Part number 47392461 1st edition English July 2012 SERVICE MANUAL 1021F 1121F Tier 2 Wheel Loader
Contents INTRODUCTION Engine.......................................................................................10 Aircleanersandlines.....................................................................10.202 Enginelubricationsystem................................................................10.304 Aftercooler................................................................................10.310 Transmission..............................................................................21 Powershifttransmission..................................................................21.113 Powershifttransmissionexternalcontrols................................................21.135 Gearboxinternalcomponents............................................................21.145 Four-WheelDrive(4WD)system..................................................23 Frontaxlesystem.......................................................................25 Hydraulicsystems.......................................................................35 Variabledisplacementpump.............................................................35.106 4739246119/06/2012
Maincontrolvalve........................................................................35.359 Auxiliaryhydraulicvalvesandlines......................................................35.525 Steering.....................................................................................41 Wheels......................................................................................44 Cabclimatecontrol.....................................................................50 Airconditioning...........................................................................50.200 Electricalsystems.......................................................................55 Enginecoolingsystem...................................................................55.012 Parkingbrakeelectricalsystem..........................................................55.031 Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.......................55.050 CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.........................55.051 Harnessesandconnectors...............................................................55.100 Enginestartingsystem...................................................................55.201 Coldstartaid.............................................................................55.202 Externallightingswitchesandrelays.....................................................55.405 4739246119/06/2012
Loaderarmandbucketcontrolsystem...................................................55.415 Cab/Platformharnessesandconnectors.................................................55.510 Cabcontrols..............................................................................55.512 Cablighting...............................................................................55.514 Wiper/Washersystem....................................................................55.518 Platform,cab,bodywork,anddecals.............................................90 Pneumatically-adjustedoperatorseat....................................................90.124 Cab.......................................................................................90.150 4739246119/06/2012
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Torque
Alternator
Alternatorpulleyretainingnut ( 70-80lbft )
Batteryterminalnut ( )
Indicatorlightterminalnut ( )
Planetarycarrierlockscrews 200N·m ( 148lbft )
Brakespringretainercover ( 25lbft )
Axlewheelendscrewplug 50N·m ( 37lbft )
NutSecuringBrakeTubetoConnector 100N·m ( 74lbft )
BrakeTubeFittingtoWheelEndFitting 36N·m ( 27lbft )
Axlehousingbolts ( 413lbft )
Inputflangeslottednut 1200N·m ( 885lbft )
Differentialreleasinghousingcoverbolts 185N·m ( 136lbft )
Differentialhousingcoverbolts ( 295lbft )
Wheelmountingbolts ( 475-530lbft )
Axlebreathervalve ( 35-53lbin )
Frontaxlemountingbolts ( 1120-1260lbft )
Reartrunnioncoverbolts ( )
Reartrunnionspacerbolts ( 210-235lbft )
Trunnioncastingmounting ( 480-540lbft )
Chassis
Cabandcanopymountingbolts ( )
Counterweightmountingbolts ( 830-930lbft )
Lowerstepsupportbolts ( 20-23lbft )
Batteryholddownbolts ( )
Cooling
Coolingframemounting ( 200-220lbft )
Fanmountingnut ( )
Drivetrain
Flexplatetoflywheelbolts ( 24-30lbft )
Carrierbearingbolt ( 110-120lbft )
Drivelinemountingbolts ( )
Transmissionsightgaugemountingbolts ( 24-48lbin )
Transmissionshockmountnuts ( 685-770lbft ) ( 830-940lbft )
)
Transmissionfilltubebolts ( 151-292lbin )
Banjotubebolt 160N·m ( 118lbft )
Bypassvalvehoseclamps
Airintakehoseclamps ( 35-44lbin )
Aspiratorhoseclamps 3N·m ( 30lbin )
Mufflerflextubeclamp ( )
Mufflerclampatturbo ( 44-53lbin )
Startermotormountingbolts ( 30-35lbft )
Engineshockmountnuts
)
) 4739246119/06/2012
INTRODUCTION
(
( ) Engine
(
(
3
Tightenthefuelsenderboltsinthesequenceasshownintheimage (2) toatorqueof (
RCPH11WHL117AAR 1
Fuelsendermountingbolts ( )
Fueltankskidplatebolts(boltsandnutsaretobe ( )
Fueltankmountingbolts(boltsandnutsaretobe ( )
Hydraulics
Priorityvalvemountingbolts ( 63-75lbft )
Mainhydraulicpumpelbow ( 63-75lbft )
Hydraulictanksightgaugemounting ( 27-53lbin )
Surgetankhoseclampmounting ( 35lbft )
Brakepumpmountingbolts ( 110-125lbft )
Hydraulicoiltanksuctionhoseclamps ( 90-100lbin )
andpriorityvalve-to-pump) ( ) valve) ( 146-179lbft )
Pumpmountingbolts ( 110-125lbft )
INTRODUCTION Fueltank
4739246119/06/2012 4
INTRODUCTION Wheels Tightenthewheelnutsintwostages.First,tightenthewheelnutsinthesequenceasshownintheimage (1) toa torqueof278N·m ( 205lbft (1) toatorque ( 472-531lbft RCPH11WHL202AAH 2 Wheelnuts Firststage: ( 205lbft ).Secondstage: 720N·m ( 472-531lbft ) 4739246119/06/2012 5
CASEA
Typeofoil
Frontaxle
Frontaxlewithaxlecooler
Heavydutyfrontaxle
CASEA
INTRODUCTION Capacities 1021FCapacitiesandspecifications Engine Typeofoil CASEAKCELA E NGINEOIL Capacity(withfilterchange) 28.5l ( 30.1USqt ) Coolingsystem Systemcapacity ( ) Fuelsystem Systemcapacity 473.0l ( 125.0USgal ) Hydraulicsystem Typeoffluid CASEAKCELA HY-TRAN®U LTRA™ HYDRAULICTRANSMISSIONOIL Totalsystemcapacity ( ) Reservoircapacity 134.0l ( 35.4USgal ) Transmission Typeofoil
KCELA NEXPLORE™ FLUID 45.4l ( 48.0USqt ) Axles
CASEAKCELA NEXPLORE™ FLUID
42.0l ( 44.4USqt ) Rearaxle 42.0l ( 44.4USqt )
45.7l ( 48.3USqt ) Rearaxlewithaxlecooler ( )
62.0l ( 65.5USqt ) Heavydutyfrontaxlewithcooler 65.7l ( 69.4USqt )
KCELA M OLYGREASE *Machinesareshippedfromthefactorywithbreak-inoil. 4739246119/06/2012 6
Axles
Frontaxlewithaxlecooler
INTRODUCTION 1121FCapacitiesandspecifications Engine Typeofoil CASEAKCELA E NGINEOIL15W-40 Capacity(withfilterchange) 28.5l ( 30.1USqt ) Coolingsystem Systemcapacity ( ) Fuelsystem Systemcapacity 473.0l ( 125.0USgal ) Hydraulicsystem Typeoffluid CASEAKCELA HY-TRAN®U LTRA™ HYDRAULICTRANSMISSIONOIL Totalsystemcapacity ( ) Reservoircapacity ( ) Transmission Typeofoil CASEAKCELA NEXPLORE™ FLUID ( )
Typeofoil CASEAKCELA NEXPLORE™ FLUID Frontaxle ( ) Rearaxle 64.0l ( 67.6USqt )
67.7l ( 71.5USqt ) Rearaxlewithaxlecooler ( ) Frontaxlewithdifferentiallock ( ) Frontaxlewithdifferentiallockandaxlecooler 65.7l ( 69.4USqt ) CASEAKCELA M OLYGREASE *Machinesareshippedfromthefactorywithbreak-inoil. 4739246119/06/2012 7
INTRODUCTION Engineoilviscosity/Temperatureranges RCPH11WHL023FAH 1 NOTE: Useofanengineoilpanheateroranenginecoolantheatermayberequiredwhenoperatingtemperatures areinWinterorArcticconditions. Transmissionoilviscosity/Temperatureranges RCPH10WHL453BAH 2 4739246119/06/2012 8
RCPH10WHL006EAL 3
INTRODUCTION Hydraulic/Brakesystem-temperaturerange
4739246119/06/2012 9
INTRODUCTION Coolantsolution andethylene-glycolcanmixandworkagainsteachother,reducinganti-corrosionprotection,formingdepositsinthe Anti-freeze/Anti-corrosion ambienttemperatureisover ( -32.8°F Forareaswherethetemperatureisbelow ( -32.8°F )-itisadvisabletouseablendof40%waterand60% anti-freeze. Fuel Usedieselfuelsuitablefortheambienttemperatureconditions(ASTM-D-975). UsegradeNo.2fuel.Theuseofothertypesoffuelcanresultinalossofpoweroftheengineandmaycausehigh Inverylowambienttemperatures,useamixtureoffuelsNo.1andNo.2asnecessary.Consultyourfuelsupplier Ifthetemperaturefallsbelowthefuelcloudpoint(pointatwhichwaxbeginstoform)thewaxcrystalswillcausepower Incoldweather,fillthefueltankattheendoftheday'sworkinordertopreventtheformationofcondensation. Fuelstorage Hydraulicfluid chartsatthebeginningofthissection. Transmissioncomponentoil Extremepressureoilshouldbeusedforenclosedtransmissioncomponents.Chooseanoilthatismanufactured Grease Thetypeofgreasetousedependsonambienttemperaturesuchas:CaseAkcelaMolydisulfideGrease Environment 4739246119/06/2012
INTRODUCTION Engineoil Thisoilinsurescorrectlubricationofyourengineinall oftheAPISERVICECI-4category. NOTE: RCPH10WHL012AAD 4 4739246119/06/2012 11
NOTICE:
NOTICE:
NOTICE:
NOTICE:
NOTICE:
Hydrauliccontamination
(A)
(A)
(A)
INTRODUCTION
Whenyoudraintheoilordisconnectanyline. (B) (C) (D) (E) (A) (B) (C) Movementofcontrolvalvespoolsisdifficult. (D) (E) (F) (G) (H) Cycletimesareslow;machinedoesnothaveenoughpower.
(B) ControlvalvespoolsdonotreturntoNEUTRAL. (C) Visiblecontaminationisforeignmaterialthatcanbefoundbysight,touch,orodor.Visiblecontaminationcancause
(B) (C) (D) Theoilhasanodorofburnedoil. (E) 4739246119/06/2012
oil
Consumable
CASEAkcelaEngineoil
Capacities
Capacities 6
Ultra™hydraulictransmission
CASEAkcelaNEXPLORE™ fluid Capacities 6
CASEAkcelaNEXPLORE™ fluid Capacities 6
CASEAkcelaMolygreaseCapacities 6
CASEAkcelaEngineoilCapacities 7
Capacities 7
CASEAkcelaHY-TRAN® Ultra™hydraulictransmission
oil
CASEAkcelaNEXPLORE™ fluid Capacities 7
CASEAkcelaNEXPLORE™ fluid Capacities 7
CASEAkcelaMolygreaseCapacities 7
CONSUMABLESINDEX
PAGE
15W-40
6
4739246119/06/2012
SERVICEMANUAL Engine 1021F 1121F 4739246119/06/2012
Contents Engine-10 Engineandcrankcase......................................................................10.001 Aircleanersandlines.......................................................................10.202 4739246119/06/2012
CONSUMABLESINDEX Consumable PAGE DOW732RTVSiliconeclear 10.001/19 4739246119/06/2012
