Case 821F Tier 4 Service Manual
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Case 821F Tier 4 Service Manual

Wheel loader
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Wheel Loader
SERVICE MANUAL
Part number 84487565
821F
921F
Tier 4
1st edition English
April 2011

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Summary of Contents for Case 821F Tier 4

  • Page 1 821F 921F Tier 4 Wheel Loader SERVICE MANUAL Part number 84487565 1st edition English April 2011...
  • Page 2 Section 1001 GENERAL TORQUE SPECIFICATIONS Find manuals at http://best-manuals.com/search?&s=CASE-84487565...
  • Page 3 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ........6 Find manuals at http://best-manuals.com/search?&s=CASE-84487565...
  • Page 4 580 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 Find manuals at http://best-manuals.com/search?&s=CASE-84487565...
  • Page 5 12.9 500 to 600 675 to 815 920 to 1100 1250 to 1500 Usually the torque values specified for grade 10.9 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9 fasteners. Find manuals at http://best-manuals.com/search?&s=CASE-84487565...
  • Page 6 20 to 27 3/8-16 240 to 300 27 to 34 7/16-14 420 to 540 47 to 61 Pound- Newton Size Feet metres 1/2-13 55 to 65 74 to 88 5/8-11 140 to 150 190 to 203 Find manuals at http://best-manuals.com/search?&s=CASE-84487565...
  • Page 7 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271 25.4 mm 1-1/4 inch 1-11/16-12 125 to 140 170 to 190 31.8 mm 1-1/2 inch 2-12 150 to 180 200 to 254 38.1 mm Find manuals at http://best-manuals.com/search?&s=CASE-84487565...
  • Page 8 Section 1002 FLUIDS AND LUBRICANTS Find manuals at http://best-manuals.com/search?&s=CASE-84487565...

  • Page 9: Table Of Contents

    MAINTENANCE POINTS ..............12 Find manuals at http://best-manuals.com/search?&s=CASE-84487565...

  • Page 10: 821F - Capacities And Lubricants

    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...

  • Page 11: 921F - Capacities And Lubricants

    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..........................

  • Page 12: Engine Oil Recommendations

    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 -4 (preferred) or CG-4.

  • Page 13: Transmission Temperature Chart

    1002-6 TRANSMISSION TEMPERATURE CHART RCPH10WHL435BAH3 DIESEL FUEL SYSTEM Use No. 2 diesel fuel in the engine of this machine. Fuel Storage The use of other fuels can cause the loss of engine If you keep fuel in storage for a period of time, you power and high fuel consumption.

  • Page 14: What Is Selective Catalytic Reduction (Scr)

    1002-7 What is Selective Catalytic Reduction (SCR)? The main components of the SCR system include the • Keep container tightly closed. SCR catalyst, the Diesel Exhaust Fluid (DEF)/ • Keep container in a cool, well-ventilated area. AdBlue® injection unit, the DEF/AdBlue® tank, and •...
  • Page 15 1002-8 Glossary Acronym Definition NOTE: The main factors taken into account to define Diesel Exhaust Fluid the shelf life in the previous figures are the ambient storage temperature and the initial alkalinity of International Organization DEF/AdBlue®. The difference in evaporation for Standardization between vented and non-vented storage containers MSDS...

  • Page 16: Selective Catalytic Reduction (Scr) - Basic Instructions

    1002-9 SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS Requirements Diesel Exhaust Fluid (DEF)/AdBlue® consumption T h e o p e r a t o r m u s t m a i n t a i n a p p r o p r i a t e DEF/AdBlue®...

  • Page 17: Maintenance Schedule

    1002-10 MAINTENANCE SCHEDULE FREQUENCY IN HOURS SERVICE SERVICE POINTS INTERVAL Radiator Coolant Level Tires Hydraulic Filter Variable Alternator, AC, Drive Belt Periodic Air cleaner ( * ) Bleed Fuel Filter of Condensation Clean SCR system DEF tank filter Fire extinguisher Every 10 Hours Check Engine Oil Level Check Engine Coolant Level...
  • Page 18 1002-11 Replace Hydraulic Oil filter 1000 Grease Articulation Fittings 1000 Change crankcase filter 1000 1000 Replace Drive Belt Every 1000 Replace Cab Air Filter 1000 Hours Change Transmission Oil and Filter 1000 Check Injector Calibration 1000 Check Valve Adjustment (Engine Manual) 1000 Trans Clutch Calibration (See Section 6002) 1000...

  • Page 19: Maintenance Points

    1002-12 MAINTENANCE POINTS 84397762 See your Operators manual for maintenance of If you operate the machine in severe conditions, safety related items and for detailed information of lubricate and service the machine more frequently. the ser vice items on this char t. Operators and service manuals are available for this machine from your dealer.
  • Page 20 Section 1003 METRIC CONVERSION CHART...
  • Page 21 1003-2 TABLE OF CONTENTS CONVERSION FACTORS ..............3 Metric to U.S.
  • Page 22 1003-3 CONVERSION FACTORS Metric to U.S. MULTIPLY TO OBTAIN Area: sq. meter 10.763 91 square foot hectare 2.471 05 acre Force: newton 3.596 942 ounce force newton 0.224 809 pound force Length: millimeter 0.039 370 inch meter 3.280 840 foot kilometer 0.621 371 mile...
  • Page 23 1003-4 U.S. to Metric MULTIPLY TO OBTAIN Area: square foot 0.092 903 square meter acre 0.404 686 hectare Force: ounce force 0.278 014 newton pound force 4.448 222 newton Length: inch 25.4 * millimeter foot 0.304 8 * meter mile 1.609 344 * kilometer Mass:...
  • Page 24 Section 2000 ENGINE AND RADIATOR REMOVAL AND INSTALLATION...
  • Page 25 2000-2 TABLE OF CONTENTS Engine ................. . 3 Removal .

  • Page 26: Engine

    2000-3 ENGINE Removal STEP 5 STEP 1 BD02N160 Put a 30 liter (32 U.S. quart) container below radiator drain. Remove radiator cap. Remove cap and drain BD03A040 coolant into container. Install cap after coolant has Park machine on a level surface and lower bucket to drained.
  • Page 27 2000-4 STEP 7 STEP 10 BD03A231 BD06F109 Double up a nylon lifting strap (1) and slide through Tag and disconnect hood wiring harness connector the exhaust stack (2) on the hood. from rear chassis wiring harness connector. STEP 8 STEP 11 BD03A230 BD03A227 Place a solid steel bar through the strap, raise the...
  • Page 28 2000-5 STEP 12 STEP 15 BD03A232 BD06F110 Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner, hood onto suitable platform and disconnect lifting remove the intake hose. equipment. STEP 16 STEP 13 BD06F110 Loosen the clamp on the turbocharger for the after BD03A224 Tag and disconnect engine wiring harness connector cooler inlet hose.
  • Page 29 2000-6 STEP 18 STEP 21 BD06F112 BD06F111 Remove the air cleaner and muffler from the bracket. Loosen the clamp on the intake manifold for the after cooler output hose. STEP 22 STEP 19 BD06F113 BD03A118 Loosen the clamp on the after cooler and remove the after cooler outlet hose from the machine.
  • Page 30 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 Remove bolt securing wiring harness clamp to the engine.
  • Page 31 2000-8 STEP 29 STEP 32 BD06F121 BD06F111 Tag and remove the wires from the starter solenoid Tag and remove the grid heater cable. (3), remove the ground cable (2), and ground strap STEP 33 (1) from the starter. NOTE: Move the starter cables away from the engine, move the wiring harness away from the engine.
  • Page 32 2000-9 STEP 35 STEP 38 BD06F127 BD06F124 Remove the lower cover for the drive shaft. Tag and disconnect the fuel filter heater wires (1), disconnect the fuel line (2) from the fuel filter head, STEP 39 plug the line and cap the fitting. STEP 36 BD03A172 Remove the drive shaft bolts from the flywheel.

  • Page 33: Installation

    2000-10 Installation BS03B035 1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT 2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE STEP 42 STEP 47 If engine rubber isolators require replacement, remove and discard isolators (3 and 4). Install new rubber isolator (4), then rubber isolator (3).
  • Page 34 2000-11 STEP 48 STEP 51 BD06F127 BD06F124 Install the lower cover for the drive shaft. Remove cap from fitting and plug from the hose, connect fuel line (2). Connect fuel filter heater wires STEP 49 (1). Remove and discard tag. STEP 52 BD06F126 Connect and turn on vacuum pump to the hydraulic...
  • Page 35 2000-12 STEP 54 STEP 57 BD06F111 BD06F121 Connect grid heater cable to grid heater. Remove Install the wires to the starter solenoid (3), install the and discard tag. ground cable (2), and ground strap (1) to the starter. Remove and discard tags. STEP 55 STEP 58 BD06F122...
  • Page 36 2000-13 STEP 60 STEP 63 BD06F118 BD06F115 Connect the wiring to the alternator. Remove and Install the drive belt. discard tags. STEP 64 STEP 61 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).
  • Page 37 2000-14 STEP 65 STEP 68 BD06F112 BD06F111 Place the muffler and air cleaner on the bracket. Tighten the clamp on the intake manifold for the after Install mounting bolts in air cleaner and tighten, cooler output hose. install the mounting bolts in the muffler and leave loose at this time.
  • Page 38 2000-15 STEP 71 STEP 74 BD06F110 BD03A232 Install the intake hose and tighten the clamps on Carefully raise and place hood over loader. turbocharger and air cleaner. NOTE: Refer to step 7 and 8 of removal for lifting procedure. STEP 72 STEP 75 BD03A225 Install the crankcase ventilation hose and tighten the...
  • Page 39 2000-16 STEP 76 STEP 78 BD03A221 BD03A228 NOTE: If hood strut is not adjusted properly the Install the pin from the top of the lifting motor, lower hood will be damaged. and remove lifting equipment. When a hood is removed and replaced an initial STEP 77 adjustment on the strut is necessary.
  • Page 40 STEP 86 Install a new oil filter on engine. Fill engine with 13.25 Put articulation lock in OPERATING position. liters (14 U.S. quarts) of Case AKCELA Engine Oil (SAE 15W-40). STEP 81 If hydraulic reservoir was drained, fill reservoir of the 821F with 90.8 liters (24.0 U.S.

  • Page 41: Radiator

    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.
  • Page 42 2000-19 STEP 8 STEP 11 BD03A108 BD03A106 Loosen the upper radiator hose clamps, remove the Remove screws and install lifting eyes (1). Attach hose. 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.

  • Page 43: Installation

    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 BD06F129 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).
  • Page 44 2000-21 STEP 18 STEP 21 BD06F131 BD03A120 Align the whole in the fender on the bolt. Have another person raise and hold the side panel up into position. Apply Loctite 242 to the threads, STEP 19 install the two mounting screws for the side panel a n d t o r q u e t o 6 .
  • Page 45 2000-22 STEP 24 WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, Put master disconnect switch in ON position. turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of STEP 25 radiator cap.
  • Page 46 Section 2002 STALL TEST...
  • Page 47 2002-2 TABLE OF CONTENTS 821F SPECIFICATIONS ..............3 STALL TESTS .

  • Page 48: 821F Specifications

    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.

  • Page 49: 921F Specifications

    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.

  • Page 50: Instrument Cluster Displays

    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.
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