CASE 821F TIER 4 WHEEL LOADER Service Repair Manual

821F 921F Tier 4 Wheel Loader

SERVICE MANUAL

Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

Part number 84487565 1st edition English April 2011

1001 Section 1001 GENERAL TORQUE SPECIFICATIONS

1001-2

TABLE OF CONTENTS TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6

1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

Size

PoundInches

Newton metres

Size

PoundFeet

Newton metres

1/4 inch

108 to 132

12 to 15

7/16 inch

70 to 84

95 to 114

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

3/8 inch

420 to 504

48 to 57

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

Newton metres

3/4 inch

380 to 456

515 to 618

Size

PoundFeet

7/8 inch

600 to 720

814 to 976

7/16 inch

54 to 64

73 to 87

1.0 inch

900 to 1080

1220 to 1465

1/2 inch

80 to 96

109 to 130

1-1/8 inch

1280 to 1440

1736 to 1953

9/16 inch

110 to 132

149 to 179

1-1/4 inch

1820 to 2000

2468 to 2712

5/8 inch

150 to 180

203 to 244

1-3/8 inch

2380 to 2720

3227 to 3688

3/4 inch

270 to 324

366 to 439

1-1/2 inch

3160 to 3560

4285 to 4827

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

NOTE: Use thick nuts with Grade 8 bolts.

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given.

These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.

Grade 8.8 Bolts, Nuts, and Studs 8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs 10.9

Size

PoundInches

Newton metres

M4

36 to 48

4 to 5

M5

84 to 96

9 to 11

M6

132 to 156

15 to 18

M8

324 to 384

37 to 43

PoundFeet

Newton metres

Newton metres

M4

24 to 36

3 to 4

Size

M5

60 to 72

7 to 8

M10

54 to 64

73 to 87

M6

96 to 108

11 to 12

M12

93 to 112

125 to 150

M8

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

1/4 inch 6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch 6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch 7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch 7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch 9.5 mm

9/16-18

120 to 300

14 to 34

3/8 inch 9.5 mm

9/16-18

300 to 480

34 to 54

1/2 inch 12.7 mm

3/4-16

180 to 504

20 to 57

1/2 inch 12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch 15.9 mm

7/8-14

300 to 696

34 to 79 Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

3/4 inch 19.0 mm

1-1/16-12

40 to 80

54 to 108

3/4 inch 19.0 mm

1-1/16-12

80 to 128

108 to 174

7/8 inch 22.2 mm

1-3/16-12

60 to 100

81 to 135

7/8 inch 22.2 mm

1-3/16-12

100 to 160

136 to 216

1.0 inch 25.4 mm

1-5/16-12

75 to 117

102 to 158

1.0 inch 25.4 mm

1-5/16-12

117 to 187

159 to 253

1-1/4 inch 31.8 mm

1-5/8-12

125 to 165

169 to 223

1-1/4 inch 31.8 mm

1-5/8-12

165 to 264

224 to 357

1-1/2 inch 38.1 mm

1-7/8-12

210 to 250

285 to 338

1-1/2 inch 38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts PoundInches

Newton metres

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS O-ring Boss End Fitting or Lock Nut

O-ring Face Seal End Nom. SAE Dash Size

Tube OD

Thread Size

PoundInches

Newton metres

Thread Size

PoundInches

Newton metres

-4

1/4 inch 6.4 mm

9/16-18

120 to 144

14 to 16

7/16-20

204 to 240

23 to 27

-6

3/8 inch 9.5 mm

11/16-16

216 to 240

24 to 27

9/16-18

300 to 360

34 to 41

-8

1/2 inch 12.7 mm

13/16-16

384 to 480

43 to 54

3/4-16

540 to 600

61 to 68

Thread Size

PoundFeet

Newton metres

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

-10

Nom. SAE Dash Size

5/8 inch 15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread Size

PoundFeet

Newton metres

1-3/16-12

95 to 100

129 to 136

-12

3/4 inch 19.0 mm

1-3/16-12

65 to 80

90 to 110

1-5/16-12

115 to 125

156 to 169

-14

7/8 inch 22.2 mm

1-3/16-12

65 to 80

90 to 110

1-5/8-12

150 to 160

203 to 217

-16

1.0 inch 25.4 mm

1-7/16-12

92 to 105

125 to 140

1-7/8-12

190 to 200

258 to 271

-20

1-1/4 inch 31.8 mm

1-11/16-12

125 to 140

170 to 190

-24

1-1/2 inch 38.1 mm

2-12

150 to 180

200 to 254

FLUIDS AND LUBRICANTS

1002

Section 1002

1002-2

TABLE OF CONTENTS 821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6 6 6 6 7 9 10 12

1002-3

821F - CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts) Type of oil .........................................Case AKCELA No. 1 engine oil see engine oil recommendations on page 4 Engine Cooling System Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 DEF (Diesel Exhaust Fluid) Tank Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts) Hydraulic System Hydraulic Reservoir Refill Capacity ..........................................................................90.8 liters (24.0 U.S. Gallons) Total System Capacity............................................................................................... 178 liters (47.0 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Front...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Type of Lubricant ............................................................................................................................. Case Nexplore NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil.

Brake System Type of Fluid (Same as Hydraulic System)................................................................ Case AKCELA Hy-Tran Ultra®

1002-4

921F - CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts) Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts) Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4 Engine Cooling System Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 DEF (Diesel Exhaust Fluid) Tank Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts) Hydraulic System Hydraulic Reservoir Refill Capacity ........................................................................... 110 liters (29.0 U.S. Gallons) Total System Capacity............................................................................................... 200 liters (53.0 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran UltraÂŽ Transmission Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Front...................................................................................................................... 42.0 liters (44.4 U.S. Quarts) Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Type of Lubricant............................................................................................................................. Case Nexplore NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil.

1002-5

ENGINE OIL RECOMMENDATIONS Case AKCELA No. 1 Engine oil is recommended for use in your Case engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions.

If Case AKCELA No. 1 Multi-Viscosity Oil is not available, use only oil meeting API engine oil service category CH-4 (preferred) or CG-4.

S e e t h e c h a r t b e l ow fo r recommended viscosity at ambient air temperature ranges.

RH99K130

NOTE: Do not put performance additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case AKCELA lubricants.

BD03A102

BC02N250

1002-6

TRANSMISSION TEMPERATURE CHART

RCPH10WHL435BAH3

DIESEL FUEL SYSTEM Use No. 2 diesel fuel in the engine of this machine.

The use of other fuels can cause the loss of engine power and high fuel consumption.

In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following Note.

NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will restrict the fuel filter and cause the engine to lose power or not start.

Fuel Storage If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel.

Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time.

Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.

The diesel fuel used in this machine must meet the specifications as shown below in, “Specifications for Acceptable No. 2 Diesel Fuel”, or “Specification D975-81” of the American Society for Testing and Materials.

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum ............................................................................................................................................. 34 Flash point, minimum ............................................................................................................................60°C (140°F) Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F) Viscosity, at 38°C (100°F) Centistokes ......................................................................................................................................... 2.0 to 4.3 Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum ..................................................................................................... 0.05%

1002-7

What is Selective Catalytic Reduction (SCR)?

The main components of the SCR system include the SCR catalyst, the Diesel Exhaust Fluid (DEF)/ AdBlue® injection unit, the DEF/AdBlue® tank, and the DEF/AdBlue® dosing control unit.

How does Selective Catalytic Reduction (SCR) work?

During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue® solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue® solution.

During cold engine operation at low engine coolant and ambient air temperatures, water vapor will be visible from the exhaust when the engine operates.

This water vapor will resemble steam or light white smoke and will dissipate as the engine and machine components warm and is considered normal.

NOTE: After engine shutdown, the SCR system will perform a purge cycle, which permits the supply module to continue to run for up to 70 seconds. This is to be considered normal and requires no action from the operator.

What is Diesel Exhaust Fluid (DEF)/AdBlue®?

DEF/AdBlue® is a non-toxic aqueous urea solution ( 3 2 .5 % ) w i th a s l i g h t a m m o n i a o d o r u s e d to chemically reduce NOx emissions from heavy-duty diesel powered vehicles.

DEF/AdBlue® is neither explosive nor harmful to the environment and is classified under the minimum-risk category of transpor table fluids. DEF/AdBlue® quality is defined by ISO 22241-1. The American Petroleum Institute (API®) has a voluntary certification program for DEF/AdBlue®. To ensure DEF/ AdBlue® satisfies the requirements of ISO 22241. DEF/AdBlue®. API Diesel Exhaust Fluid Certification Mark is a registered trademark of API in the United States and or other countries.

Storage, handling, and transport NOTICE: Storage temperatures above 30 °C (86 °F) greatly reduce the shelf life of DEF/AdBlue®.

DEF/AdBlue® has a typical shelf life of 6-12 months.

Refer to the SHELF LIFE table below. In order for DEF/AdBlue® to remain in a usable condition, storage requirements need to be met.

• Store between -11 °C (12 °F) and 30 °C (86 °F).

• Use only an approved DEF/AdBlue® container.

• Keep container tightly closed.

• Keep container in a cool, well-ventilated area.

• Keep away from heat and direct sunlight.

Thawing • The machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue®. The machine will still function until the DEF/AdBlue® begins to flow. The SCR system will then function normally.

• Do not heat DEF/AdBlue® for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life.

NOTICE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue®. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue® mixture will lessen its ability to perform correctly and may cause damage to the SCR components.

Handling and supply of additives, if any.

• Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, imper vious gloves are recommended.

Follow the precautions listed in the SAFETY INFORMATION chapter when handling any service fluid.

• No additives are required.

NOTICE: Contaminated DEF/AdBlue® can affect the performance of your machine. Follow all instructions in this manual when handling DEF/AdBlue®.

Shelf life Constant ambient storage temperature and minimum shelf life Less than or equal to 10 °C (50 °F) 36 months Less than or equal to 25 °C (77 °F) ¹ 18 months Less than or equal to 30 °C (86 °F) 12 months Less than or equal to 35 °C (95 °F) 6 months Greater than 35 °C (95 °F) -² ¹ To prevent decomposition of DEF/AdBlue®, prolonged transportation or storage above 25 °C (77 °F) should be avoided. ² Significant loss of shelf life: check every batch before use. See your [Brand] dealer for more information on testing.

1002-8 NOTE: The main factors taken into account to define the shelf life in the previous figures are the ambient storage temperature and the initial alkalinity of DEF/AdBlue®. The difference in evaporation between vented and non-vented storage containers is an additional factor.

NOTE: The information in this table is for reference only and has been provided by the International Organization for Standardization, Document number ISO 22241-3 Diesel engines - NOx reduction agent AUS 32 - Part 3: Handling, transportation and storage.

Disposal • Dispose of DEF/AdBlue® and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal.

For machines sold in California CNH must warrant the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owner’s manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment.

Please review your owner’s manual for other warranty information. The diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, and other emission-related assemblies.

Glossary Acronym Definition DEF

Diesel Exhaust Fluid

ISO

International Organization for Standardization

MSDS

Material Safety Data Sheet

NOx

Nitrogen Oxide

PPE

Pe r s o n a l Equipment

Protective

SCR

Selective Reduction

Catalytic

ULSD

Ultra Low Sulfur Diesel

1002-9

SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS Requirements The operator must maintain appropriate DEF/AdBlue® levels at all times. The SCR system is compatible with up to 7% bio-diesel fuel.

Diesel Exhaust Fluid (DEF)/AdBlue® refilling The DEF/AdBlue® tank cap (1) can be identified by the “blue” color of the cap. A fitting under the cap prevents the insertion of a diesel fill nozzle.

NOTE: If any DEF/AdBlue® spills or contacts any surface other than the storage tanks, immediately clean the affected surface with clear water.

DEF/AdBlue® will cause corrosion on painted and unpainted metallic surfaces, and may distort some plastic and rubber components.

It i s r e c o m m e n d e d t h a t D E F /A d B l u e ® f i l l i n g equipment should be used having a fill nozzle/pump with the correct length and diameter, triggered by the magnet in the tank filler neck and with overfill flow cut out.

This will ensure that: ●

The screen in the filler neck will not be damaged.

●

Impurities are not entering the DEF/AdBlue® tank.

The standardized DEF/AdBlue® nozzle matches the filler neck diameter.

●

The DEF/AdBlue® tank is not overfilled, as the DEF/AdBlue® pump will stop when the DEF/AdBlue® tank is full.

●

DEF/AdBlue® is not pumped in the fuel tank, as the DEF/AdBlue® nozzle cannot pump when the magnet is not sensed.

NOTICE: Refilling with a funnel is not recommended as this may lead to damage of the screen in the filler neck.

NOTE: The information above has been provided by the International Organization for Standardization (ISO), Document number ISO 22241-4 Diesel engines - NOx reduction agent AUS 32 - Part 4: Refilling interface.

Diesel Exhaust Fluid (DEF)/AdBlue® consumption NOTE: DEF/AdBlue® consumption is highly dependent on engine loads, humidity levels, DEF/AdBlue® fluid concentration, and engine speed.

The “typical” consumption is only a guideline to verify proper function of the SCR system. CNH recommends to fill the DEF/AdBlue® tanks at every fuel refilling interval.

1002-10

MAINTENANCE SCHEDULE

Variable Periodic (* )

2

Radiator Coolant Level

*

13

Tires

*

16

Hydraulic Filter

*

12

Alternator, AC, Drive Belt

*

31

Air cleaner

*

19

Bleed Fuel Filter of Condensation

28

Clean SCR system DEF tank filter

XX

Fire extinguisher

*

Check Engine Oil Level

10

13

Check Engine Coolant Level

50

3

Check Transmission Oil Level

50

Check Hydraulic Oil Level

50

Every 10 Hours 1

Every 50 Hours 4

First 100 Hours

Every 500 Hours

* *

Grease Bucket Mounting Fittings

50

7

Grease machine and attachments

50

16

Change Engine Oil and Filters

100

18

Replace Fuel Filters

100

20

Change Hydraulic Filter

100

25

Change Oil in Axles

100

13

Check wheel torque

28

Clean in-line DEF supply filter

8

Lubricate The Steering Cylinder Pivots - Rod And Closed End (4 Fittings)

100

Grease Front Drive Shaft Support Bearing

100

10

Lubricate Loader Lift & Cylinder Pivots (10) Z-bar

100

10

Lubricate Loader Lift & Cylinder Pivots (18) XT

100

11

Check Cab Air Filter

14

Check Tire Pressure & Wheel Torque

12

Check Drive Belt

XX

Trans Clutch Calibration (See Section 6002)

14

Check Axle Oil Level

500

15

Check Battery Electrolyte Level

500

16

Change Engine Oil and Filter

XX

Check ROPS

18

Drain Fuel Tank Condensation & Water Separator

19

Replace Fuel Filter

100 100

250 4

250 250

250

1000

500 500 500 500

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

*

5&6

Every 100 Hours 9

Every 250 Hours

SERVICE POINTS

CHECK

ITEM NUMBER

SERVICE INTERVAL

Initial Service

FREQUENCY IN HOURS

1002-11

Every 1000 Hours

Every 1500 Hours

Every 2000 Hours

Every 3000 Hours Every 6000 Hours

20

Replace Hydraulic Oil filter

1000

21

Grease Articulation Fittings

24

Change crankcase filter

23

Replace Drive Belt

11

Replace Cab Air Filter

26

Change Transmission Oil and Filter

XX

Check Injector Calibration

XX

Check Valve Adjustment (Engine Manual)

1000

XX

Trans Clutch Calibration (See Section 6002)

1000

21

Change Front & Rear Axle Oil

1500

26

Change Transmission Oil and Filter

1500

28

Clean in-line DEF filter

29

Change Hydraulic Oil

2000

30

Change Coolant

2000

31

Replace Engine Air Cleaner

32

Lubricate cab and door

XX

Valve Clearance (Engine Manual)

XX

Replace DEF supply module filter

XX

Engine Injectors (Engine Manual)

6000

XX

Fuel Pump (Engine Manual)

6000

1000 1000

1000

1000 1000 1000

2000 2000 2000 3000

6000

1002-12

MAINTENANCE POINTS

84397762

See your Operators manual for maintenance of safety related items and for detailed information of the ser vice items on this char t. Operators and service manuals are available for this machine from your dealer.

If you operate the machine in severe conditions, lubricate and service the machine more frequently.

METRIC CONVERSION CHART

1003

Section 1003

1003-2

TABLE OF CONTENTS CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1003-3

CONVERSION FACTORS Metric to U.S. MULTIPLY

BY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

Force:

newton newton

3.596 942 0.224 809

ounce force pound force

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C +32

degree F

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969

cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial)

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

gallon/min. (US liquid) gallon/min. (Imperial)

1003-4

U.S. to Metric MULTIPLY

BY

TO OBTAIN

Area:

square foot acre

0.092 903 0.404 686

square meter hectare

Force:

ounce force pound force

0.278 014 4.448 222

newton newton

Length:

inch foot mile

25.4 * 0.304 8 * 1.609 344 *

millimeter meter kilometer

Mass:

pound ounce

0.453 592 28.35

kilogram gram

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Power:

horsepower

0.745 700

kilowatt

Pressure:

lbs/sq. in. lbs/sq. in. lbs/sq. in.

6.894 757 0.069 0.070 303

kilopascal bar kg/sq. cm

Temperature:

degree F

1.8 F - 32

degree C

Torque:

pound/inch pound/foot

0.112 985 1.355 818

newton meter newton meter

Velocity:

miles/hr.

1.609 344 *

kilometer/hr.

Volume:

cubic inch cubic foot cubic yard ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US) gallons (Imperial)

16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

Volume/Time:

gallon/min.

3.785 412

litre/min.

* = exact

Section 2000

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 10 18 18 20

2000-3

ENGINE Removal

STEP 5

STEP 1

BD02N160

Park machine on a level surface and lower bucket to ground. Put articulation lock in LOCKED position.

Put a 30 liter (32 U.S. quart) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

STEP 2

STEP 6

BD03A040

Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

STEP 3 Slowly loosen the filler cap for hydraulic reservoir to release air pressure in hydraulic reservoir.

STEP 4 BD02N160

Put a 15.1 liter (16 U.S. quart) container below engine oil drain. Remove cap and drain oil into container. Install cap after oil has drained.

NOTE: After draining oil disconnect drain hose from frame for removal with engine.

BD06F108

The master and hood raise switch are located by the battery box. Raise the hood with the hood lift motor.

Put master disconnect switch in OFF position.

Remove both batte r y cove rs and disconn ec t batteries from the machine.

2000-4

STEP 7

STEP 10

1

2

BD03A231

BD06F109

Double up a nylon lifting strap (1) and slide through the exhaust stack (2) on the hood.

Tag and disconnect hood wiring harness connector from rear chassis wiring harness connector.

STEP 8

STEP 11

2

1 BD03A230

BD03A227

Place a solid steel bar through the strap, raise the hood and release tension on the lifting motor.

STEP 9 2

BD03A226

BD03A228

Remove the pin from the top of the lifting motor.

Remove mount bolt (1) and backup alarm wiring harness clamp from cooler housing. Have another person balance the hood and remove the hood hinge mounting bolts (2) from the cooler frame.

2000-5

STEP 12

STEP 15

BD03A232

BD06F110

Carefully raise and remove hood from loader. Lower hood onto suitable platform and disconnect lifting equipment.

Loosen clamps on turbocharger and air cleaner, remove the intake hose.

STEP 16 STEP 13

BD06F110 BD03A224

Tag and disconnect engine wiring harness connector from air filter restriction switch.

Loosen the clamp on the turbocharger for the after cooler inlet hose.

STEP 17 STEP 14

BD03A115 BD03A225

Loosen clamp on air cleaner intake hose and remove the crankcase ventilation hose.

Loosen the clamp on the after cooler and remove the after cooler inlet hose from the machine.

2000-6

STEP 18

STEP 21

BD06F111

BD06F112

Loosen the clamp on the intake manifold for the after cooler output hose.

Remove the air cleaner and muffler from the bracket.

STEP 22

STEP 19

BD06F113 BD03A118

Loosen the clamp on the after cooler and remove the after cooler outlet hose from the machine.

STEP 20

BD06F114

Remove the four mounting bolts from the belt cover, remove the cover.

NOTE: After removing the belt cover remove the cover mounting brackets from the machine frame.

BD06F110

Loosen the exhaust clamp from the turbocharger.

2000-7

STEP 23

STEP 26

BD06F115

BD06F118

Remove the drive belt from the engine.

Tag and disconnect the wiring from the alternator.

STEP 24

STEP 27

BD06F116

BD06F119

Loosen clamps and remove lower cooler hose from the engine.

Remove bolt securing wiring harness clamp to engine.

STEP 25

STEP 28 1

1 2

2

BD06F117

BD06F120

If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness connectors from air compressor clutch connector (1).

Remove the thre e m oun tin g b olts (2) for the compressor and set the compressor on the left battery cover.

Remove bolt securing wiring harness clamp (1) to the engine. Remove ground wires (2) from the engine.

2000-8

STEP 29

STEP 32

1 3

2

BD06F121

Tag and remove the wires from the starter solenoid (3), remove the ground cable (2), and ground strap (1) from the starter.

BD06F111

Tag and remove the grid heater cable.

STEP 33

NOTE: Move the starter cables away from the engine, move the wiring harness away from the engine.

STEP 30

BD03A142

Disconnect the wiring harness from the EDC 7 controller.

NOTE: Lifting up on the lever will release the connector from the controller.

BD06F146

Disconnect the engine coolant vent hose and root to the rear of the engine.

STEP 34

STEP 31 3 2 1

BD06F123

Remove the fuel line from the top of the EDC 7 controller, plug the line and cap the fitting.

BD06F122

Remove the radiator hose (1) from the rear of the engine, remove the heater hose from the rear of the engine (2), remove the clamp bolts and clamps (3) from the bell housing.

2000-9

STEP 35

STEP 38

1

2

BD06F127

BD06F124

Tag and disconnect the fuel filter heater wires (1), disconnect the fuel line (2) from the fuel filter head, plug the line and cap the fitting.

Remove the lower cover for the drive shaft.

STEP 39

STEP 36

BD03A172

BD06F125

Remove bolt and clamp.

Remove the drive shaft bolts from the flywheel. Move the drive shaft clear of the flywheel.

STEP 40

STEP 37

Connect suitable lifting equipment to engine lifting brackets. Take up all slack in lifting equipment.

Remove the engine mounting bolts and lift the engine enough to gain access to the drain hose, pull the drain hose with the engine.

STEP 41 Slowly raise engine from rear chassis. Be sure all h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n disconnected and are clear of the engine. Remove engine from machine.

BD06F126

Connect and turn on vacuum pump to hydraulic reservoir. Tag and remove the hydraulic lines from the brake system pump, plug the lines and cap the fittings.

2000-10

Installation

1 2

1

3

2 3

4 5 6

1

4

2

5

3

6 7

7 8

4 5 6 7 BS03B035

1. ENGINE MOUNT BOLT 2. WASHER

3. INSOLATOR UPPER 4. INSOLATOR LOWER

STEP 42

5. WASHER 6. WASHER

7. NUT 8. REMOTE OIL DRAIN HOSE

STEP 47

If engine rubber isolators require replacement, remove and discard isolators (3 and 4). Install new rubber isolator (4), then rubber isolator (3).

STEP 43 Slowly raise engine and move into position over rear chassis. Be sure all harness connections and hoses are out of the way then lower engine. Put washer (5) between front rubber isolator (4) and chassis. Install washer (2), bolt (1), washer (6), and nut (7) in engine isolators. Lower engine into position.

BD03A172

STEP 44 Tighten engine mounting bolts to a torque of 244 to 298 Nm (180 to 220 lb-ft).

STEP 45 Disconnect lifting equipment from engine lifting brackets.

STEP 46 Connect engine oil drain hose to frame bracket.

At front of engine, position drive shaft on engine coupling. Install six bolts to secure drive shaft to engine coupling. Tighten the six bolts to a torque of 53 to 62 Nm (39 to 46 lb-ft).

2000-11

STEP 48

STEP 51

1

2

BD06F127

Install the lower cover for the drive shaft.

BD06F124

Remove cap from fitting and plug from the hose, connect fuel line (2). Connect fuel filter heater wires (1). Remove and discard tag.

STEP 49

STEP 52

BD06F126

Connect and turn on vacuum pump to the hydraulic reservoir. Remove caps from fittings and plugs from hoses. Connect hoses to brake pump following tags installed during removal. Remove and discard tags.

Turn off and disconnect vacuum pump from hydraulic reservoir.

BD06F123

Remove cap from fitting and plug from the hose, connect fuel line to EDC 7.

STEP 53

STEP 50

BD03A142

Connect wiring harness to EDC 7 controller.

BD06F125

Install bolt and clamp for fuel return hose.

NOTE: Start the connector on the EDC 7 with lever straight out from EDC 7. Use lever to pull connector into position.

2000-12

STEP 54

STEP 57

1 2

3

BD06F111

BD06F121

Connect grid heater cable to grid heater. Remove and discard tag.

Install the wires to the starter solenoid (3), install the ground cable (2), and ground strap (1) to the starter.

Remove and discard tags.

STEP 55 STEP 58 3

1 2 2

1

BD06F122

Install the heater hose (2) to the rear of the engine, mount the clamps (3), install the radiator hose (1).

STEP 56

BD06F120

Install bolt securing wiring harness (1) clamp to the engine. Install ground wires (2) to the engine.

STEP 59

BD06F146

Connect the engine coolant vent hose.

BD06F119

Install bolt securing wiring harness clamp to engine.

2000-13

STEP 60

STEP 63

BD06F118

Connect the wiring to the alternator. Remove and discard tags.

BD06F115

Install the drive belt.

STEP 64 STEP 61 1 2

BD06F113 BD06F117

If loader is equipped with air conditioning, mount the compressor using the three mounting bolts (2), connect the engine wiring harness connectors to air compressor clutch connector (1). Remove and discard tags.

STEP 62

BD06F114

Install the cover mounting brackets to the machine frame. Install the belt cover, install the four mounting bolts for the belt cover.

BD06F116

Install lower cooler hose to the engine and tighten the clamps to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

2000-14

STEP 65

STEP 68

BD06F112

BD06F111

Place the muffler and air cleaner on the bracket.

Install mounting bolts in air cleaner and tighten, install the mounting bolts in the muffler and leave loose at this time.

Tighten the clamp on the intake manifold for the after cooler output hose.

STEP 69

STEP 66

BD03A115

BD06F110

Install and tighten the exhaust clamp on the turbocharger, tighten the muffler mounting bolts.

Place the after cooler inlet hose on the machine.

Tighten the clamp on the after cooler.

STEP 70

STEP 67

BD06F110

BD03A118

Place the after cooler outlet hose on the machine.

Tighten the clamp on the after cooler.

Tighten the clamp on the turbocharger for the after cooler inlet hose.

2000-15

STEP 71

STEP 74

BD06F110

Install the intake hose and tighten the clamps on turbocharger and air cleaner.

STEP 72

BD03A232

Carefully raise and place hood over loader.

NOTE: Refer to step 7 and 8 of removal for lifting procedure.

STEP 75

2

1

BD03A225

Install the crankcase ventilation hose and tighten the clamp on air cleaner intake hose.

BD03A227

STEP 73

2

BD03A226

BD03A224

Connect engine wiring harness connector to air filter restriction switch. Remove and discard tag.

Have another person balance the hood, install the hood hinge mounting bolts (2) to the cooler frame.

Install mount bolt (1) and backup alarm wiring harness clamp to cooler housing.

2000-16

STEP 76

STEP 78

2

1 BD03A228

BD03A221

Install the pin from the top of the lifting motor, lower and remove lifting equipment.

NOTE: If hood strut is not adjusted properly the hood will be damaged.

When a hood is removed and replaced an initial adjustment on the strut is necessary. Adjust between the top of the lift motor adjusting jam nut (1) to the top of the threads (2) to 20 mm (X). With the motor down to its lowest point take a measurement between the left hand side hood bumper and the counter weight, record this measurement (Y). Use the following table to adjust the strut (X).

STEP 77

Hood Adjustment Table Y X (MM) (MM)

BD06F109

Connect hood wiring harness connector to rear chassis wiring harness connector. Remove and discard tag.

Y X (MM) (MM)

Y X (MM) (MM)

Y X (MM) (MM)

1

19

21

14

41

9

61

5

2

19

22

14

42

9

62

5

3

18

23

14

43

9

63

4

4

18

24

13

44

9

64

4

5

18

25

13

45

9

65

4

6

18

26

13

46

8

66

4

7

17

27

13

47

8

67

3

8

17

28

12

48

8

68

3

9

17

29

12

49

8

69

3

10

17

30

12

50

7

70

3

11

16

31

12

51

7

71

2

12

16

32

12

52

7

72

2

13

16

33

11

53

7

73

2

14

16

34

11

54

6

74

2

15

16

35

11

55

6

75

2

16

15

36

11

56

6

76

1

17

15

37

10

57

6

77

1

18

15

38

10

58

6

78

1

19

15

39

10

59

5

79

1

20

14

40

10

60

5

80

0

2000-17

STEP 79

STEP 85

BD02N160

BD06F108

Check and make sure that drain caps are tight.

Lower the hood with the hood lift motor.

STEP 80

STEP 86

Install a new oil filter on engine. Fill engine with 13.25 liters (14 U.S. quarts) of Case AKCELA Engine Oil (SAE 15W-40).

Put articulation lock in OPERATING position.

STEP 81 If hydraulic reservoir was drained, fill reservoir of the 821F with 90.8 liters (24.0 U.S. gallons) of Case AKCELA Hy-Tran UltraÂŽ fluid. Fill the reservoir of the 921F with 110 liters (29.0 U.S. gallons) of Case AKCELA Hy-Tran UltraÂŽ fluid.

STEP 82 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liters (32 U.S. quarts). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 83 Connect the batteries, install battery covers, put master disconnect switch in ON position.

STEP 84 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wat er. Wh en the coo lan t is at o pe ra ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir.

WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

2000-18

RADIATOR Removal

STEP 5

STEP 1 Park loader on level surface and lower bucket to ground. Apply parking brake and shut down engine.

STEP 2

BD06F128

Remove bolt and washer securing LH fender.

Remove LH fender.

STEP 6 BD03A040

Put articulation lock in LOCKED position.

STEP 3 Put master disconnect switch in OFF position.

STEP 4

BD02N160

Put a 30.0 liter (32.0 U.S. quart) container below radiator drain. Remove radiator cap then remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

STEP 7 BD03A120

Have another person raise and hold the side panel up into the raised position. Remove the two mounting screws for the side panel, remove the panel.

NOTE: Photo is of the oil cooler side of the machine, the procedure is the same.

BD03A109

Release catch and tilt air conditioning condenser core up to gain access to upper radiator hose.

2000-19

STEP 8

STEP 11

1 2

2

BD03A108

BD03A106

Loosen the upper radiator hose clamps, remove the hose.

Remove screws and install lifting eyes (1). Attach suitable lifting equipment to lifting eyes. Remove four mounting bolts (2), remove radiator from machine.

STEP 9

BD06F129

Loose and remove the lower radiator hose from the radiator.

STEP 10

BD03A113

Disconnect overflow hose from radiator. Disconnect connector from coolant level sender.

2000-20

Installation

STEP 15

STEP 12 Move radiator into position above cooling frame.

Carefully lower radiator while guiding it into position in cooling frame.

STEP 13

1 BD06F129

2

At bottom of radiator, install bottom radiator hose.

Position and tighten two hose clamps to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

2

STEP 16 BD03A106

Install four lock washers and bolts (2) to secure ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g equipment from lifting eyes. Remove lifting eyes and install screws (1).

STEP 14

BD03A108

At top of cooling system frame, install hose. Position hose clamps and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 17

BD03A113

Connect connector to coolant level sender, connect overflow hose to radiator.

BD06F130

When installing fender make sure it is behind the fender mounting bolt.

2000-21

STEP 18

STEP 21

BD06F131

Align the whole in the fender on the bolt.

BD03A120

Have another person raise and hold the side panel up into position. Apply Loctite 242 to the threads, install the two mounting screws for the side panel and torque to 6.5 Âą 3.0 Nm (57.5 Âą 26.5 pound-inches).

STEP 19

NOTE: Photo is of the oil cooler side of the machine, the procedure is the same.

STEP 22

BD06F132

Align the slots in the fender with the tabs on the body of the machine.

STEP 20 BD02N160

Check that coolant drain cap is tight.

STEP 23 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liters (32.0 U.S. quarts). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

DSC00105.TIF

Push the fender towards the front of the machine and secure it using washer and bolt.

2000-22

STEP 24 Put master disconnect switch in ON position.

STEP 25 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wate r. Wh en the coo lan t is at o pe ra ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir.

WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

STEP 26 Put articulation lock in OPERATING position.

STALL TEST

2002

Section 2002

2002-2

TABLE OF CONTENTS 821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

921F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 5 7 7 7 8 9 9 9 9 9 10 10

2002-3

821F SPECIFICATIONS Engine with 4 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm C. Converter Stall ............................................................................................................................1883 to 1963 rpm D. Hydraulic Stall .............................................................................................................................1883 to 1963 rpm E. Converter & Hydraulic Stall .........................................................................................................1497 to 1577 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F) Engine with 5 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm C. Converter Stall ............................................................................................................................1860 to 1900 rpm D. Hydraulic Stall .............................................................................................................................1923 to 2003 rpm E. Converter & Hydraulic Stall .........................................................................................................1524 to 1604 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd gear.

STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.

2002-4

921F SPECIFICATIONS Engine with 4 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm C. Converter Stall ............................................................................................................................1900 to 1940 rpm D. Hydraulic Stall .............................................................................................................................1860 to 1940 rpm E. Converter & Hydraulic Stall .........................................................................................................1525 to 1605 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F) Engine with 5 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2135 to 2185 rpm C. Converter Stall ............................................................................................................................1945 to 1985 rpm D. Hydraulic Stall .............................................................................................................................2017 to 2097 rpm E. Converter & Hydraulic Stall .........................................................................................................1531 to 1611 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd gear.

STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.

2002-5

INSTRUMENT CLUSTER DISPLAYS 1. With the engine running, press the up or down key and scroll through the information screens and trip screens. The following sequence is using the down key only.

NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

BD06F027

4. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, engine oil temperature in either Fahrenheit or Celsius, as well as oil pressure.

BD06F188

2. From the driving screen push the down arrow, as shown.

BD06F184

BD06F183

3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, and fuel level.

5. Push the down button again for the Info 3 screen.

T h i s s c r e e n d i s p l ay s t h e t e m p e ra t u r e i n Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil.

2002-6

BD06F169

6. Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

BD06F170

7. By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.

2002-7

PROCEDURE TO HEAT THE OIL Torque Converter

Hydraulic System

1. Sit in the seat.

1. Apply the parking brake.

2. Start the engine and run the engine at low idle.

2. Start the engine and run at full throttle.

3. To measure the oil temperature with the instrument cluster:

3. To measure the oil temperature with the instrument cluster:

A. Press the up or down arrow key.

A. Press the up or down arrow key.

B. Stop at the info screen with the temperatures that need to be monitored.

B. Stop at the info screen with the temperatures that need to be monitored are on.

4. Place the declutch switch in the OFF position.

5. Place the automatic switch in the manual mode position. Push down and hold the brake pedal for the remainder of this procedure.

6. Release the parking brake.

7. Move the transmission control lever to Forward and turn the transmission control lever to 3rd gear.

8. Increase the engine speed to full throttle and run the engine at this speed for 30 seconds.

9. Decrease the engine speed to low idle and move the transmission control lever to the Neutral position for 15 seconds.

10. Repeat steps 7, 8, and 9 until the temperature of the torque converter oil is 82° to 104°C (180° to 220°F).

4. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

5. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).

2002-8

POWER MODE SELECTION 1. After the oil temperatures have been raised to operating temperatures the power mode must be set to “Auto”.

3. Use down arrow to scroll through the menu’s.

4. High light Power Mode and press the enter key.

5. Power Mode Menu A. Max - Maximum power possible B. Standard - Standard operation C. Auto - Will cycle between Max and Standard D. Eco - Limited power for economy 6. High light Auto mode and press the enter key.

7. Press the escape key to return to the normal driving screen.

BD06H038

2. Press and hold the confirmation “enter” button for two seconds to arrive at the above ser vice screen.

2002-9

PERFORMING STALL TESTS Test No. 1 - Torque Converter and Hydraulic Stall Together 1. Sit in the seat.

2. Start the engine and run the engine at low idle.

3. Press the brake pedal, release the park brake, shift into Forward.

4. Run engine at low idle. Push the clutch cutout switch to OFF. Put the transmission in manual mode. Push down and hold the brake pedal for the remainder of this procedure.

Test No. 2 - Torque Converter Stall 1. Sit in the seat.

2. Start the engine and run the engine at low idle.

3. Press the brake pedal, release the park brake, shift into Forward.

4. Run the engine at low idle.

5. Push down and hold the brake pedal for the remainder of this test.

6. Turn the transmission control lever to third gear.

5. Turn the transmission control lever to third gear.

7. Increase the engine speed to full throttle.

6. Increase the engine speed to full throttle.

8. Check the engine speed.

7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms.

9. Decrease the engine speed to low idle.

NOTE: The stall speed must be read while the lift arms are in motion.

10. Place the transmission in neutral and apply the parking brake.

11. Stop the engine.

8. Check the engine speed.

9. Release the bucket control lever.

10. Decrease the engine speed to low idle.

11. Lower the bucket to the ground, place the transmission in neutral and apply the parking brake.

12. Stop the engine.

Understanding the Results of Test No. 1 1. If the engine speed was as specified, the engine, torque converter, transmission and hydraulic system are probably good.

2. If the engine speed was not as specified, do Test No. 2 and 3.

Understanding the Results of Test No. 2 1. If the engine speed was as specified, the engine, torque converter and transmission are probably good.

2. If the engine speed was more than specified, the problem can be in the torque converter or the t r a n s m i s s i o n . S e e S e c t i o n 6 0 0 2 fo r troubleshooting information.

3. If the engine speed was less than specified, do Test No. 3.

2002-10

Test No. 3 - Hydraulic Stall 1. Sit in the seat.

2. Start the engine and run the engine at low idle.

3. Increase the engine speed to full throttle.

4. Hold the bucket control lever in the ROLLBACK position and raise the lift arms.

NOTE: The stall speed must be read while the lift arms are in motion.

5. Check the engine speed.

6. Release the bucket control lever.

7. Decrease the engine speed to low idle.

8. Lower the bucket to the ground.

9. Stop the engine.

Understanding the Results of Test No. 3 1. If the engine speed was as specified, the engine and hydraulic system are good.

2. If the engine speed was more or less than specified the main relieef setting may be too low or too high. See Section 8002 for troubleshooting information.

3. If the engine speed was less than specified in all tests, the engine is probably the cause.

AFTER COOLER

2003

Section 2003

2003-2

TABLE OF CONTENTS TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 6 6

2003-3

TROUBLESHOOTING AFTER COOLER STEP 1 Park machine on level ground, lower the bucket. Put transmission in neutral, apply the parking brake. Turn off engine.

STEP 2 Raise hood. Install ‘T’ fitting in waste gate valve hose.

Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 3 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. If the pressure difference is greater than 60 mbar (0.87 psi), inspect cooler components for damaged or missing parts.

BD03A118

Inspect the after cooler outlet flex hose for leaks or holes and insure that the clamps are tight.

STEP 6

STEP 4

BD03A119 BD03A116

Inspect the turbocharger flex hose for leaks or holes and insure that the clamps are tight.

Inspect the intake manifold flex hose for leaks or holes and insure that the clamps are tight.

STEP 7

STEP 5

BD03A109 BD03A115

Inspect the after cooler inlet flex hose for leaks or holes and insure that the clamps are tight.

Visually inspect top of after cooler for damage or leaks NOTE: If the leak source has not been located, remove and test the after cooler.

2003-4

AFTERCOOLER REMOVAL Removal

STEP 4

STEP 1

BD03A118

Loosen clamps and remove air cooler outlet hose.

BD03A116

Loosen clamps and remove turbocharger outlet components.

STEP 5

STEP 2

BD03112

BD03A115

Raise air conditioning/air cooler cover. Support cover with appropriate lifting device. Remove cover support latch.

Loosen clamps and remove air cooler inlet hose.

STEP 6

STEP 3

BD03A111 BD03A119

Loosen clamps and remove Intake hose.

Remove three cover mounting bolts and lift cover off.

2003-5

STEP 7

STEP 10

BD03A109

Unlatch air conditioning condenser clamp.

BD03A113

Remove two bolts, one from each side of the after cooler mounting frame.

STEP 8 STEP 11 L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h appropriate lifting devise.

STEP 12

BD03A107

Rotate air conditioning condenser up and remove the two retaining bolts, one on each side. Move the air conditioning condenser back away from the air cooler

STEP 9

BD03A111

Remove four bolts that mount air cooler in the air cooler frame. Remove air cooler from frame.

BD03A117

Remove the two bolts at the rear of the after cooler mounting frame.

2003-6

Leak Test

Installation STEP 1

BD03A111 BS03B028

Check the core for leaks by closing off the outlet tube and attaching regulated air pressure 550kPa (80psi) to the inlet tube. Submerge the cooler in water and watch for air leakage.

NOTE: If leakage is detected replace the after cooler.

Install after cooler in its frame. Install four mounting bolts. Support after cooler with appropriate lifting device. Install the after cooler and frame in the machine.

STEP 2

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

Install two bolts at the rear of the after cooler mounting frame.

2003-7

STEP 4

STEP 7

BD03A107

BD03A116

Position air conditioner condenser and install mounting bolts. Rotate the condenser down and latch.

Install air cooler inlet hose. Tighten clamps at turbocharger outlet.

STEP 8 STEP 5

BD03A115 BD03112

Support cover with appropriate lifting device. Raise air conditioning/air cooler cover over machine. Install cover support latch.

Tighten clamps at air cooler inlet.

STEP 9

STEP 6

BD03A119

Install air cooler outlet hose and tighten clamps at engine intake.

BD03A111

Install three cover mounting bolts.

2003-8

STEP 10

STEP 11 Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 12 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. confirm that the pressure difference is less than 60 mBar (0.87 psi).

BD03A118

Tighten clamps at air cooler outlet.

Section 2010

2010

ENGINE INTAKE AIR FILTRATION

2010-2

TABLE OF CONTENTS Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5

2010-3

AIR FILTRATION Pre-cleaner Disassembly & Reassembly

STEP 3

STEP 1

IMG_1682.AI.TIF

Disassemble and remove precleaner from machine.

721F-8469.PNG

Access pre-cleaner located on top of engine compartment hood.

STEP 4

STEP 2

IMG_1680.AI.TIF

Empty debris and clean wipe precleaner with a damp clean cloth. Reassemble/install unit on machine.

IMG_1683.AI.TIF

Loosen wing nut.

2010-4

Primary/Secondary Fillter Element Disassembly

STEP 3

STEP 1 1

2

IMG_0115.PNGD

Release all clips securing air filter element housing cover.

721F-8469.PNG

Raise engine compartment hood using controls located behind access cover (1). Air filter housing/element (2) is located in main engine compartment on left hand side of engine.

STEP 4

STEP 2

IMG_0142.PNG

Remove cover from air filter element housing.

STEP 5 IMG_0099.PNG

Turn master electric switch “off�.

IMG_0143A.PNG

Remove primary filter element by lifting up on handle

2010-5

STEP 6

STEP 2

IMG_0144A.PNG

IMG_0143A.PNG

Remove secondary filter element from right side of housing. Remove debris from inside filter element housing before installing new filter elements.

Install new primary filter element by sliding it down into housing.

NOTE: Do not clean the seconday filter element. It must be replaced if damaged or clogged.

NOTE: Make sure primary and secondary filter elements form an effective seal.

STEP 3

Primary/Secondary Element Reassembly STEP 1

IMG_0142.PNG

Install housing cover.

STEP 4 IMG_0144A.PNG

Install new secondary filter element by inserting it into positioning slot.

NOTE: Make sure filter element is firmly seated into housing.

721F-8508.PNG

Lock clips to secure filter housing cover.

NOTE: If cover does not fit properly, recheck filter element installation. Cover will be difficult to install if filter elements are not properly installed.

2010-6

STEP 5

IMG_0099.PNG

Turn master electric power switch “on�. Clear any fault codes. Start machine and confirm problem has been corrected.

Section 2020

2020

SCR SYSTEM SENSORS

2020-2

TABLE OF CONTENTS SCR System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOx Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 6 7 9

2020-3

SCR SYSTEM SENSORS Upstream Exhaust Temperature Sensor Removal NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 3 1

2

STEP 1

IMG_0912.TIF

Locate exhaust temperature sensor (1) on exhaust system before the catalyst (2).

721F-8469.PNG

STEP 4

Raise the hood using controls located behind the access cover.

STEP 2

IMG_1507.TIF

Loosen hex nut on sensor.

IMG_0099.PNG

Turn master electric switch to the “off” position.

2020-4

Upstream Exhaust Temperature Sensor Reinstall

STEP 5

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.�

STEP 1

IMG_1510.JPG

Remove temperature sensor from exhaust system.

STEP 6 IMG_1510.TIF

Install temperature sensor into exhaust pipe.

STEP 2

IMG_1514.TIF

Remove wire ties securing wire harness to support brackets. Unplug sensor from machine wiring harness and remove it.

IMG_1507.TIF

Secure sensor into exhaust pipe. Sensor torque 40 to 50 Nm (30 to 36 lb ft.). Reconnect sensor to wire harness and secure harness to support brackets using new wire ties.

2020-5

STEP 3

STEP 2

IMG_0099.PNG

Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.

IMG_0099.PNG

Turn master electric switch to the “off” position.

STEP 3

Downstream Exhaust Temperature Sensor Removal

1

2

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

IMG_1465.TIF

Locate the exhaust temperature sensor (1) on exhaust system after catalyst (2).

STEP 4 721F-8469.PNG

Raise the hood using controls located behind the access panel.

GRAPHIC_ID

Loosen hex nut and remove sensor from exhaust system.

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