY AND ASSEMBLY

71

72 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

SECTION 35 - HYDRAULIC SYSTEM Elastic ring Shim Seal ring Engine body Screw Plug Plug Setscrew Locknut Rotary assy Gasket Regulator assy Screw Regulator assy body Positioning spool Elastic ring Shim Bearing Shim Bearing Shaft Return plate Screw Central piston Spring Shim Pistons Piston gasket

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

Cylinder Pin Distributor plate Screw Cover O-ring Dowel Cross pin Plug Pin Valve body O-ring Screw Spring Seat Spring Needle Ring Piston Pin O-ring Plug Cover Cross pin Setscrew Nut Screw

SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY To disassemble the regulator assy (12) set rotary assy to a tilting angle of 0°.  Mark value “X”  Loosen and remove the upper setscrew (8) and the upper locknut (9)  Place rotary assy to 0° handling on lower screw (8)  Mark position to 0°  Loosen and remove the screws (13)  Remove the regulator assy (12) and the gasket (11)

Remove the elastic ring (1) and the shim (2).

73

74

SECTION 35 - HYDRAULIC SYSTEM

Fit the sleeve for gasket (A) assembly until you touch it and mark the position. Screw up screws (V) into the rubber coated holes of the gasket (3).

Remove the seal ring (3).

By means of a puller, remove the rotary assy (10).

Disassemble the rotary assy.

SECTION 35 - HYDRAULIC SYSTEM Remove the control plate (31), the pin (30) and the cylinder (29).

Unscrew the screws (23) (use torsion tool because they are glued). Remove the plate (22), the central piston (24) and the pistons (27).

Remove the elastic ring (16) and the shim (17). Remove the bearings (18) and (20) and the shim (19) from the shaft (21).

75

76

SECTION 35 - HYDRAULIC SYSTEM

If necessary, disassemble the regulator assy.

Remove the regulator body (14):  unscrew and remove the screws (55);  unscrew and remove the screw (53) and the nut (54) and take out the pin (52);  remove the cover (51) checking the condition of Oring (49);  remove the pin (48), the piston (47), the ring (46), the pilot piston (45), the spring (44), the seat (43) and the spring (42).

Loosen and remove the screws (32).

Remove the cover (33) checking the condition of the O-ring (34).

Remove the actuator spool (15).

SECTION 35 - HYDRAULIC SYSTEM Loosen and remove the screw (41).

Remove the screw (41), the valve body (39) and the pin (38).

Check the O-ring (40) conditions.

INSPECTIONS AND CHECKS Check shaft for:  presence of corrosion, erosion or fretting; no damage to teeth.

77

78

SECTION 35 - HYDRAULIC SYSTEM

Check the central pin for:  scores and pittings.

Check the pistons for:  scores and pittings.

Check the return plate for:  scores and wear.

Check the cylinder for: A. Bores with no scores, not worn.

B. Even surface, without splits or scores.

SECTION 35 - HYDRAULIC SYSTEM Check the regulator body for:  gliding surface and side guides free of scores and wear.

Check the engine body for:  bearing areas free of scoring and no evidence of wear.

ASSEMBLY Assemble the bearings.

79

80

SECTION 35 - HYDRAULIC SYSTEM

Caulk the bearings (18) and (20) on the shaft (21).

Determine the value of the shim (19) according to the value of M (correct preload dimension).

Preload the bearings.

Determine the value of shim (17):  assemble the elastic ring (16) to determine the value S;  determine the value of the shim and disassemble the elastic ring;  assemble the shim (17) and reassemble the elastic ring (16).

Assemble the gaskets (28) on the pistons. Assemble the pistons (27) and the central piston (24) on the disc (22).

Fit disc with pistons and fix it by tightening screws (23).

SECTION 35 - HYDRAULIC SYSTEM Fit the spring (25) and the shim (26), assemble the cylinder (29). Stop rotary assy in vertical position and lock the liner with a screw and a nut (J).

Assemble the sleeve (A) for the rotary assy (10) assembly.

Heat the body (4) to 80 °C (176 °F).

81

82

SECTION 35 - HYDRAULIC SYSTEM

Assemble the rotary assy (10) up to the stroke end (4) on the body (to the maximum tilting angle).

Unscrew and remove the screw and the nut (J). Assemble the gasket (11).

Assemble the pin (30) and the centring joint (31).

Assemble body of regulator assy (14) by tightening the screws (13). Achieve the correct inclination of the regulator assy through the setscrew (8) and the locknuts (9).

SECTION 35 - HYDRAULIC SYSTEM Check and/or determine values X using the measuring gauge (J).

Assemble the regulator assy.

83

84

SECTION 35 - HYDRAULIC SYSTEM

Assemble the gasket (3). By means of sleeve (A) fit gasket by inserting the sleeve up to mark applied before disassembly.

Assemble the shim (2) and the elastic ring (1).

SECTION 35 - HYDRAULIC SYSTEM

7.

ONE-WAY DISTRIBUTOR VALVE

TSS = discharge line from working attachment control valve FMS = drain line from travel motor HTF = to oil tank T = to oil tank TLE = discharge line from power steering 51 = discharge line from brake pedal valve OLS = discharge line from OLS valve and brake pedal valve RV1, RV2, RV3 = check valve

85

86

8.

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC OIL TANK 21E

121E

221E

321E

67

67

74

(17.60)

(17.60)

(19.50)

40 (10.50)

40 (10.50)

40 (10.50)

System capacity

litres (gal)

56 (14.70)

Tank capacity

litres (gal)

40 (10.50)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Oil tank Level gauge Filter Nut Washer Vent filter Pressure gauge Cover Gasket Filter element O-ring Filter head

SECTION 35 - HYDRAULIC SYSTEM 8.1

87

OIL FILTER

1.

2.

QR QS QR > QS

Return oil to hydraulic tank Oil under pressure for supply pump A2 Return oil of working equipment Oil under pressure and filtered for supply pump A2 Condition: return flow must be higher than suction flow

Return suction filters are installed on machines both with open hydraulic circulation (for instance with working equipment) and with hydrostatic activation closed (for instance with transmission).

These filters incorporate in a single filter both the return filter operation of open circuit and the suction filter closed activation.

The return flow QR must always be higher than the flow rate QS of supply pump.

The return quantity of working equipment is conveyed to the filter by means of connection (A) and cleaned by filter element.

Through setting under pressure of valve (V1) a standard pressure (of 0.5 bar (7.25 psi)) is accumulated, this ensures that the necessary flow rate for supply pump of power steering is taken from the non-return quantity filtered through connection (B).

A. B. FE V1 V2 V3 T

Return pipes, filter inlet, connection A Suction pipes, filter outlet, connection B Filter element Valve under pressure By-pass valve Valve actuating after suction Tank inlet or emergency suction

Exceeding quantities are discharged into the tank (connection T) through the setting under pressure valve.

With high dynamic pressures the flow rate is led to the tank through the by-pass valve (V2) (standard 2.5 bar (36.25 psi)) (pressure limitation: unfiltered oil does not reach the suction pump).

In this way the formation of excessive pressure into the return pipes or inside of hydrostatic activation casing is prevented (protection of ring gaskets, particularly with cold start).

Through valve (V3) after suction, it is possible to ensure a passage from the tank to suction side (emergency operation).

88

9.

SECTION 35 - HYDRAULIC SYSTEM

TROUBLESHOOTING FAULT

Hydraulic system does not operate regularly.

Hydraulic oil overheated.

CAUSE

ACTION

Oil level low.

Top up oil level.

Oil filter clogged.

Replace the oil filter.

Hydraulic system faulty.

Consult your Dealer.

Oil level low.

Top up oil level.

Oil filter clogged.

Replace the oil filter.

Delivery control wrongly adjusted.

Adjust delivery control for lower delivery.

Hydraulics of steering and Transmission coupling faulty. working system does not react.

Replace the coupler.

Machine does not move.

Oil level low.

Top up oil level.

Engine does not come under load.

Operation faults in the pressure con- Consult your Dealer. trol circuit of travel pump.

Travel motor not connected with rear Recheck installation of travel motor. axle.

Engine under load.

Parking brake still applied.

Release the parking brake.

Parking brake switch still stuck in opening position.

Replace the switch.

Travel direction lever faulty.

Replace the lever.

Rear axle locked.

Check axle.

Brake locked.

Release the brake.

Machine does not move either Travel direction valve faulty. forward or back.

On a flat surface the machine starts only with high engine speed.

Replace the solenoid.

Travel direction lever faulty.

Replace the lever.

Supply filter contaminated.

Clean or replace the filter, if necessary.

SECTION 35 - HYDRAULIC SYSTEM

FAULT

CAUSE

Insufficient acceleration in both Supply filter contaminated. travelling directions.

89

ACTION Clean or replace the filter, if necessary.

Unsuitable oil.

Replace with correct oil.

Oil temperature too high.

Check and try to lower the temperature.

Friction loss in the axle traction.

Consult your Dealer.

Operation faults in the pressure con- Consult your Dealer. trol circuit of travel pump.

Operation faults in the high pressure Consult your Dealer. circuit of transmission.

Operation faults in the pressure feed Consult your Dealer. circuit of travel pump.

Maximum travelling speed not Supply filter contaminated. reached.

Clean or replace the filter, if necessary.

Unsuitable oil.

Replace with correct oil.

Oil temperature too high.

Check and try to lower the temperature.

Friction loss in the axle traction.

Consult your Dealer.

Operation faults in the pressure con- Consult your Dealer. trol circuit of travel pump.

Operation faults in the high pressure Consult your Dealer. circuit of transmission.

Operation faults in the pressure feed Consult your Dealer. circuit of travel pump.

90 NOTES:

SECTION 35 - HYDRAULIC SYSTEM

SECTION 39 - FRAME 1. ARTICULATED JOINT.................................................................................................................................. 1 1.1 COMPONENTS ..................................................................................................................................... 1 1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 2

SECTION 39 - FRAME

SECTION 39 - FRAME

1.

ARTICULATED JOINT

1.1

COMPONENTS

1.

2.

3.

4.

5.

6.

Screw Cover Tension rings Rings Screw Plate

7.

8.

9.

10.

11.

12.

Shim Pin Bearing Spacer Front frame Rear frame

1

2

SECTION 39 - FRAME

The articulated joint connects the front frame with the rear one.

1.2

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY Before changing the components of the articulated joint, separate the front frame (11) from the rear frame (12).

S WARNING Before disassembly of articulated joint, lock the front frame and the rear one so as to avoid any accidental movement.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Extract the pins from the steering cylinders on the front frame. Remove the supports of the hoses. Disconnect the cardan shaft from the gear box.

Arrange a wooden support under both swinging axle sides and lay it on it.

Arrange a wooden support under the front frame.

Place a mobile hoist (hydraulic jack) under the rear frame, close to the articulated joint.

Loosen and remove the screws (1), then remove the covers (2).

Apply a stroke with a hammer under the lower side of pin (8). Tension rings (3) get loose.

Remove the lower rings (3) and the ring (4).

Push out pin (8) upwards, using a proper hydraulic tool. Remove upper tension rings (3) and the ring (4).

NOTE: while pulling out or pushing in the pin with a press, pay attention not to incline the front and rear frame. The holes for pin alignment must be aligned.

SECTION 39 - FRAME Separate both frames one from the other so that they cannot move.

Loosen and remove the screws (5), then remove the cover (6) and the disc (7).

Place a sleeve or tube on outer ring of lower bearing (9). With great care, push the bearing upwards only as far as required to place a puller between the upper bearing (9) and the spacer (10).

NOTE: the lower bearing must not be pushed completely out of its seat, otherwise it cannot be taken out from the frame.

Pull out the upper bearing (9).

Pull out the lower bearing (9) and the spacer (10).

ASSEMBLY Assembly has to be performed in reverse sequence.

NOTE: clean and cover with a thin layer of oil components contact surfaces.

Use exclusively oil without bisulphite of molybdenum (MoS2).

Press the upper bearing (9) up to stroke end.

Measure the gap between “t” and “t1”.

Remove the backlash “a” (a = t - t1) between the bearing (9) and the cover (6), with the shim (7).

Screw in the screws (5) and tighten them to the prescribed torque of 75 Nm (55.31 lbf·ft).

Assemble the spacer (10) and the lower bearing (9).

NOTE: the spacer (10) must not have backlash and it must be centred on the inner rings of the bearings (9).

Approach both frames and align them.

Press them from the top downwards up to the pin (8) stroke end.

Measure the pin (8) projection at top (X) and at bottom (Y). It must have the same value.

Assemble the rings (4) and (3) in the outlined position.

Place the covers (2), evenly screw in the screws (1) and tighten to the prescribed torque of 105 Nm (77.44 lbf·ft) crosswise.

Lubricate the bearings (9).

3

4 NOTES:

SECTION 39 - FRAME

SECTION 41 - STEERING SYSTEM 1. OPERATION................................................................................................................................................. 1 1.1 EMERGENCY STEERING .................................................................................................................... 3 1.2 PRESSURE ADJUSTMENT .................................................................................................................. 4 2. POWER STEERING ..................................................................................................................................... 5 2.1 TECHNICAL SPECIFICATIONS............................................................................................................ 6 2.2 COMPONENTS ..................................................................................................................................... 7 2.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8 2.4 TROUBLESHOOTING......................................................................................................................... 24 2.5 SPECIAL TOOLS................................................................................................................................. 25 3. STEERING CYLINDER .............................................................................................................................. 26 3.1 REMOVAL AND INSTALLATION ........................................................................................................ 27 3.2 DISASSEMBLY.................................................................................................................................... 29 4. TROUBLESHOOTING................................................................................................................................ 34

SECTION 41 - STEERING SYSTEM

SECTION 41 - STEERING SYSTEM

1.

1.

2.

3.

4.

5.

6.

OPERATION

Diesel engine Pump at variable displacement Gear pump Priority valve Steering wheel Power steering

7.

8.

9.

10.

11.

Steering cylinder Oil tank Return filter One-way distributor valve Valve

1

2

SECTION 41 - STEERING SYSTEM

The gear pump (3), activated by the diesel engine (1), sucks oil from the oil tank (8) and delivers it to the priority valve (4). When the steering system is inoperative, the power steering (6) does not send any signal in the form of pressure to the priority valve, therefore delivery oil is available for working attachment.

When the steering is activated, a pressure generates inside the pipe for control delivery, which moves the switching piston of the priority valve (4).

According to the intensity of the signal, the priority valve (4) now sends a higher or lower quantity of oil to the power steering (6).

Downstream, the steering is ensured by two valves inside the power steering, set at 240 bar (3480 psi).

After the activation of the steering cylinder (7), the oil, through the power steering (6), the one-way distributor valve (10) and the return filter (9), returns to the oil tank (8). The check valve inside the one-way distributor valve (10) prevents, during this operation, that the steering oil returns to the oil tank (8) without being filtered.

The check valve allows the power steering (6) to suck oil from the tank, in case of pump (3) fault, thus allowing further movements of the steering.

SECTION 41 - STEERING SYSTEM 1.1

1.

2.

3.

4.

5.

6.

EMERGENCY STEERING

Diesel engine Variable-displacement pump Gear pump Priority valve Steering wheel Power steering

The machines in the high speed version are equipped with more than one emergency steering device, activated by the accumulators (12).

The filling of the accumulators (12) with oil for emergency steering is performed through the brake pedal valve (8). The filling pressure of the accumulators is 130 bar (1885.5 psi), controlled by the pressure switch (10).

The pressure switch (11) installed on the priority valve (4) checks that there is at least a minimum pressure of 10 bar (145 psi) for the steering. Otherwise, the valve (9) opens the accumulators (12) of the emergency steering.

7.

8.

9.

10.

11.

12.

Steering cylinder Brake pedal valve Emergency steering valve Pressure switch Pressure switch Accumulator

3

4 1.2

SECTION 41 - STEERING SYSTEM PRESSURE ADJUSTMENT

Connect a pressure gauge (PH) to the measuring point. By steering at stroke end, the steering pressure can be detected (about 175 bar (2537 psi)). If primary pressure of steering system is not achieved, first of all check the pump conditions, by measuring the pressure of working attachment. If this pressure is correct, the fault is probably to be searched in the high pressure valve of the power steering system.

POWER STEERING HIGH PRESSURE VALVE If it is necessary to check the valves already installed, mount a measuring fitting on the relevant steering cylinder line and connect a proper pressure gauge to it. By steering to stroke end, a maximum pressure of 175 bar (2537 psi) can be obtained. An higher pressure can be achieved eventually by pushing the steered machine against the material and by not activating the steering. Even in this way though the pressure of 240 bar (3480 psi) is not achieved.

To measure the correct secondary pressure, a further T-connection on steering cylinders pipes could be fitted, and with steering not actuated, start pressure from outside carefully.

SECTION 41 - STEERING SYSTEM

2.

5

POWER STEERING

The power steering consists of a metering pump and of an emergency pump including:  a gear wheel assy with fixed stator (with inner teeth) and a rotor (with outer teeth);  a 4-way rotary control valve consisting of an outer sleeve and an inner selection rotor;  the rotor is connected to the steering wheel by means of the steering column;

 a cardan shaft, mechanically tied to gear wheel assembly and to outer sleeve, allows the movement transmission;  set of centering springs between outer sleeve and inner rotor.

L. Left port (steering cylinder) R. Right port (steering cylinder) P. Inlet from steering pump

T. Outlet to hydraulic oil tank LS. Outlet to steering pump

6 2.1

SECTION 41 - STEERING SYSTEM TECHNICAL SPECIFICATIONS 21E - 121E - 221E

321E

OSPC 200 LS

OSPC 315 LS

Displacement

200 cm3/rev (12.20 in3/rev)

315 cm3/rev (19.22 in3/rev)

Rated oil flow

20 l/min (5.30 gal/min)

32 l/min (8.40 gal/min)

5.8 kg (13 lb)

6.2 kg (14 lb)

240 bar (3480 psi)

240 bar (3480 psi)

Model

Weight Relief valve adjustment TIGHTENING TORQUES Steering wheel nut

55 Nm (40.56 lbf·ft)

Steering column bracket

23 Nm (16.96 lbf·ft)

End cover

30 Nm (22.12 lbf·ft)

Connector

45 Nm (33.19 lbf·ft)

Adaptors

55 Nm (40.56 lbf·ft)

Check valve

30 Nm (22.12 lbf·ft)

HYDRAULIC DIAGRAM

1. Check valve 2. Power steering control valve

3. High pressure valve 240 bar (3480 psi) 4. Anticavitation valve

SECTION 41 - STEERING SYSTEM 2.2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

COMPONENTS

Sleeve Spool Ball Thread bushing O-ring Bearing Ring Cross pin Cardan shaft Springs O-ring Distributor plate Rotor stator/gear

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

O-ring End cover Washer Special screw Screw Body Ball Pin Valve Pressure relief valve Dust sealing ring Seat Check valve

7

8 2.3

SECTION 41 - STEERING SYSTEM DISASSEMBLY AND ASSEMBLY

Disconnect the fittings and collect the O-rings, noting down the assembly positions.

Remove the four screws from within the cab.

The power steering can be removed from the front of the cab through the engine compartment.

DISASSEMBLY Loosen and remove the screws (18), the special screw (17) and the washers (16) from the end cover (15).

Remove the end cover (15).

Take out the rotor/stator gear (13) from power steering (with spacer if fitted). Take out the two O-rings (14).

SECTION 41 - STEERING SYSTEM Remove the cardan shaft (9).

Remove the distributor plate (12).

Loosen and remove the threaded bushing (4).

Remove the O-ring (11).

9

10

SECTION 41 - STEERING SYSTEM

Shake out and remove the check valve ball (3), the pins (21) and the balls (20). Replace the pins (21) prior to reassembly.

Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool (2) inwards and the sleeve, the ring, the bearing cups and the bearing will be pushed together out of the housing.

Extract the ring (7), the bearing cups and the bearing (6) from the sleeve and the spool. The outer (thin) bearing cup can sometimes “stick” in the housing, therefore check that is has come out.

Press out the cross pin (8). Use the special screw (17). A small mark has been made with a pumice stone on both spool and sleeve close to one of the slots for the neutral position springs. If the mark is not visible, remember to leave a mark of your own on sleeve and spool before the neutral position springs are dismantled.

SECTION 41 - STEERING SYSTEM Carefully press the spool (2) out of the sleeve (1).

Press the springs (10) out of their slots in the spool.

Remove the dust seal ring (24) and the O-ring (5).

Remove the plugs from the valves using an Allen wrench.

11

12

SECTION 41 - STEERING SYSTEM

Remove the seal rings.

Loosen and remove the setscrews.

Shake out the two springs and two valve balls into your hand. The valve seats are bonded into the housing and cannot be removed.

The valves (23) are now disassembled.

SECTION 41 - STEERING SYSTEM CLEANING Clean all parts carefully.

INSPECTION AND REPLACEMENT Check for signs of wear in the following areas:  the rotor and the stator move freely;  check the drive pin is not cracked or bent;  check the rollers in the bearing are free to rotate;  ensure that the springs are not warped or cracked;  ensure non-return valve ball is free to move;  check control valve, spool and sleeve for wear or scoring;  replace the seal rings and the O-rings.

LUBRICATION Before assembling, lubricate all parts with hydraulic oil.

ASSEMBLY Place the two flat springs into the slot. Place the curved springs between the flat ones and press them into place.

13

14

SECTION 41 - STEERING SYSTEM

Line up the spring set (10).

Guide the spool (2) into the sleeve (1). Make sure that spool and sleeve are placed correctly in relation to each other.

Assemble spool and sleeve.

When assembling spool and sleeve only one of two possible ways of positioning the spring slots is correct. There are three slots in the spool and three holes in the sleeve in the end of the spool/sleeve opposite to the end with spring slots. Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool.

Press the springs together (10) and push them into place in the sleeve.

SECTION 41 - STEERING SYSTEM Line up the springs (10) and centre them.

Guide the ring (7) down over the sleeve.

NOTE: the ring should be able to move - free of springs.

Fit the pin (8) into the spool and sleeve.

Fit the cups and the bearings (6).

15

16

SECTION 41 - STEERING SYSTEM

1. Sleeve 2. Spool 6. Bearing 6A. Outer bearing cup 6B. Bearing 6C. Inner bearing cup The inside chamfer on the inner bearing cup must face the inner spool.

Turn the steering valve until the hole is horizontal.

Guide the outer part of the assembly tool into the hole for the spool/sleeve.

Lubricate the O-ring (5) with hydraulic oil and install it onto the tool.

Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.

SECTION 41 - STEERING SYSTEM Press and position the O-ring into the housing.

Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore.

Lubricate the dust seal ring (24) with hydraulic oil and place it onto the assembly tool.

Guide the assembly tool right to the bottom.

17

18

SECTION 41 - STEERING SYSTEM

Press and turn the seal ring in the housing.

With a light turning movement, guide the spool and sleeve into the hole.

Fit the spool set holding the cross pin horizontal.

The spool set will push out the assembly tool guide.

The O-ring is now in position.

Turn the power steering until the hole is vertical again. Insert the ball (3) of the check valve.

SECTION 41 - STEERING SYSTEM Screw the threaded bushing (4) lightly into the nonreturn valve bore. The top of the bush must lie just below the surface of the housing.

Insert a ball (20) into the two holes.

Insert the pins (21) in the same two holes.

Grease the O-ring (11) with mineral oil.

19

20

SECTION 41 - STEERING SYSTEM

Place the distributor plate (12) so that the channel holes match the holes in the housing.

Guide the cardan shaft (9) down into the hole so that the slot is parallel to the connection flange.

Place the cardan shaft (9) so that it is held in position by the mounting fork.

Grease the two O-rings and place them in the two grooves in the gear rim. Fit the rotor/stator gear (13) on the cardan shaft (9).

SECTION 41 - STEERING SYSTEM Fit the gearwheel (rotor) and cardan shaft so that a tooth base in the rotor is positioned in relation to the shaft slot.

Turn the gear so that the seven through holes match the holes in the housing.

For precise keying and alignment of steering control valve, pay attention to the parallelism of (A), (B), (C) and (D) reference marks.

A. B. C. D. E. F.

Rotor/stator surface Distributor plate surface Pin axis Housing surface Rotor surface Cardan shaft

Position the end cover (15).

21

22

SECTION 41 - STEERING SYSTEM

Install the special screw (17) with the washer (16).

Fit the 6 screws (18) with washers (16) and insert them. Cross-tighten all the screws and the rolled pin with a torque of 30 ± 6 Nm (22.12 ± 4.42 lbf·ft) in the sequence shown. Initial torque of 10.8 Nm (7.96 lbf·ft).

Insert a ball into the two holes.

Place springs and valve cones over the two balls.

SECTION 41 - STEERING SYSTEM Screw in the two setting screws.

Screw plug with seal ring into the two shock valves and tighten them with a torque of 30 ± 10 Nm (22.12 ± 7.37 lbf·ft).

Place the dust seal ring (24) in the housing.

Fit the seal ring in the housing using the special tool and a plastic hammer.

23

24 2.4

SECTION 41 - STEERING SYSTEM TROUBLESHOOTING FAULT

No steering or excessive effort required to steer.

Steering wanders.

Front wheels surge when steering.

Noisy pump.

CAUSE

ACTION

Incorrect oil level in tank.

Fill with the correct grade and quantity of oil.

Air in system.

Check for loose connections or damaged tubing. Purge system of air.

Pressure relief valve defective.

Check system pressure.

Pump worn out.

Inspect and repair.

Cylinder leaking.

Inspect and repair.

Damaged spool.

Inspect and replace.

Broken or damaged steering column.

Inspect and replace.

Damaged or worn metering element.

Inspect and replace.

Excessive play in steering linkage ball joints.

Inspect and replace.

Leaking power cylinder.

Inspect and repair.

Spool sticking or worn.

Inspect and replace.

Damaged or worn metering element.

Inspect and replace.

Cylinder leaking.

Inspect and repair.

Spool sticking or worn.

Inspect and repair.

Damaged or worn metering element.

Inspect and replace.

Incorrect oil level in tank.

Fill with the correct grade and quantity of oil.

Air in system.

Check for loose connections or damaged tubing. Purge system of oil.

Water in oil.

Drain and replace the oil.

Pump worn out.

Replace pump.

SECTION 41 - STEERING SYSTEM 2.5

SPECIAL TOOLS P/N CNH

DESCRIPTION

380000281

Assembly tool for seal ring.

380002677

Assembly tool for dust seal.

380002679

Assembly tool for cardan shaft.

380002680

Assembly tool for O-ring.

25

26

3.

SECTION 41 - STEERING SYSTEM

STEERING CYLINDER

21E - 121E - 221E

321E

A. Stroke B. Closed

SECTION 41 - STEERING SYSTEM 3.1

REMOVAL AND INSTALLATION

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Support the steering cylinder (1) with a rope or a hoist.

Disconnect the hydraulic lines (1) from the steering cylinder (2), paying attention to possible oil leaks and plug all openings in order to prevent dirt intrusion.

Loosen and remove the screw (3) and the washer (4). Remove the pin (5) and release the steering cylinder rod (1).

27

28

SECTION 41 - STEERING SYSTEM

Loosen and remove the screw (6) and the washer (7). Remove pin (8) and release the steering cylinder bottom (1).

Now it is possible to remove the steering cylinder.

As to installation, proceed in reverse sequence of operations described above.

SECTION 41 - STEERING SYSTEM 3.2

DISASSEMBLY

21E - 121E - 221E

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cylinder rod Elastic ring Washer Ring Snap ring Back-up ring O-ring Wiper ring Cylinder head

10.

11.

12.

13.

14.

15.

16.

17.

18.

Seal ring Guide bushing Seal ring O-ring Piston Piston guide ring Piston gasket Nut Cylinder liner

29

30

SECTION 41 - STEERING SYSTEM

321E

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cylinder rod Elastic ring Washer Ring Snap ring Back-up ring O-ring Wiper ring Cylinder head

10.

11.

12.

13.

14.

15.

16.

17.

18.

Seal ring Guide bushing Seal ring O-ring Piston Piston guide ring Piston gasket Piston lock ring Cylinder liner

SECTION 41 - STEERING SYSTEM The following disassembly procedure is based on the condition that the hydraulic lines have already been removed.

Lift and place the cylinder on a workbench and secure it. Make sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

Fully extend the cylinder rod (1).

Remove the elastic ring (2) and the washer (3).

Remove the ring (4).

Remove the snap ring (5).

Take out the cylinder head (9) from the cylinder liner (18). Remove the cylinder rod and the cylinder head.

IMPORTANT: make sure to pull out the cylinder rod (1) straight so as not to damage the sliding surfaces.

31

32

SECTION 41 - STEERING SYSTEM

21E - 121E - 221E Unscrew and remove the nut (17).

Slide out the cylinder rod (1), the piston assy (14) and the cylinder head assy (9).

Only if necessary:  remove the wiper ring (8), the seal ring (10), the guide bushing (11) and the back-up ring (6) with the O-ring (7) from the cylinder head (9);  remove the O-ring (13), the piston guide rings (15) and the piston gasket (16) from the piston (14).

321E Remove the piston lock ring (17).

Loosen and remove the piston assy (14).

Take out the cylinder head assy (9) from the cylinder rod (1).

SECTION 41 - STEERING SYSTEM Only if necessary:  remove the wiper ring (8), the seal ring (10), the guide bushing (11) and the back-up ring (6) with the O-ring (7) from the cylinder head (9);  remove the O-ring (13), the piston guide rings (15) and the piston gasket (16) from the piston (14).

33

34

4.

SECTION 41 - STEERING SYSTEM

TROUBLESHOOTING FAULT

CAUSE

ACTION

Steering wheel hard.

Pump drive coupling defective.

Consult your Dealer.

Steering wheel hard to turn when travelling on level ground.

Oil level too low.

Refill.

Pressure too low.

Consult your Dealer.

Limited-slip differential or steering mechanics sluggish.

Consult your Dealer.

Air in hydraulic system.

Purge system of air.

Internal leaks in steering valve.

Repair or replace.

Steering wheel easy to turn at stopper.

Internal leaks in steering valve.

Repair or replace.

During fast steering action, wheel turns fast for a short time (steering catching up).

Air in hydraulic system.

Purge system of air.

Internal leaks in steering valve.

Repair or replace.

Oil supply rate insufficient.

Consult your Dealer.

Steering valve jams.

Consult your Dealer.

Steering wobbly, permanent tread correction necessary.

The steering wheel when released still turns.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 1. HEATING ...................................................................................................................................................... 1 2. AIR CONDITIONING .................................................................................................................................... 3 3. TROUBLESHOOTING................................................................................................................................ 29

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

1.

HEATING

1.1

OPERATION

The cab is heated by an heat exchanger (2) mounted below the cab seat, which is supplied with hot water from the engine cooling system. The heat is sent inside of the cab by means of a fan (1) mounted behind.

The heating efficiency depends on the temperature of the engine. Full heating performance is therefore available only after the engine has reached its operating temperature.

The heating intensity is controlled by means of rotary knob (3).

The rotary knob (3) has two stages: turn right to switch off heating; turn left to switch on heating.

Even if it is not needed during longer periods, the heating should be switched on at least once a week for about 5 minutes at full performance to allow the engine oil to mix with the heating oil.

By means of rotary knob (4) the fan speed for heating or ventilation is switched on and adjusted.

Rotary knob (4) has four stages: = fan off 1

= low speed

2

= middle speed

3

= high speed

1

2 1.2

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM OVERHAUL

IMPORTANT: when overhauling the heating system remember that, with the engine running or shortly after it is turned off, the system will be at engine temperature and therefore the water will be hot and under pressure.

Heat exchanger: Drain the heating system.

Disconnect the heat exchanger pipes (1).

Remove the fixing screws and disassemble the heat exchanger (1).

Check water flow through the heater pipe which should be free running; if not, clear any blockage.

Fins should be free of all debris and not damaged; clean and or repair.

Clean the heat exchanger (1) with compressed air not exceeding 7 bar and taking care not to damage the fins.

Ensure that the heat exchanger is not leaking under pressure; repair or replace as required.

Fan: The fan motor (2) can be removed by removal of the attaching hardware and disconnection of the wiring connector.

Check if the fan is working; if not, check fuse and continuity of fan motor. If defective replace the fan unit as an assembly.

Filter: If the filter (3) is contaminated, remove the cover (4) and then the filter. Clean the filter with water jets.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

2.

AIR CONDITIONING

2.1

PRINCIPALS OF AIR CONDITIONING

The function of the air conditioning system is to improve the operator’s comfort by cooling the air temperature inside the cab and reducing the humidity level. In order to achieve this heat transfer the following principals of heat generation and transfer are applied within the air conditioning system.

When two bodies of different temperature come together heat is transferred from one to another. On air conditioning systems an evaporator is used to hold the low temperature coolant which absorbs the heat from the air within the cab.

When a gas is pressurized the temperature of the gas will rise. In air conditioning systems the increase in pressure is achieved using a compressor.

When a gas is cooled it will condense into a liquid. In the air conditioning system a condenser is used to cool the gas and the resulting liquid is stored in a receiver dryer.

3

4

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

When a liquid is atomized through an orifice, the temperature of the resultant vapour will lower.

The low temperature of the atomized liquid will then absorb heat from its surrounding. On air conditioning systems the coolant is atomized using an expansion valve.

LOW PRESSURE SIDE

HIGH PRESSURE SIDE

EXPANSION VALVE Liquid filtered and dehumidified at high pressure and low temperature

Liquid atomized at a lower temperature and at low pressure

RECEIVER/ DRYER

Liquid at lower temperature and high pressure

EVAPORATOR

CONDENSER Warm vapour at low pressure Vapour at high temperature and high pressure

COMPRESSOR Heat transfers from inside the cab to the coolant

Heat transfers from the coolant to the outside air

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 2.2

5

SAFETY INSTRUCTIONS

S WARNING Before overhauling an air conditioning system read and observe the following safety precautions. If a repair or replacement becomes necessary, ensure that only certified air conditioning technicians are employed, using approved equipment to effect repairs.

Do not attempt to disassemble the air conditioning system. It is possible to be severely frostbitten or injured by escaping coolant.

REFRIGERATING AGENT R 134a If handled in a wrong manner the refrigerating agent R 134a can be dangerous.

The coolant R 134a has a boiling point of 12 °C (53.6 °F).

Never expose any part of the air conditioning system to flames or excessive heat because of the risk of fire or explosions and the production of phosgene gas.

Never disconnect or disassemble any part of the air conditioning system as escaping coolant can cause frostbite.

When charging and discharging the system always wear goggles and take suitable precautions to protect the face in general and the eyes in particular, from accidental spillage of coolant.

The oil and coolant mixture inside the air conditioning system is pressurized. Consequently, never loosen fittings or tamper with lines unless the system has been properly discharged.

Before loosening any connection, cover the fitting in question with a cloth and wear gloves and goggles in order to prevent coolant from reaching the skin or eyes.

In the event of an accident, proceed as follows: If the coolant has reached the eyes, wash them immediately with copious amounts of sterilized water or mains pressure tap water and transfer to hospital for immediate medical help.

If the coolant has touched the skin, wash with cold water and transfer to hospital for immediate medical help.

Never discharge coolant into the atmosphere. When servicing air conditioning units a certified coolant recovery unit operated by a certified technician must be used.

When discharging the coolant in the system make sure you are operating in well-ventilated premises with good air circulation and far away from open flames.

6 2.3

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM OPERATION

NOTE: to ensure correct operation and full efficiency of the air conditioning system, it must be used at least once a week, even for a short time.

ACTIVATION Activate the air conditioning with switch (A).

Turn the fan knob (B) to level 1 or higher.

AIR TEMPERATURE ADJUSTMENT The temperature of the air blown into the cab can be steplessly adjusted with rotary knob (B). For higher cooling or heating performance, the fan can be switched to levels 2 and 3.

Prerequisites for good cooling performance:  the suction opening for fresh air on the right side of the cab must not be covered up or soiled;  filter, cooler/heater and the fins of the evaporator and the heat exchanger must be cleaned;  keep cab door and windows closed.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 2.4

7

SYSTEM OVERHAUL

Overhaul of the air conditioning system should only be undertaken by a certified specialist refrigeration engineer using a comprehensive air conditioning test kit, including a gas leak detector, suitable for R 134a cooling gas.

S WARNING Before dismantling an air conditioning system for repair, the gas within the system must be discharged and recovered using a certified recovery system designed for the type of refrigerant gas used in the system.

NEVER discharge refrigerant gas into the atmosphere.

ALWAYS wear safety goggles and gloves when servicing any part of the air conditioning system.

To prevent the entry of any foreign material, it is necessary to take the following precautions.

Ensure all tools, gauges, hoses and spare parts are kept clean and dry and are suitable for the type of refrigerant gas used in the system.

Clean all hoses and fittings before disconnecting.

Cap or plug all openings when disconnected.

When adding oil to the system, always open and close the oil container immediately before and after use. Always ensure the oil remains free of moisture.

PRELIMINARY CHECKS Always conduct the preliminary checks before performance testing the system: Run the engine at 1000-1200 rpm for 10 minutes with the air conditioner set to maximum cooling and the fan at maximum speed.

Check that the heater temperature control is switched OFF. Check that the fan is operating at all speeds.

Check that the compressor clutch engages when the temperature control switch is turned from “ ” to “1” position. A clicking sound indicates the clutch is engaging. If the clutch fails to operate it may indicate an electrical problem in the high low pressure cut out switches or malfunction of the electrical drive clutch on the compressor.

Check that motor fan is drawing cool air through the condenser.

Check the compressor drive belt tension.

Check the condenser core and grid is clean and free of obstruction.

Check the cab air filter is clean and free of obstruction.

Check the evaporator fins are not clogged or excessively dirty.

8

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

SYSTEM PERFORMANCE TEST

1.

2.

3.

4.

5.

Low side gauge High side gauge Shut-off valve Test hose to high side service connector Centre hose (not used)

The manifold gauge set is the most important tool used in testing and servicing the air conditioning system.

The following instructions for performance testing the air conditioning system is based on the use of the gauge set shown. The principal of operation is however similar when testing the system using a recovery and recharging station with integral gauges.

When using this type of equipment always consult the manufacturers operating instructions.

IMPORTANT: always ensure the shut-off valves are closed (turn clockwise until seated) during all test operations.

6.

7.

8.

9.

Test hose to low side service connector Shut-off valve Low pressure (suction) side service valve High pressure (release) side service valve

In the closed position, coolant circulates around the valve stems to the gauges. Therefore, when the manifold gauge set is connected into a system, pressure is registered on both gauges.  Never open the shut-off valve of the high pressure side when the system is operating.  Always open the shut-off valve of the low pressure side when adding coolant.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

9

Attaching the gauge set to the tractor

S WARNING

S WARNING

To avoid personal injury, stop the tractor engine during connection of the manifold gauge set.

A significant amount of coolant vapour may have condensed to a liquid at the service fitting at the high side of the compressor. Use a cloth or other protective material when disconnecting the manifold hose from this fitting to prevent personal injury to hands and face.

 Check that the gauge set shut off valves are closed (turned fully clockwise).  Connect the high side gauge hose (normally red) to the high pressure (release) side service valve and the low side gauge hose (normally blue) to the low pressure (suction) side service valve on the tractor. Ensure the hose connections are fully tightened.

Test procedure After the manifold gauge set has been connected and before pressure tests can be made, the system must be stabilized as follows:  apply the parking brake, check that the levers are in neutral and close the cab windows and doors;  re-check that both the high and low side shut off valves on the manifold gauge set are fully closed;  run the engine at 1000 - 1200 rpm;  turn the heater temperature control “off”;  operate the system at maximum cooling, with the fan at high speed for 10 minutes to stabilize all components;  check the manifold low pressure gauge reading is within the specified range of approximately 0.28 - 2.48 bar (4 - 36 psi);  check the manifold high pressure gauge reading and compare the reading to the pressure indicated on the pressure temperature chart below;  measure and compare the temperature of conditioned air entering the cab through the louvered air vents with the ambient air at the air intake filters on the outside of the cab. If the system is operating correctly the conditioned air entering the cab should be 6-9 °C (42.8 - 48.2 °F) cooler than the ambient temperature of the outside air.

If it is confirmed that the system is not operating correctly refer to the fault diagnostic charts and performance test gauge reading examples on the following pages for possible corrective action.

10

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

PERFORMANCE TEST TROUBLESHOOTING Gauge readings: FAULT Evaporator air not cold.

Low pressure - Low High Pressure - Low CAUSE Low coolant charge.

ACTION Perform leak tests and repair.

Evacuate the system.

Charge system, re-test system.

Evaporator air warm.

Extremely low coolant charge.

Perform leak tests and repair.

Evacuate the system.

Charge system, re-test system.

Expansion valve not permitting suffiEvaporator air cool, but not cient flow. sufficiently cold.

Stuck valve.

Low pressure switch cutting out.

Expansion valve to evaporator tube shows considerable condensation or frost.

Too cold to touch.

Check expansion valve as follows: Set for maximum cooling.

Low pressure gauge should lower slowly.

If expansion valve is defective: Discharge the system.

Replace expansion valve.

Evacuate the system.

Charge the system.

Re-test.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM Gauge readings:

11

Low pressure - Low High Pressure - Low

FAULT

CAUSE

Evaporator air warm.

Improper operation of condenser.

Liquid line hot (condenser outlet to expansion valve tube).

ACTION Inspect for dirty condenser restricting air flow and cooling.

Check operation of condenser cooling fans. Repair or replace as needed.

High pressure switch cutting out.

Coolant overfilled.

Air in system.

Evaporator air not cold.

Expansion valve allowing too much coolant to flow through the evaporator.

Check for overcharge as follows: Stop the engine. Collect and recycle the charge using correct recovery equipment.

Recharge the system with the correct quantity of coolant, replacing any lost lubricant. Recheck performance of air conditioning system.

Check expansion valve as follows: Set for maximum cooling.

Low pressure gauge should lower slowly.

If expansion valve is defective: Discharge the system.

Replace expansion valve.

Evacuate the system.

Charge the system.

Re-test.

12

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

Pressure gauges readings: FAULT Evaporator air not cold.

Pressure gauges readings: FAULT

Low pressure - High High Pressure - Low CAUSE Internal leak in compressor (reed valves, gasket, worn or scored piston rings or cylinder).

CAUSE System low on charge. Air or moisture in system.

Pressure gauges readings:

Low pressure - High High Pressure - Normal

Compressor cycles “on” and “off” too frequently.

Gauge readings: FAULT Insufficient cooling.

Discharge the system.

Replace the compressor.

Evacuate the system.

Charge the system.

Re-test.

Low pressure - Normal High Pressure - Normal

Insufficient cooling.

Low pressure reading does not fluctuate with changes in temperature control switch (pressure should lower until compressor cycles).

Evaporator air not cold.

FAULT

ACTION

CAUSE Defective temperature control (thermostatic) switch.

ACTION Perform leak test.

Discharge the system.

Repair leaks.

Replace the receiver/dryer.

Check oil level.

Evacuate the system.

Charge the system.

Re-test.

ACTION Stop the engine and shut off A/C system.

Replace temperature control switch.

Re-test system and check compressor cycling.

Low pressure - Low High pressure - High CAUSE Restriction in liquid line.

ACTION Discharge the system.

Replace the receiver/dryer.

Inspect all lines and tubing from compressor outlet to expansion valve.

Replace if needed.

Evacuate the system.

Charge the system.

Re-test.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 2.5

COMPONENTS OVERHAUL

S WARNING Before disconnecting components from the air conditioning system, the refrigerant gas must be discharged and recovered using a certified recovery system. Refer to “Evacuating the system”.

Do not discharge the gas into the atmosphere.

If an air conditioning component is to be replaced during a system overhaul it is necessary to drain any cooling oil that has collected in the component being replaced into a clean calibrated container.

A volume of clean coolant equivalent to that removed from the replaced component must then be added to the new item before being installed onto the machine.

Upon completion of the repair drain, recharge, leak test and performance test the system to ensure correct operation.

EVAPORATOR Discharge and recuperate the refrigerant gas using certified recovery systems.

Remove the seat and the panel (2) to make evaporator assy (1) accessible.

Remove temperature cycling control thermocouple.

Disconnect tubing to valve (3).

Remove the evaporator (1).

Check evaporator fins for damage. Straighten fins if necessary.

Clean the evaporator core from all foreign materials and make sure it is free from obstructions.

Check that evaporator (1) is not leaking any coolant.

If damage or leaks are evident, replace the evaporator core.

If a new evaporator is to be installed, drain the cooling oil inside of it into a clean calibrated container.

Measure the quantity of oil obtained and add the same quantity of clean cooling oil directly into the new evaporator core.

Reassemble the evaporator by following the disassembly procedure in reverse sequence.

Drain, leak test and recharge the system.

13

14

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

FAN MOTOR If necessary, the fan motor can be removed without discharging the system, as follows:  Remove the seat and the panel (2).

NOTE: take care not to damage hoses during this operation. If the cab heater hoses restrict movement of the housing drain the heater assembly and disconnect the hoses.

Disconnect the motor (4) wiring connector block.

Take out the motor (4) after removing the remaining fixing screws.

Re-assembly follows the disassembly procedure in reverse.

HEAT EXCHANGER Drain the heating system.

Remove the cover (2).

Disconnect the heat exchanger pipes (5).

Remove the fixing screws and disassemble the heat exchanger (5).

Check water flow through the heater pipe which should be free running; if not, clear any blockage.

Fins should be free of all debris and not damaged; clean and or repair.

Clean the heat exchanger (5) with compressed air not exceeding 7 bar (102 psi) and taking care not to damage the fins.

Ensure that the heat exchanger is not leaking under pressure; repair or replace as required.

FILTER If the filter (6) is contaminated, remove the cover (2) and then the filter. Clean the filter with water jets.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM CONDENSER  Open the engine guard.  Inspect the condenser (7) assembly fins for damage and be sure they are not plugged.  Contaminated condensers have a bad condensing performance. Clean by blowing out or wash with water (do not use high-pressure jet cleaners). Deformed ribs can be repaired by straightening.  Check the condenser for signs of leakage. If the condenser is damaged or leaking, install a new condenser assembly.  If the condenser is to be replaced, drain the coolant from the condenser into a clean calibrated container. Measure the quantity of obtained and add the same quantity of new coolant directly into the new condenser.  Drain, leak test and recharge the system.

COOLANT TANK With the engine running and the system connected, the coolant inside of the tank (8) must reach the top of the tank (arrow) and be free of bubbles. Bubbles in the inspection glass are a sign of coolant low level in the system.

The tank (8) cannot be overhauled and must be replaced as an assembly. The tank assembly should be replaced if it is suspected that moisture is in the system.

The tank must also be replaced if the system has been discharged and the air conditioning joints disconnected.

Discharge and recollect the coolant.

Disconnect the hoses and switch and remove the tank from the machine.

Drain the coolant from the tank into a clean calibrated container. Measure the quantity of obtained and add the same quantity of new coolant directly into the new element.

Cap and plug all fittings to prevent any dirt entering the system.

Install a new tank.

COMPRESSOR BELT Check the tension belt (9) of the compressor (10).

15

16 2.6

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM LEAK TESTING

To perform a leak test if coolant leakage is suspected, use a leak detector following the manufacturer’s instructions.

Leak detectors use light or sound dependent upon the type used to alert the operator of a leak. If the leak detector’s sensitivity is adjustable, be sure you calibrate the detector according to the manufacturer’s instructions before use.

When using a leak detector, keep in mind that a very slight amount of leakage in the compressor pulley area is normal and does not necessarily indicate a repair is required.

When a leak is located, follow these steps:  discharge the system using a certified coolant recovery system;  repair the leak;  evacuate the system;  partially charge system with 400 g (0.88 lb) of coolant;  check system for leaks;  fully charge the system.

2.7

SYSTEM DISCHARGE

Legislation has been introduced banning the release of coolant into the atmosphere.

Whenever overhauling the air conditioning system or performing other tasks which require the air conditioning system to be dismantled it is necessary to discharge the cooling gas before commencing repair.

Before you can dismantle an air conditioning system for repairs, you must discharge and recollect the coolant using a certified recovery unit in accordance with the manufacturer's instructions.

Shown is a combined coolant recovery, evacuation and recycling/charging station. This equipment removes R 134a coolant from the air conditioning system, recycles and recharges all in one hook up.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 2.8

FLUSHING THE SYSTEM

Air conditioning systems may occasionally become contaminated with solid particles. This contamination may be the result of allowing dirt to enter the system while it was open, from aluminium corrosion or sludge, or from disintegrated compressor reed plates. Contamination of this nature can result in plugged evaporators, condensers and valves.

Flush system with dry nitrogen.

Each individual component must be flushed after disconnecting every hose fitting.

The compressor and valve can not be flushed, therefore, the compressor should be disassembled and cleaned or replaced and the valve should be replaced. When flushing the system always replace the receiver/drier.

NOTE: never use any solvent for flushing an air conditioning system other than a special flush solvent made specifically for air conditioning systems. Always follow the manufacturer’s recommendations and directions for using the flushing equipment and solvent.

2.9

17

COMPRESSOR

The air conditioning compressor is mounted on the left-hand side of the engine and is belt-driven by the crankshaft pulley.

The compressor separates the low and high pressure sides of the system and has two functions:  to raise the coolant temperature by compression to a higher degree of temperature than the ambient (outside air) temperature;  to circulate the required volume of coolant through the system.

The coolant compressor is a 7-cylinder wobble plate unit, housed in an aluminium body.

Drive to the wobble plate is from the pulley, through the electro-magnetic clutch to the main drive shaft.

Attached to the drive shaft is a cam rotor which oscillates the wobble plate. The wobble plate is prevented from rotating by a static gear engaging with teeth formed in the face of the plate. The seven pistons are connected to the wobble plate by rods located in ball sockets.

Refrigerant is drawn in on the downward stroke of a piston through the reed valves located either end of the cylinder assembly. Refrigerant enters the cylinder assembly through a gallery in the outer circumference of the cylinder assembly.

The upwards stroke of the piston compresses the coolant and expels it through another reed valve into an inner gallery in the cylinder and out into the coolant system.

The compressor is lubricated with a Polyalklene Glycol (PAG) oil Type SP20. This oil can mix with the coolant and is carried around in the coolant system itself.

The compressor is activated by an electro-magnetic clutch which functions to engage or disengage the compressor as required in the operation of the air conditioning system.

18

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

TECHNICAL SPECIFICATIONS

Model .....................................................................................................................................................SD7H13 Displacement .......................................................................................................... 129.2 cm3/rev (7.88 in3/rev) Highest rpm (constant speed) .............................................................................................................. 6000 rpm Highest rpm (changing gears downward) ............................................................................................ 7000 rpm Rotation................................................................................................................................................ clockwise Coolant.....................................................................................................................................................R 134a Oil............................................................................................................................................................... SP20

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM REMOVAL AND INSTALLATION Removal Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Open the engine guard.

Discharge the air conditioning system.

Disconnect the electrical harness of the compressor from the engine harness.

Disconnect the compressor pipes paying attention to possible oil leaks.

Loosen and remove the screw (5) with the nut (8) and the washer (7).

The belt (9) has slackened and it is now possible to release it from the compressor (1).

Loosen and remove the screw (4) with the nut (2) and the washer (3).

It is now possible to remove the compressor (1) from the support (6).

Installation Installation follows the removal procedure in reverse order.

Drain the oil from the new compressor to be fitted into a clean container, or if the old compressor is to be reassembled, obtain a new can of cooling oil.

Calculate the amount of oil to be installed and refill the compressor.

Reconnect the hoses to the compressor and tighten all bolts and hoses.

19

20

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

DISASSEMBLY AND ASSEMBLY Disassembly of clutch assy

1.

2.

3.

4.

5.

6.

Screw Cover Nut Front plate Shims Cover

All operations on clutches should be carried out with the compressor removed from the machine. Support the compressor. If using a vice, do not hold on to the housing. If the cover (2) is present, remove the 3 or 6 bolts (1) holding it in place and remove cover. If auxiliary sheet metal pulley is present, remove the screws holding it in place. Then remove pulley assembly (8).

Attach tool to the cover on the front of the clutch plate and with a wrench remove the nut (3).

7.

8.

9.

10.

11.

Elastic ring Pulley assy Elastic ring Coil Key

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM By means of tool (K), hold the clutch disc locked and with wrench (C) remove the nut (3).

Place the screw (V) into the tool (K) and by tightening the bolt onto the end of the shaft the front plate will be extracted from the shaft (4).

Now remove the shims (5) if placed on the shaft key (11). If the shims (5) are below the shaft key (11), remove this one with the cover (6) before removing the shims.

Remove the cover (6) (if installed). Use caution to prevent distorting the cover when removing it.

Remove shaft key by tapping loose with a flat blade screwdriver and hammer. Remove shims (5). Use a pointed tool and a small screwdriver to prevent the shims from binding on the shaft.

Remove the elastic ring (7) and pull out the pulley assy (8) from the compressor.

Inspect the pulley assy (8) for wear and replace it as necessary.

21

22

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

Remove the elastic ring (9) of the coil.

Remove the coil (10) and replace it if necessary.

Assembly of clutch assy Assemble the coil (10).

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM Install the elastic ring (9).

Position the pulley assy (8) on the housing hub and carefully slide the pulley (8) down the shaft.

Install the elastic ring (7).

Install the cover (6). Fit the key (11) on shaft. Fit the shims (5).

23

24

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

Restore the plate (4) and the nut (3) into position.

Tighten nut (3) to prescribed torque 18 Nm (13.27 lbf·ft).

Check the clearance between the plate (4) and pulley (8). This should be consistent around the circumference and be between 0.4 mm (0.015 in) and 0.8 mm (0.03 in).

NOTE: if the air gap is not consistent, lightly pry up on the counter weighted front plate at the low spots or lightly tap down at the high spots.

If the clearance is not within specification the shims (5) under the front plate should be added to or subtracted from, until the correct clearance is obtained.

NOTE: new shims are available in sizes 1.00 or 0.50 or 0.13 mm (0.04 or 0.02 or 0.005 in).

Replace the cover (2) if present and torque 3 on 6 screws (1).

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM Compressor disassembly

1.

2.

3.

4.

5.

Key Ring Elastic ring Seal ring Shaft

Remove the shaft key (1) and the ring (2).

Then remove the elastic ring (3).

Position the tool (A).

Rotate the tool to engage the slots in the ring. Remove the seal ring (4).

6.

7.

8.

9.

10.

Gasket Plate Gasket Head Screw

25

26

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

Remove the six head bolts (10) and gently tap the head (9) with a hide mallet to release it. The use of a gasket scraper may also be required to free the cylinder head from the compressor body.

If the plate (7) and/or the head are to be reused, carefully remove the gasket (8) using a suitable scraper.

Gently pry-off the plate (7) and remove the gasket (6).

Inspect the plate (7) for damage.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM Assemble the compressor Coat the top of the valve plate with clean cooling oil and reassemble the cylinder head using the reverse of the disassembly procedure. When installing the gaskets and valve plate ensure they are correctly positioned over the locating pins in the cylinder block. Install the cylinder head screws and tighten using the sequence shown. Tighten to prescribed torque 20 Nm (14.75 lbf·ft).

Thoroughly clean the seal ring (4) cavity on the hub.

Use “lint free” cloth only.

Ensure that the new O-ring of hub is installed onto the seal ring (4). Dip the new seal assembly in clean cooling oil and attach it to the disassembly/assembly tool.

Thoroughly clean the seal ring (4) on the hub.

NOTE: if the tool is not available, carefully position the seal ring on the hub and gently tap until it is fully seated.

Install the elastic ring (3). If the elastic ring has a bevelled edge, this should be oriented outwards.

27

28

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

Install a new ring (2) and push into position.

Position the shims on the shaft (5) and refit the shaft key (1).

INSPECTION Rotate the compressor shaft. Use a suitable socket on the hub centre bolt or by hand using the rubber dampers. If severe roughness is felt while rotating the hub, the compressor should be disassembled.

Using a 12 V battery check the current drawn of field coil: it should be between 3.6 and 4.2 A. Very high current readings indicate a short circuit in the field coil and no current reading indicate an open circuit. Replace coil with either fault. Resistance of the coil using an ohmmeter should be approximately 3.0  at 20 °C (68 °F).

A poor ground connection of the field coil will result in a low voltage.

Ensure clutch is disengaged and rotate pulley by hand. If roughness in the bearing is felt, it will be necessary to replace the pulley and bearing as an assembly.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

3.

29

TROUBLESHOOTING FAULT

Dust enters the cab.

CAUSE

ACTION

Improper seal around filter element.

Check seal condition.

Air filter clogged.

Clean or replace filter.

Defective air filter.

Replace the filter.

Excessive air leak(s) around doors and windows.

Repair and seal air leak(s).

Air filter clogged.

Clean or replace filter.

Heater radiator core blocked.

Clean radiator core thoroughly.

Fan motor not working.

Fuse blown.

Replace fuse.

Cab does not heat up.

Engine not reaching operating temperature. Thermostat stuck open.

Replace the thermostat.

Fan motor air flow low.

Heater hose from engine to cab radi- Ensure water flow to heater radiator ator, kinked or blocked. is adequate and not restricted.

Cab does not cool.

Heater control turned on.

Turn temperature rotary knob fully counterclockwise for maximum cooling.

Heater control valve stuck in open position.

Free up valve or change as required.

Temperature not stable.

Low coolant level.

Top up the coolant tank.

System very noisy.

Belt loose or worn.

Retension belt or replace.

Clutch noisy.

Repair clutch.

Compressor supporting bracket loose or internal compressor parts worn out.

Repair bracket, replace compressor.

Fan motor excessively worn.

Replace fan.

System overfilled.

Evacuate coolant until the high pressure reading is normal again.

Not enough coolant in the system.

Check for leaks and refill the system.

30

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

FAULT Fan does not operate.

CAUSE Fuse blown or loose.

ACTION Check fuse contact, if necessary plug in correctly. Replace defective fuse. Reappearance of the defect after a short time indicates a shortcircuit.

Check fan for blocking or other faults. Eliminate the cause.

Connector loose.

Check that connectors at the bottom of the unit are firmly in place and correct, if necessary.

Check connections at fan switch.

Open the unit and check the electrical connections inside.

Connecting cable damaged or broken.

Replace cable, observing correct cable run and connection.

Electrical connections interchanged.

Check connecting cables and reconnect properly, if necessary.

Fan switch defective.

Replace switch.

Blocked fan.

Eliminate the cause of the blockage, e.g. by removing foreign object from rotor. If necessary, install a new fan.

Fan motor defective.

Replace the engine.

Fan cannot be switched off.

Bridge the fan switch.

Replace fan switch.

Reduced fan performance.

Rated supply voltage incorrect.

Rated voltage of conditioner and of vehicle system must be identical.

Replace fan.

Dirty clamps.

Clean connector contacts. Proceed with care to avoid short-circuits.

Insufficient cross-section of electrical Lay cables with the recommended cables. cross-sections.

Heat exchanger heavily contaminated.

Clean carefully to avoid causing damage to the exchanger which might result in consequential leaks.

Fan ducts obstructed.

Check air ducts and outlets for obstructions and remove any foreign objects. Remove trouble.

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

31

TRANSMISSION COOLER FAULT Compressor not working.

CAUSE

ACTION

Open circuit in compressor solenoid. Check power supply to the clutch.

Faulty thermostat.

Replace the thermostat.

Belt loose or broken.

Adjust belt tension, replace belt.

Belt pulley not turning although mag- Check compressor and replace, if netic clutch is engaged. necessary.

Compressor clutch slipping.

Repair clutch or replace compressor.

Evaporator flooded.

Expansion valve jammed or stuck in open position.

Replace expansion valve.

Evaporator frozen.

Thermostat sensor in wrong position.

Install sensor in another place.

Evaporator clogged up.

Cooling ribs dirty.

Clean evaporator.

Coolant leaking.

Refrigerant line defective.

Check all lines for defects caused by external influences or chafing.

Leaks in the system.

Evacuate the system, refill, check for leaks and repair.

Air filter clogged.

Clean or replace the air filter.

Air filter.

32

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

HEATING FAULT Heating does not work.

Heating performance reduced.

Heating cannot be switched off.

Air distribution flaps cannot be adjusted.

CAUSE

ACTION

Heating liquid still cold.

Wait until the engine has reached operating temperature.

Heating valve closed.

Open the valve.

Heat exchanger or filter heavily contaminated.

Clean carefully, to avoid causing damage which might result in consequential leaks.

Adjustment of tie-rod cable controlling the heating valve inappropriate.

Readjust the tie-rod cable.

Air in heat exchanger.

The radiator is self-venting. Wait until the radiator has finished selfventing.

Unit under-dimensioned.

Consider installing an additional heating or more powerful unit.

Adjustment of tie-rod cable controlling the heating valve inappropriate.

Readjust the tie-rod cable.

Control element or tie-rod cable defective.

Check control element or tie-rod cable and replace, if necessary.

Flap hinges sluggish.

Check flap and lubricate, if necessary.

Flap deformed.

Inspect and replace the flap.

Flap clogged.

Check flap and remove foreign object, if any.

SECTION 55 - ELECTRICAL SYSTEM 1. ELECTRICAL DIAGRAMS............................................................................................................................ 1 2. FUSES AND RELAYS ................................................................................................................................ 17 3. VOLTAGE AND CONTINUITY CHECK...................................................................................................... 20 4. BATTERY ................................................................................................................................................... 21 4.1 REPLACEMENT .................................................................................................................................. 24 5. BULBS ........................................................................................................................................................ 25 6. TROUBLESHOOTING................................................................................................................................ 29

SECTION 55 - ELECTRICAL SYSTEM

SECTION 55 - ELECTRICAL SYSTEM

1.

ELECTRICAL DIAGRAMS

ENGINE AND “GRID HEATER”

1

2 STARTING

SECTION 55 - ELECTRICAL SYSTEM

SECTION 55 - ELECTRICAL SYSTEM SIGNAL LAMPS

3

4 INDICATORS

SECTION 55 - ELECTRICAL SYSTEM

SECTION 55 - ELECTRICAL SYSTEM EMERGENCY STEERING AND “RIDE CONTROL”

5

6

SECTION 55 - ELECTRICAL SYSTEM

HORN AND WORK LIGHTS AND QUICK COUPLER

SECTION 55 - ELECTRICAL SYSTEM REAR WINDSCREEN WASHER/WIPER AND RADIO

7

8 LIGHTS

SECTION 55 - ELECTRICAL SYSTEM

SECTION 55 - ELECTRICAL SYSTEM LIGHTS

9

10

SECTION 55 - ELECTRICAL SYSTEM

TURN SIGNAL LIGHTS AND ACOUSTIC ALARM

SECTION 55 - ELECTRICAL SYSTEM FRONT WINDSCREEN WASHER/WIPER

11

12 SECOND GEAR

SECTION 55 - ELECTRICAL SYSTEM

SECTION 55 - ELECTRICAL SYSTEM RETURN TO DIG

13

14 TRAVEL DIRECTION

SECTION 55 - ELECTRICAL SYSTEM

SECTION 55 - ELECTRICAL SYSTEM HEATING AND AIR CONDITIONING SYSTEM

15

16

SECTION 55 - ELECTRICAL SYSTEM

ENGINE CONTROL UNIT / MAIN RELIEF VALVE

SECTION 55 - ELECTRICAL SYSTEM

2.

FUSES AND RELAYS

CONTROL UNIT

FUSES Fuses in the cab The fuses (2) can be accessed after opening the door (1) located outside the cab on the right side under the window.

17

18

SECTION 55 - ELECTRICAL SYSTEM

CODE

AMPERAGE

FUNCTION

F1

7.5A

Emergency steering

F2

7.5A

Ride Control, return to dig

F3

7.5A

2nd gear switch, brake pressure relay, high speed travel relay

F4

5A

Right parking light, rear left light, license plate light

F5

15A

Power outlet, switch lighting

F6

7.5A

Control lever, low speed, 2nd gear relay, slow speed travel relay

F7

7.5A

Instrument, parking brake, parking brake relay

F8

7.5A

Forward and reverse travel

F9

7.5A

Main beam left

F10

7.5A

Reverse travel light, back-up alarm

F11

7.5A

Engine stop

F12

7.5A

Available

F13

10A

Hazard warning lights, turn signal lights

F14

10A

Rotary beacon

F15

10A

Radio +30, cigarette lighter, cab light

F16

7.5A

Rear windscreen wiper and washer

F17

5A

Attachment quick coupler

F18

5A

Engine control unit, diagnostics, main valve releasing relay

F19

5A

Left parking light, rear right light, instrument cluster backlighting

F20

10A

Brake light, acoustic alarm, flasher control unit relay

F21

15A

Front windscreen wiper and washer, radio +15

F22

15A

Rear work lights

F23

7.5A

Low beam left

F24

7.5A

Low beam right

F25

7.5A

Right main beam

F26

5A

Power supply

F27

15A

Front work lights

F28

15A

Horn

F29

5A

Engine control unit

F30

10A

Anti-start (optional)

SECTION 55 - ELECTRICAL SYSTEM RELAY Relays in the cab Relays (2) can be accessed by opening the door (1) located outside the cab on the right side under the window.

Optional relays K1

Relay gear switching

K2

Brake pressure monitoring relay

K3

High speed releasing relay

K4

Ride Control relay

K5

Available

K6

Front work lights

K7

Main valve releasing relay

K21 A/C relay K22 A/C relay Standard relay K8

Relay creep gear

K9

Parking brake relay

K10 Low beam relay K11

Main beam relay

K12 Flasher control unit relay K13 Low brake pressure relay K14 Reversing light relay, back-up alarm relay K15 Reverse speed relay K16 Relay front windscreen wiper K17 Forward speed relay K18 Start interlock relay K19 Horn relay K20 Blower relay Relays in the engine compartment The starting relay and the preheating control relay are located on the front right side, under the engine guard.

K1.3 Preheating interrupting relay K1.4 “Grid heater” relay K1.5 Starting relay

19

20

3.

SECTION 55 - ELECTRICAL SYSTEM

VOLTAGE AND CONTINUITY CHECK

Before carrying out any operation on the electrical system, disconnect the battery.

Disconnect the negative terminal first, then the positive terminal.

After work, connect first the positive clamp then the negative.

Use only measuring instrument for voltage and continuity testing:  never use a test lamps;  never tap against ground.

This causes a short circuit with consequent damage to the alternator or to the electronic system.

To start up the engine, the alternator is controlled (pre-excited) by an electronic circuit, whose task consists in enabling the alternator to supply power.

The circuit is an integral part of the central electronic system in the control console.

A lamp on the instrument panel indicates the correct operation of the alternator. This lamp must turn on when the starter switch key is turned to on; it turns off as soon as the engine is started.

If this is not the case, there is a fault in the electric system or in the instrument cluster.

To prevent further damage, the cause of the fault must be traced and eliminated as quickly as possible.

Address to After-sales Service.

SECTION 55 - ELECTRICAL SYSTEM

4.

BATTERY

S WARNING Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

Antidote: EXTERNAL: rinse well with water, removing any soiled clothing.

INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor.

EYES: rinse thoroughly with water for 15 minutes and get prompt medical attention.

When working with batteries, always wear gloves, protection goggles and suitable clothes.

S WARNING Never touch the battery terminals with your hands.

This could generate an electrolysis inside the human body and damage the body’s vital organs.

S CAUTION Batteries give off explosive gases.

Never handle naked flames and unshielded light sources near batteries, never smoke.

Battery acid is toxic and corrosive.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short circuit resulting in burns.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

21

22 4.1

SECTION 55 - ELECTRICAL SYSTEM TECHNICAL SPECIFICATIONS

EUROPE MODELS Voltage .........................................................................................................................................................12 V Battery (without cold start) Number ............................................................................................................................................................ 1 Capacity (20 hours):...................................................................................................................................95 Ah Discharge current.......................................................................................................................................900 A Weight (with electrolyte).................................................................................................................. 25 kg (55 lb) Battery (with cold start) Number ............................................................................................................................................................ 2 Capacity (20 hours):...................................................................................................................................74 Ah Discharge current.......................................................................................................................................680 A Weight (with electrolyte).................................................................................................................. 18 kg (40 lb) NORTH AMERICA MODELS Voltage .........................................................................................................................................................12 V Battery Number ............................................................................................................................................................ 1 Capacity (20 hours):...................................................................................................................................95 Ah Discharge current.......................................................................................................................................900 A Weight (with electrolyte).................................................................................................................. 25 kg (55 lb)

SECTION 55 - ELECTRICAL SYSTEM 4.2

CHECKS

CHECKING THE ELECTROLYTE LEVEL Remove the caps (1).

When the undercaps (2) are present:  electrolyte level should reach base of these.

Without undercaps:  electrolyte level should be 10 - 15 mm (0.39 0.59 in) above top of plates.

If necessary, top up with distilled water.

Retighten the caps (1).

CHARGE CHECK Unscrew caps (1) and undercaps (2) if installed.

Measure electrolyte density of individual cells with commercial hydrometer (3).

Hydrometer reading (see table on following page) indicates battery’s state of charge.

During measurement, temperature of electrolyte should preferably be +20 °C (68 °F).

Electrolyte density kg/dm3

Charge

Normal

Tropical

1.28

1.23

(0.046)

(0.044)

1.20

1.12

(0.043)

(0.040)

1.12

1.08

(0.040)

(0.039)

correct low: charge discharged: recharge immediately

CLAMPS CHECK Keep battery clean and dry.

Disconnect any dirty terminals.

Clean battery poles (+) and (-) and clamps and grease with acid-free and acid resistant grease.

When assembling, make sure that the terminal surfaces make good contact.

Tighten the terminal nuts by hand.

23

24 4.3

SECTION 55 - ELECTRICAL SYSTEM REPLACEMENT

Move the machine to a level and firm ground.

Stop the engine and remove the starter switch key.

Activate the parking brake.

Place some wedges under the wheels to prevent the machine from moving.

S WARNING Never exchange the battery terminals. Connect the positive cable to the positive terminal (+) and the negative cable to the negative terminal (-).

When disconnecting the battery cables, always disconnect the negative (-) cable first.

To reconnect the battery cables, always connect the negative (-) cable last.

Never short-circuit the battery terminals with metal objects.

Never touch the battery terminals with your hands.

This could generate an electrolysis inside the human body and damage the body’s vital organs.

Open the engine guard.

Place the battery master switch key in the “OFF” position (disconnected).

Remove old batteries.

Before installing the new battery, thoroughly clean the contact surfaces of the battery poles and clamps.

Install the new batteries.

Connect the positive cable to the positive terminal and the negative cable to the negative terminal.

Do not overtighten the terminal nuts, to prevent damaging them.

Grease battery poles and clamps with appropriate grease or neutral vaseline.

SECTION 55 - ELECTRICAL SYSTEM

5.

BULBS

1. Front light 2. Turn signal light 3. Rear light, stop light, turn signal and reversing light 4. Front work light (optional) 5. Rear work light (optional) 6. Rotary light (optional)

5.1

REPLACEMENT

Before replacing a bulb, stop the engine and remove the starter switch key.

Burnt bulbs have to be replaced with bulbs of same power.

Never touch new bulbs with bare fingers. Finger marks and dirt will burn in when the bulb is hot and may reduce the service life of the bulb.

Before installing a new bulb:  remove all traces of corrosion from the holder and the electrical contacts.

This helps avoid contact problems and high contact resistances.

FRONT LIGHT Loosen the 4 screws at the rear (3).

Remove the plug (4) and the rubber hood (5).

Remove the bulb (1) from holder (2) and install new bulb.

Reassemble in reverse order.

25

26

SECTION 55 - ELECTRICAL SYSTEM

TURN SIGNAL LIGHT Loosen the two rear screws (1).

Remove the front cover (3).

Replace the defective bulb (2).

Reassemble in reverse order.

FRONT WORK LIGHT (OPTIONAL) Unscrew the screws (1) and remove the headlight glass (2) carefully.

Shift the safety bracket (3).

Remove the defective bulb (5) from the holder (4) and install the new bulb.

Reassemble in reverse order.

SECTION 55 - ELECTRICAL SYSTEM REAR STOP LIGHT AND TURN SIGNAL LIGHT Unscrew and remove the covers (A) and (B).

Now the bulbs are accessible.

1. Tail light 2. Stop light 3. Turn signal light 4. Reversing light

Replace the defective bulb.

A. Tail light bulb B. Stop light bulb C. Turn signal light bulb D. Reversing light bulb

CAB LIGHT Remove the cover (1).

Replace the defective bulb.

ROTARY LIGHT Bulb replacement Depress the catch (1) and take off the cover (2).

27

28

SECTION 55 - ELECTRICAL SYSTEM

Extract the bulb (3) and insert a new one.

Place the back cover (2). Press the lever (1) and insert the cover (2) with snap-lock.

Reflector replacement Remove the cover (2). Withdraw the clip (4) using small pincers. The reflector can then be completely withdrawn together with motor (5).

Fit new reflector with motor (5). Insert the clip (4) and put on the cover (2).

SECTION 55 - ELECTRICAL SYSTEM

6.

29

TROUBLESHOOTING FAULT

Electrical system is inoperative.

Insufficient starter motor speed, the engine cranks slowly.

The starter motor does not operate.

The lamp on the instrument panel remains on with the engine running.

Batteries will not charge.

Charge indicator flashing indicating excessive charging voltage.

CAUSE

ACTION

Loose or oxidised battery connections.

Clean and tighten connections.

Battery faulty.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Battery switch to “OFF”.

Set battery switch to “ON”.

Low battery output.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Incorrect viscosity engine oil.

Use correct viscosity oil for temperature conditions.

Loose or oxidised battery connections.

Clean and tighten connections.

Defective battery.

Charge or replace batteries.

Low engine idle speed.

Increase idle speed.

Loose belt.

Check belt tension.

Malfunctioning battery.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Alternator malfunctioning.

Have the alternator checked by your Dealer.

Loose or oxidised battery connections.

Clean and tighten connections.

Battery faulty.

Check battery open circuit voltage for 12.6 V minimum. Check electrolyte density.

Loose or worn belt.

Check belt tension. Replace belt if required.

Alternator malfunctioning.

Have the alternator checked by your Dealer.

30 NOTES:

SECTION 55 - ELECTRICAL SYSTEM

SECTION 82 - WORKING EQUIPMENT 1. HYDRAULIC DIAGRAM ............................................................................................................................... 2 2. OPERATION................................................................................................................................................. 3 3. REMOVAL AND INSTALLATION ................................................................................................................. 4 4. QUICK TOOL COUPLER ............................................................................................................................. 6 4.1 COMPONENTS ..................................................................................................................................... 7 4.2 QUICK TOOL COUPLER CYLINDERS................................................................................................. 8 5. BUCKET ....................................................................................................................................................... 9 5.1 ASSEMBLY............................................................................................................................................ 9 5.2 DISASSEMBLY.................................................................................................................................... 10 5.3 BUCKET TEETH - REPLACEMENT ................................................................................................... 11 6. FORKS........................................................................................................................................................ 12 6.1 DISASSEMBLY AND ASSEMBLY....................................................................................................... 13 6.2 CHECKS .............................................................................................................................................. 14 7. CYLINDERS ............................................................................................................................................... 16 7.1 BOOM CYLINDER............................................................................................................................... 16 7.2 DUMPING CYLINDER......................................................................................................................... 20 8. CONTROL VALVE...................................................................................................................................... 24 9. LOAD HOLDING VALVE ............................................................................................................................ 27 9.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 27 10. TROUBLESHOOTING.............................................................................................................................. 28

SECTION 82 - WORKING EQUIPMENT

SECTION 82 - WORKING EQUIPMENT The machine can be equipped with various working attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the working attachment to the specific application.

Operate the machine only with the attachments and component combinations expressly approved by the Manufacturer.

Attachments from other manufacturers may be assembled and put into operation only if in compliance with Machinery Directive 89/392 EEC and only if the Manufacturer’s Declaration of Conformity of the attachment as well as the Manufacturer’s Declaration of Compatibility of the machine are available.

The machines can be equipped with different working equipment, included that of other machines, also equipped with quick coupler. But this is not the allowed and approved use for this machine.

Use exclusively approved attachments, delivered by an authorized Dealer.

Non approved equipment, according to the situation, cannot bear the lifting or tensile force of the wheel loader, this can of course damage the loader and its equipment.

Damaged attachments represent a real danger for the operator and the persons in the machine vicinity and can cause accidents or serious injuries or even death.

S WARNING Use approved equipment only, delivered by New Holland authorized Dealer. The non compliance with this instruction can cause accidents with serious injuries or even death.

1.

2.

3.

4.

5.

6.

Bucket Quick tool coupler Connecting rods Boom Lifting cylinder Dumping cylinder

1

2

1.

1.

2.

3.

4.

5.

6.

7.

8.

SECTION 82 - WORKING EQUIPMENT

HYDRAULIC DIAGRAM

Diesel engine Variable-displacement pump Gear pump Priority valve Oil tank Oil return filter One-way distributor valve Working equipment control valve a. Primary valve b. Lifting spool c. Dumping spool d. 3rd function spool e. Valve f. Secondary valve g. Secondary valve h. Secondary valve i. Secondary valve j. Secondary valve

9.

10.

11.

12.

13.

14.

Load-holding valve Quick tool coupler cylinders valve Quick tool coupler cylinders 3rd function cylinders Dumping cylinder Lifting cylinder

SECTION 82 - WORKING EQUIPMENT

2.

3

OPERATION

Hydraulic oil delivered to gear pump (3) is set at disposal of working equipment and steering unit.

For safety reasons, during oil supply, the priority valve (4) gives priority to the steering system, so that, even if steering system and working attachment are activated simultaneously, the steering system is always supplied with oil first, and the working equipment only receives the remaining hydraulic oil afterwards.

The measuring port (PH) is located on priority valve (4), through this port the gear pump (3) pressure can be checked; that is the setting of primary valve (8a).

From priority valve (4), the oil reaches the control valve (8).

The pump’s maximum pressure is relieved here by the primary valve (8a).

If the no operation of working equipment has been actuated, the oil, flowing though the control valve (8), returns into the tank (5) through the one-way distributor valve (7) and oil return filter (6).

If one of the control valve spools are shifted, the oil is delivered to the relevant hydraulic cylinders and the required operation is performed.

The control valve spool (8b) monitors the oil for lifting and lowering operation. If control lever is pushed beyond the lowering position, the spool stops and engages the floating position.

In the floating position, the oil not under pressure returns to the tank and the boom cylinders (12) are connected between them on the bottom side as well as on the rod side, through the control channels of the control valve spool (8d).

In this position the bucket or working equipment rest on the ground, laying exclusively because of its weight.

During quick lowering, to allow a sufficient quantity of oil on the rod side of the boom cylinders (14), the replenishing valve (8e) can, in case of need, suck hydraulic oil from the tank return line.

The lifting operation is limited by the secondary valve (8f). In this way damages generated by an excess of forces involved, is avoided.

The secondary valve incorporates a replenishing valve that, in case of need, sucks oil from the tank return line.

The back-tipping and dumping operation is controlled by the control valve spool (8c). To prevent any damage caused by external forces, the pressure inside the back-tipping line is ensured by the secondary valve (8h), and the pressure in the dumping line is ensured by the secondary valve (8g).

Both secondary valves operates also as replenishing valves, that in case of need, suck oil from the tank return line.

The control valve spool (8d) engages the 3rd function (12).

The pressure of the 3rd function cylinder motion (12) is relieved by the secondary valves (8i) and (8j). In this way damages generated by an excess of forces involved, is avoided.

All three spools (8b), (8c) and (8d) contain uphill, on pump side, a check valve that, working as a pressure holding valve, prevents accidental movements (boom (13) or bucket dumping (14) cylinder stall).

The oil flows though the control valve (8) and reaches the hydraulic oil tank (5), flowing through the oneway distributor valve (7) and oil return filter (6).

4

3.

SECTION 82 - WORKING EQUIPMENT

REMOVAL AND INSTALLATION

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Sling the working equipment with ropes and support it with an hoist.

Sling the dumping connecting rods.

Disconnect the hydraulic lines (1) and (2) from both sides, paying attention to possible oil leaks, and plug all openings in order to prevent dirt intrusion.

Loosen and remove the nut (3) and the screw (4).

Remove the pin (5) from the opposite side as far as necessary to release the dumping cylinder rod (6).

Once the dumping cylinder rod (6) is free, reposition the pin (5) into the connecting rod hole (7). Reassemble screw (4) and nut (3) to avoid that connecting rod (7) shifts during the working equipment removal.

SECTION 82 - WORKING EQUIPMENT Loosen and remove the screw (8) and the washer (9).

Remove the pin (10) to release the lifting cylinder rod (11).

Loosen and remove the screw (12) and the washer (13).

Slide out the pin (14).

Remove the whole working attachment from the machine.

As to installation, proceed in reverse sequence of operations described above.

5

6

4.

SECTION 82 - WORKING EQUIPMENT

QUICK TOOL COUPLER

The machine is equipped with a universal quick tool coupler as per SAE J2513 / ISO 24410 standards.

The quick tool coupler is activated by means of the switch installed on the cab console at the right of the seat. The switch has two positions, quick coupler open (lamp on) and quick coupler locked (lamp off).

In the locked position, the switch is secured by a mechanical lock against a possible accidental activation. To set the switch to the open position, slightly pull the lock towards the operator (arrow direction) and, by pressing on the symbol, lower the switch.

With activation disconnected, the quick coupler is always locked. If the activation is disconnected with quick coupler open, this locks automatically.

As soon as the activation is enabled, the quick coupler locks go/shift to the open (lamp on) or closed position (lamp off) set on the switch.

The hydraulic system of the quick coupler is equipped with an accumulator which, during normal operation, creates a continuous hydraulic preload of the quick coupler cylinders.

During operation, the accumulator is loaded and reloaded by the pressure of the working hydraulic line.

The oil stored in the accumulator activates also the cylinders during the equipment change.

Also when the accumulator is unloaded, the hydraulic system receives an oil feed sufficient to enable the activation of the quick tool coupler.

However, when the accumulator is discharged, the locking cylinder movement is slower. During operation the accumulator preload holds the working equipment constantly under load.

If, due to a long-term inactivity of the machine, e.g. after a long stop of the machine, the accumulator discharges, the safe locking of the quick coupler is always active thanks to the locking valves.

However, it can happen that the quick coupler hooks get jammed, thus hindering the opening of the locking system. In such a case, the accumulator has to be manually charged. This is possible by quickly retracting the working equipment to stroke end (for instance by fully tipping back the bucket), in this way the main relief valve inside the control valve can activate (sound similar to a whistle).

When the accumulator of the quick coupler is completely charged, the coupler gets open without any problem.

O. Swing point of lifting assy W. Central line of lifting assy

138°. Extended boom cylinder 47.8°. Retracted boom cylinder

Dumping cylinder completely retracted = 1116 mm (43.96 in) Dumping cylinder stroke = 459 mm (18.07 in)

SECTION 82 - WORKING EQUIPMENT 4.1

COMPONENTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Quick coupler cylinder Pin Split pin Washer Elastic ring Shim Coupling Screw Nut Shim Upper pin

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Bottom pin Screw Nut Shim Nut Screw Bushing Coupling Grease nipple Shim

7

8

SECTION 82 - WORKING EQUIPMENT

4.2

QUICK TOOL COUPLER CYLINDERS

ø1 (rod)

mm (in)

25 (0.98)

ø2 (liner)

mm (in)

40 (1.57)

ø3 (bottom connection)

mm (in)

20 (0.78)

ø4 (rod connection)

mm (in)

20 (0.78)

L (completely retracted)

mm (in)

190 (7.48)

C (stroke)

mm (in)

60 (2.36)

H1

mm (in)

16.5 (0.64)

H2

mm (in)

36 ± 1 (1.41 ± 0.03)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cylinder rod Wiper ring Seal ring Piston Piston gasket Cylinder head Gasket Ring nut Cylinder liner

SECTION 82 - WORKING EQUIPMENT

5.

BUCKET 21E

SAE capacity

m3

0.65

0.70

121E 0.80

0.80

0.90

221E 0.90

1.00

321E 1.00

1.10

1.20

(ft ) (22.95) (24.72) (28.25) (28.25) (31.78) (31.78) (35.31) (35.31) (38.83) (42.37) 3

mm 1800

Width

1900

1900

2050

2050

2050

2100

2100

2100

2100

(in) (70.86) (74.80) (74.80) (80.70) (80.70) (80.70) (82.67) (82.67) (82.67) (82.67)

Weight

5.1

9

kg

250

265

295

315

335

335

365

365

370

410

(lb)

(550)

(583)

(649)

(693)

(737)

(737)

(803)

(803)

(814)

(902)

ASSEMBLY

Rest the bucket on the ground.

By moving the machine forward, bring the lifting arm (1) and the bucket (2) to assembly position.

Unlock the switch (3) from the mechanical lock and press the symbol face of the switch (lamp on).

Move the machine until the upper support (4) of the quick coupler can fit into the bucket housing (5). Lift the bucket and tip it back to enable the support to fit into the housing (5).

Set switch (3) to locked position (lamp off). The hook (7) fits into the housing (6). The bucket is now locked (3) (lamp off).

10

SECTION 82 - WORKING EQUIPMENT

LOCKING CHECK Lift and tip back the bucket to enable the check of the locking system (visual check).

Hooks (1) must protrude out of the plate slots (2).

5.2

DISASSEMBLY

Slightly tilt back the bucket and lay it on the ground.

Unlock the switch (3) from mechanical lock and press the symbol face of switch at the same time.

Slightly lower the boom so that the support (4) and the hooks (7) can come out of the bucket housings.

During reverse travel, the boom remains free.

SECTION 82 - WORKING EQUIPMENT 5.3

BUCKET TEETH - REPLACEMENT

S WARNING Nobody must stay in the way of the tooth or tooth safety latch that has to be extracted.

The safety latch or the tooth can suddenly be ejected when driven out and hit persons.

Metal splinters may cause injury.

Wear your personal protective equipment and goggles.

Drive out the safety pin (1) using a metal or wood bar (2).

Drive out the tooth (3) from the tooth holder (4) using a metal or wood bar (2).

Clean the inside of the housing and remove dirt and rust.

Fit new tooth (3) into the housing (4).

The tooth (3) must rest against the point indicated by the arrow.

Drive in new safety latch (1) into the port (5) of the housing (4). The latch can be driven into the housing from either side.

11

12

6.

SECTION 82 - WORKING EQUIPMENT

FORKS

Always take up the load with both fork prongs.

Check the prongs by permanent visual inspections and put them out of operation immediately if damage is detected.

Fork prongs are not designed to withstand lateral forces. Avoid driving the prongs diagonally under the load or pushing the load with the side.

Do not let loads fall on fork prongs.

The transport of molten or fused material is forbidden.

The transport of persons on fork prongs is forbidden.

Do not lift loads with the tip of the prongs. Risk of overloading.

Have legally prescribed checks performed regularly by qualified personnel or by the After-sales service.

The rules and regulations in force in the country of use must be observed.

Perform regular measurements of prong wear.

Drive with folded forks with no load, as this reduces the risk of accidents. It is not necessary to remove the forks to connect certain types of attachment.

FORK TYPES Standard forks (1).

Collapsible forks (2).

SECTION 82 - WORKING EQUIPMENT 6.1

DISASSEMBLY AND ASSEMBLY

Place the tool (1) with lifting forks (2) on the ground and attach as described.

Assembly and disassembly of lifting forks are similar to a bucket assembly/disassembly procedure.

13

14 6.2

SECTION 82 - WORKING EQUIPMENT CHECKS

Inspections have to be performed regularly.

ISO 5057 prescribes an inspection at least every 12 months. Depending on the conditions of use, for instance multi-shift work or severe operating conditions, the inspections are to be performed more frequently. Moreover, the operator is obliged to perform regular visual checks.

The following points must be checked:  wear  cracking in the bent area  cracking in welding seams  deformations and warping  functioning of the arresters  damage of fork hook and fork tip  general condition CRACKING TEST

S CAUTION Cracking tests must be performed by specially qualified experts.

In the event of positive cracking test results, both prongs must be replaced immediately.

Critical zones are the fork bending point and the welds at the suspensions.

The usual methods of testing applied are the magnetic powder test or the dye penetration test.

Principle of destruction-free testing for cracks by means of the dye penetration method.

1. Clean the zone to be tested thoroughly.

2. Spray red penetrant on the test zone.

3. Remove red penetrant.

4. Spray developer on the test zone.

Cracks are now visible.

SECTION 82 - WORKING EQUIPMENT DEFORMATION CHECK

S WARNING If the bending angle of the prongs is greater than 91° or less than 88°, both fork prongs must be replaced immediately.

Fork prongs are delivered with a bending angle of 90°.

They are designed in such a way that they can withstand even twice the nominal load without any remaining deformation.

In practice, permanent deformation may, however, occur by overloading, misuse or unilateral loading.

Measurement: Make a mark at the vertical and horizontal distance of 500 mm (19.68 in).

Measure the diagonal distance (d).

The diagonal must be between 695 and 713 mm (27.36 - 28.07 in).

If the measured distance is less than 695 mm (27.36 in) or greater than 713 mm (28.07 in), both fork prongs must be replaced immediately.

WEAR CHECK

S CAUTION When wear exceeds 10%, immediately replace both forks.

Fork prong wear occurs most often in the outer bending area.

Start measuring wear from the original nominal thickness (n).

At a nominal thickness of, for instance, 40 mm (1.57 in), the wear limit is 36 mm (1.41 mm).

When wear exceeds 10%, immediately replace both forks.

15

16

SECTION 82 - WORKING EQUIPMENT

7.

CYLINDERS

7.1

BOOM CYLINDER

21E

121E

221E

321E

ø1 (rod)

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

ø2 (liner)

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

ø3 (bottom connection)

mm (in)

55 (2.16)

55 (2.16)

60 (2.36)

60 (2.36)

ø4 (rod connection)

mm (in)

60 (2.36)

60 (2.36)

60 (2.36)

60 (2.36)

L (completely retracted)

mm (in)

1078 (42.44)

1071 (42.16)

1081 (42.55)

1125 (44.30)

C (stroke)

mm (in)

721 (28.38)

728 (28.66)

718 (28.26)

730 (28.74)

H1

mm (in)

60 (2.36)

60 (2.36)

80 (3.14)

80 (3.14)

H2

mm (in)

80 (3.14)

80 (3.14)

80 (3.14)

80 (3.14)

SECTION 82 - WORKING EQUIPMENT REMOVAL AND INSTALLATION Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Support the boom cylinder with a rope or a hoist.

Disconnect the hydraulic lines (1) from the boom cylinder (2), paying attention to possible oil leaks, and plug all openings in order to prevent dirt intrusion.

Loosen and remove the screw (3) and the washer (4).

Remove the pin (5) to release the lifting cylinder rod (2).

Loosen and remove the screw (6) and the washer (7).

Remove the pin (8) from cutting edge of wheel loader frame.

By removing the pin (8) so as to release the bottom of the lifting cylinder (2).

Now it is possible to remove the boom cylinder from the machine.

As to installation, proceed in reverse sequence of operations described above.

17

18

SECTION 82 - WORKING EQUIPMENT

DISASSEMBLY

1.

2.

3.

4.

5.

6.

7.

8.

9.

Elastic ring Grease nipple Cylinder rod Bushing Wiper ring Seal ring Seal ring Cylinder head Back-up ring

The following disassembly procedure is based on the condition that the hydraulic lines have already been removed.

Lift and place the cylinder on a workbench and secure it. Make sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

10.

11.

12.

13.

14.

15.

16.

17.

O-ring O-ring Piston Piston gasket Cylinder liner Bushing Elastic ring Grease nipple

SECTION 82 - WORKING EQUIPMENT Fully extend the cylinder rod (3).

Loosen the cylinder head (8). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.

Extract the cylinder head (8) from the cylinder liner (14) by using a plastic hammer. Remove the cylinder rod (3) and the cylinder head (8).

IMPORTANT: make sure to pull out the cylinder rod (3) straight so as not to damage the sliding surfaces.

Remove the piston assy (12) and the cylinder head assy (8) from the cylinder rod (3).

Only if necessary:  remove the wiper ring (5), the seal rings (6) and (7) and the O-ring (10) with the back-up ring (9) from the cylinder head (8);  remove the O-ring (11) and the piston gasket (13) from the piston (12).

19

20 7.2

SECTION 82 - WORKING EQUIPMENT DUMPING CYLINDER

21E

121E

221E

321E

ø1 (rod)

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

ø2 (liner)

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

ø3 (bottom connection)

mm (in)

55 (2.16)

55 (2.16)

60 (2.36)

60 (2.36)

ø4 (rod connection)

mm (in)

70 (2.75)

70 (2.75)

70 (2.75)

70 (2.75)

L (completely retracted)

mm (in)

1116 (43.93)

1121 (44.13)

1196 (47.08)

1244 (48.98)

C (stroke)

mm (in)

459 (18.07)

454 (17.87)

490 (19.30)

490 (19.30)

H1

mm (in)

60 (2.36)

60 (2.36)

80 (3.14)

80 (3.14)

H2

mm (in)

80 (3.14)

80 (3.14)

80 (3.14)

80 (3.14)

SECTION 82 - WORKING EQUIPMENT REMOVAL AND INSTALLATION Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Support the dumping cylinder with a rope or a hoist.

Disconnect the hydraulic lines (1) from the dumping cylinder (2), paying attention to possible oil leaks and plug all openings in order to prevent dirt intrusion.

Loosen and remove the nut (3) and the screw (4).

Remove pin (5) from opposite side as far as necessary to release the dumping cylinder rod.

Once the dumping cylinder rod is free, reposition pin (5) and reassemble screw (4) and nut (3).

Loosen and remove the screw (6) and the washer (7).

Remove the pin (8) so as to release the dumping cylinder bottom (2).

Now it is possible to remove the dumping cylinder from the machine.

As to installation, proceed in reverse sequence of operations described above.

21

22

SECTION 82 - WORKING EQUIPMENT

DISASSEMBLY

1.

2.

3.

4.

5.

6.

7.

8.

9.

Elastic ring Grease nipple Cylinder rod Bushing Wiper ring Seal ring Seal ring Cylinder head Back-up ring

The following disassembly procedure is based on the condition that the hydraulic lines have already been removed.

Lift and place the cylinder on a workbench and secure it. Make sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

10.

11.

12.

13.

14.

15.

16.

17.

O-ring O-ring Piston Piston gasket Cylinder liner Bushing Elastic ring Grease nipple

SECTION 82 - WORKING EQUIPMENT Fully extend the cylinder rod (3).

Loosen the cylinder head (8). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.

Extract the cylinder head (8) from the cylinder liner (14) by using a plastic hammer. Remove the cylinder rod (3) and the cylinder head (8).

IMPORTANT: make sure to pull out the cylinder rod (3) straight so as not to damage the sliding surfaces.

Remove the piston assy (12) and the cylinder head assy (8) from the cylinder rod (3).

Only if necessary:  remove the wiper ring (5), the seal rings (6) and (7) and the O-ring (10) with the back-up ring (9) from the cylinder head (8);  remove the O-ring (11) and the piston gasket (13) from the piston (12).

23

24

8.

1.

2.

3.

4.

5.

6.

SECTION 82 - WORKING EQUIPMENT

CONTROL VALVE

High pressure relief valve (230 bar) (3335 psi) Auxiliary spool Dumping spool Lifting spool Anticavitation shock valve (180 bar) (2610 psi) Anticavitation shock valve (250 bar) (3625 psi) for bucket dumping 7. Anticavitation shock valve (200 bar) (2900 psi) for bucket back-tipping

8. Auxiliary anticavitation and (200 bar) (2900 psi) 9. Auxiliary anticavitation and (200 bar) (2900 psi) 10. Lowering anticavitation valve 11. Lifting holding valve 12. Dumping holding valve 13. Auxiliary holding valve

shock

valve

shock

valve

SECTION 82 - WORKING EQUIPMENT

A1

Oil for boom cylinder (rod side)

A2

Oil for dumping cylinder (bottom side)

A3

Oil for auxiliary function cylinders (bottom side)

B1

Oil for boom cylinder (bottom side)

B2

Oil for dumping cylinder (rod side)

B3

Oil for auxiliary function cylinders (rod side)

P

Oil from priority valve

T2

Return to oil tank through the distributor valve

25

ADJUSTMENTS To carry out any check and adjustment work on hydraulic system, the hydraulic oil temperature should be about 60 - 70 °C (140 - 158 °F).

Connect a suitable pressure gauge with measuring port (PH) of priority valve. The working equipment is checked, by bringing the lifting cylinder to stroke end. At this point the reading of primary pressure on pressure gauge should be 230 bar (3335 psi).

Primary pressure is adjusted on the pressure relief valve (1).

The best way to check the valves is to proceed in this way:  connect a suitable pressure gauge to the dumping cylinder’s bottom side;  place the boom in horizontal position;  dump completely the bucket up to stroke end;  lift working equipment without actuating the dumping. Because of the boom effort, the pressure gauge now indicates the pressure of the dumping shock and anticavitation valve (6).

To check the shock and anticavitation valve for bucket back-tipping (7), invert the connection lines of the dumping cylinder and carry out all previous operations again.

To check the boom shock and anticavitation valve (5), invert it with the dumping shock and anticavitation valve (6), already adjusted, then repeat all previous operations.

Valve

Value bar (psi)

High pressure relief valve (1)

230 ± 10 (3335 ± 145)

Shock and anticavitation valve (7)

280 ± 5 (4060 ± 73)

Shock and anticavitation valve (6)

250 ± 5 (3625 ± 73)

Shock and anticavitation valve (5)

280 ± 5 (4060 ± 73)

Shock and anticavitation valve (9)

200 ± 5 (2900 ± 73)

Shock and anticavitation valve (8)

200 ± 5 (2900 ± 73)

“OLS” Valve

250 ± 5 (3625 ± 73)

26

SECTION 82 - WORKING EQUIPMENT

OTHER CHECKS Even if the adjustment of primary and secondary pressure is correct, this does not mean that the hydraulic system is in order.

To be sure that the system is in order you have to check also the delivery. As this is a very complex measurement and often necessary means are not available, take advantage of the lifting time.

With engine at maximum rpm, the lifting time should be approximately of 6 seconds.

Cause

Measure

Lifting cylinders leaking.

Remove the leaking.

Dumping cylinder leaking. Remove the leaking.

The control valve leaks too strongly.

Replace control valve or involved spools.

Fault in the secondary valve for back-tipping.

Adjust, clean or replace valve.

NOTE: a condition for the correctness of this check is that the engine has been adjusted correctly.

No seal to the outside.

Remove any leaks.

If the lifting time is quite exceeded, this means that either priority valve is defective or the hydraulic pump is faulty.

A further check is the measurement of the lowering time. For this operation equip the machine with standard bucket and set boom and bucket to horizontal position.

Now stop the engine. In 15 minutes the bucket tip can be lowered of about 60 mm (2.36 in). If the lowering time is higher, make sure that the fault depends on the lifting or dumping operation.

In this period of time, lifting cylinders can yield of about 15 mm (0.59 in) (read on the rod).

The reasons for a too quick lowering time could be:

Working equipment lowering time (mm/min) (in/min)

Lifting time at maximum engine rpm (sec.)

Measure on bucket tip

60 / 15 (2.36 / 0.59)

21E

121E

221E

321E

6

5.7

5.5

6.3

SECTION 82 - WORKING EQUIPMENT

9.

27

LOAD HOLDING VALVE

1. Load holding valve, adjustment pressure 250 bar (3625 psi).

2. Valve setscrew. Do not excessively loosen the screw. Before adjusting the screw, sufficiently loosen the nut so that the seal ring is not damaged.

L = 19 ÷ 28 mm (0.74 ÷ 1.10 in)

9.1

TECHNICAL SPECIFICATIONS

Pressure range ................................................................................................ 131 ÷ 150 bar (1899 ÷ 2175 psi) Pressure setting retaining valve............................................................................................. 285 bar (4132 psi) Pressure setting shock valve ................................................................................................. 285 bar (4132 psi) Ratio.......................................................................................................................................................... 1 : 4.4 Flow rate maximum...................................................................................................... 100 l/min (26.30 gal/min)

28

SECTION 82 - WORKING EQUIPMENT

10. TROUBLESHOOTING FAULT Lifting or dumping not functional.

CAUSE

ACTION

Low oil level.

Top up with oil.

Pump drive coupling defective.

Replace the coupler.

Kinematics fault (working equipment Consult your Dealer. components deformed).

Control lever of bucket equipment does not hold locking in floating position.

Defective kinematics in the control valve slide.

Consult your Dealer.

Defective kinematics in the control valve section.

Consult your Dealer.

Defect of control piston block in con- Consult your Dealer. trol valve section.

Dumping or lifting time too long.

Pressure setting too low.

Set the pressure.

Engine rpm too low.

Raise engine speed.

Pump delivery rate too low.

Consult your Dealer.

Defective kinematics in the control valve section.

Consult your Dealer.

Internal leaks in control valve section Find and eliminate the leak. or in cylinders.

Spool travel in the control valve section too short.

Consult your Dealer.

Lowering time too long.

Defective kinematics in the control valve section.

Consult your Dealer.

Lifting force insufficient.

Pressure setting too low.

Set the pressure.

Internal leaks in control valve section Find and eliminate the leak. or in cylinders.

Dumping force insufficient.

Pressure setting too low.

Set the pressure.

Internal leaks in control valve section Find and eliminate the leak. or in cylinders.