Case 1021G Service Manual
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Case 1021G Service Manual

Wheel loader
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1021G
1121G
Tier 4B (final)
Wheel Loader
SERVICE MANUAL
Part number 51428268
2
edition English
nd
December 2017

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  • Page 1 1021G 1121G Tier 4B (final) Wheel Loader SERVICE MANUAL Part number 51428268 edition English December 2017...
  • Page 2 SERVICE MANUAL 1021G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA 51428268_EN 19/12/2017 Find manuals at https://best-manuals.com...
  • Page 3 Link Product / Engine Product Market Product Engine 1021G WHEEL LOADER North America F2CFE614H*B004 ZBAR-EH, NEW CAB TIER4B NA North America 1021G WHEEL LOADER XR-EH, F2CFE614H*B004 NEW CAB TIER4B NA 51428268_EN 19/12/2017 Find manuals at https://best-manuals.com...
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
  • Page 5 [33.202] Hydraulic service brakes ............33.1 [33.110] Parking brake or parking lock .
  • Page 6 [55.301] Alternator ................55.3 [55.988] Selective Catalytic Reduction (SCR) electrical system .
  • Page 7 51428268_EN 19/12/2017 Find manuals at https://best-manuals.com...
  • Page 8 INTRODUCTION 51428268_EN 19/12/2017 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Safety rules ..................3 Personal safety .
  • Page 10 INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.
  • Page 11 INTRODUCTION Personal safety Carefully read this Manual before proceeding with main- tenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and in- structed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy ham- mers.
  • Page 12 Keep the exhaust manifold and tube free from combustible materials. Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage. Never attempt to check or adjust the belts when the en- gine is running.
  • Page 13 INTRODUCTION Pay attention to rotating components and do not allow anyone to approach these areas to avoid becoming en- tangled. Hands, clothing or tools getting caught in the fan blades or engine belts, can cause amputations, violent hemorrages and generate conditions of grave danger. For this reason avoid touching or approaching all rotating or moving parts.
  • Page 14 INTRODUCTION When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital. If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid penetrating the skin must be removed within a few hours to avoid serious infections.
  • Page 15 INTRODUCTION Hoses and tubes Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the correct position be- fore tightening the connections.
  • Page 16 INTRODUCTION Battery Batteries give off explosive gases. Never handle open flames and unshielded light sources near batteries. (No smoking is addressed in the next in- struction). To prevent any risk of explosion, observe the following instructions: • When disconnecting the battery cables, always discon- nect the negative (-) cable first.
  • Page 17 INTRODUCTION Flammable liquids When handling flammable liquids: • Do not smoke. • Keep away from unshielded light sources and open flames. Fuels often have a low flash point and are readily ignited. Never attempt to extinguish burning liquids with water. Use: •...

  • Page 18: Personal Safety

    INTRODUCTION Tires Before inflating the tires, always check the condition of rims and the outer condition of tires for the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tire, make sure that there are no nearby persons, then position yourself at tread side.
  • Page 19 INTRODUCTION Waste disposal Improperly disposing of waste can threaten the environ- ment. Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

  • Page 20: Basic Instructions - Important Notice Regarding Equipment Servicing

    In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

  • Page 21: Basic Instructions - How To Use The Maintenance Standard And Precautions

    INTRODUCTION Basic instructions - How to use the maintenance standard and precautions Application WHEN THE MACHINE IS NEW Confirm that the performances are in accordance with standard specifications as compared to the performance stan- dards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY) Use the data for the criterion, for the purpose of correction, adjustment and replacement.
  • Page 22 INTRODUCTION PARTS REQUIRING REGULAR REPLACEMENT Critical hoses that are necessary to secure safety, we designate as Very Important Parts (V.I.P.) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize themselves with the machine and handle safely. Use caution when inspecting and replacing oils and grease.

  • Page 23: Basic Instructions - Precaution For Disassembly And Assembly

    • Confirm ready access to a first-aid kit and fire extinguisher, as well as appropriate emergency personnel contacts in the case of a medical accident or fire. • Before performing any work on the machine, follow lockout/tagout procedures by attaching a “maintenance in progress tag”.
  • Page 24 INTRODUCTION Reassembling hydraulic equipment • Clean parts in a well ventilated room. • Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly. • Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling. •...

  • Page 25: Basic Instructions - Electrical Equipment Precautions

    INTRODUCTION Basic instructions - Electrical equipment precautions WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. An- tidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk.

  • Page 26: Consumables - Biodiesel Fuel

    INTRODUCTION Consumables - Biodiesel Fuel Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters. NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751.

  • Page 27: Consumables

    CASE AKCELA UNITEK NO. 1™ SBL CJ-4 Technical specifications SAE 10W-40 API CJ-4 CASE CONSTRUCTION specifications MAT3521 Type of oil CASE AKCELA UNITEK NO. 1™ SSL CJ-4 SAE 0W-40 (cold weather) Technical specifications SAE 0W-40 API CJ-4 CASE CONSTRUCTION specifications MAT3521 Capacity (with filter change) 28.5 l (30.1 US qt)
  • Page 28 CASE AKCELA UNITEK NO. 1™ SBL CJ-4 Technical specifications SAE 10W-40 API CJ-4 CASE CONSTRUCTION specifications MAT3521 Type of oil CASE AKCELA UNITEK NO. 1™ SSL CJ-4 SAE 0W-40 (cold weather) Technical specifications SAE 0W-40 API CJ-4 CASE CONSTRUCTION specifications MAT3521 Capacity (with filter change) 28.5 l (30.1 US qt)

  • Page 29: Hydraulic Contamination

    INTRODUCTION Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: • When you drain the oil or disconnect any line •...

  • Page 30: Product Identification - Machine Orientation

    INTRODUCTION Product identification - Machine orientation MACHINE SIDES The terms “right-hand”, “left-hand”, “front”, and “rear”, when used in this manual, indicate the sides of the ma- chine as they are seen from the operator’s seat. 1. Front side 2. Rear side 3.

  • Page 31: Product Identification

    INTRODUCTION Product identification LEIL17WHL1734FB 1. Cab door and hand holds 6. Roll Over Protection System (ROPS) cab 2. Steps 7. Loader lift arms 3. Bucket (Z-bar version) 8. Battery access 4. Timed disconnect switch and battery jump post 9. Hand rails 5.
  • Page 32 INTRODUCTION LEIL17WHL1733FB 1. Hand rails 5. Battery access 2. Pre-cleaner 6. Bucket (Z-bar version) 3. Cab air filter access 7. Windshield washer reservoir 4. Bucket cylinder 8. Steps 51428268_EN 19/12/2017...
  • Page 33 INTRODUCTION 51428268_EN 19/12/2017...
  • Page 34 SERVICE MANUAL Engine 1021G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA 51428268_EN 19/12/2017...
  • Page 35 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.216] Fuel tanks .
  • Page 36 Engine - 10 Engine and crankcase - 001 1021G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA 51428268_EN 19/12/2017 10.1 [10.001] / 1...
  • Page 37 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine General specification (*) ..............3 General specification (*) .
  • Page 38 Engine - Engine and crankcase Engine - General specification 1021G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA Engine with 4 Speed Transmission A. Low idle 870-930 RPM Alternate low idle 670-730 RPM...
  • Page 39 Engine - Engine and crankcase LEIL17WHL0362GA NOTE: performances detected at engine test bench. NOTE: BSFC indicates the Brake Specific Fuel Consumption. Engine - Engine horse power 1121G WHEEL LOADER XR-EH, NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B NA Design characteristics Displacement 8710 cm³...
  • Page 40 Engine - Engine and crankcase High Idle Speed 2287 RPM Low Idle Speed 700 RPM Rated Power 235 kW at 2100 RPM Peak Torque 1604 N·m at 1400 RPM LEIL17WHL0363GA NOTE: performances detected at engine test bench. NOTE: BSFC indicates the Brake Specific Fuel Consumption. 51428268_EN 19/12/2017 10.1 [10.001] / 5...
  • Page 41 Engine - Engine and crankcase Engine - Remove Prior operation: Engine hood - Remove (90.105) NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen- erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors.
  • Page 42 Engine - Engine and crankcase 6. Actuate the brake pedal several times to discharge brake accumulators. LEIL15WHL0564AA 7. Slowly loosen the filler cap on the hydraulic oil tank to release air pressure. LEIL15WHL0825AA 8. Locate the timed disconnect switch in the battery box. Put the timed disconnect switch in the OFF position.
  • Page 43 Engine - Engine and crankcase 10. Loosen and remove the bolts that hold the battery cover in place on both the left-hand and right-hand rear of the machine. Disconnect the battery cable from the battery. LEIL16WHL0891AB LEIL15WHL1489AA 11. Open the access cover. Place a suitable container below radiator drain, re- move the radiator cap and coolant drain plug (arrow) to drain the engine coolant.
  • Page 44 Engine - Engine and crankcase 13. Loosen the hose clamp (1) on the air intake hose un- der the air inlet engine hood. NOTICE: for clarity the engine hood compartment top cover is not shown in the figure. LEIL15WHL0673AB 14. Remove the mounting bolts (arrows) from engine compartment top cover (1).
  • Page 45 Engine - Engine and crankcase 18. Disconnect the hoses (1) from the Dosing Module (2). LEIL15WHL0675AB 19. Disconnect the electrical connector (3) from the Dos- ing Module (2). LEIL15WHL0821AB 20. Remove the two bolts (1), the four washers (2), and the two nuts (3) to separate the P-clamps (4) and (6) from the bracket (8).
  • Page 46 Engine - Engine and crankcase 23. Remove the two bolts (5) and the related washers and nuts to separate the bracket (1) from the support (6). 24. Remove the bolt (7) and the related washers and nut to separate the P-clamp (8) from the DEF/A ®...
  • Page 47 Engine - Engine and crankcase 30. Loosen the hexagonal nut of the outlet temperature sensor (1). Loosen the hexagonal nut of outlet the Nitrogen Ox- ides (NOx) sensor (2). Loosen the hexagonal nut of the ammonia (NH3) sen- sor (3). Remove any straps holding the sensor wiring harness to the others.
  • Page 48 Engine - Engine and crankcase 35. Remove the P-clamp (1). Loosen the bolt (2) to separate the P-clamps (3) and (4) from the exhaust support bracket (5). Remove the P-clamps (3) and (4) from the hoses (6) and (7). LEIL15WHL0831AA 36.
  • Page 49 Engine - Engine and crankcase 40. Loosen the bolts (1) to remove the sensor mounting bracket (2) with the two the NOx sensor modules (4) and the NH3 Electronic Control Unit (5) from the hy- draulic tank (3). LEIL15WHL1328AB 41. Loosen the two clamps (1) from the intercooler tube (2).
  • Page 50 Engine - Engine and crankcase 44. Loosen the clamps (2) from the air intake tube (1) and remove the tube through the engine wall. NOTE: for clarity, the engine wall is not shown in the figure. LEIL15WHL1084AB 45. Loosen the clamps (2) to remove the upper radiator tube (1) through the engine wall.
  • Page 51 Engine - Engine and crankcase 48. Tag and disconnect the DEF/ADBLUE® supply and return lines (1) from the supply module. Tag and disconnect the coolant water supply and return lines (2) from the supply module. Tag and disconnect the wiring harness (3) from the supply module. 49.
  • Page 52 Engine - Engine and crankcase 53. Remove the two bolts (1), with related washers and nut to separate the supply module bracket (2) from the left-hand side chassis (3). LEIL15WHL0841AB 54. Loosen the bolt (1) to disconnect the wire (2) and related P-clamp from the support bracket (3) of the crankcase vent filter.
  • Page 53 Engine - Engine and crankcase 56. Remove the bolts (1), with related washers and nuts to separate the P-clamps (2) and (4) from the bracket (6). Remove the P-clamp (2) from the coolant by-pass hose (3). Remove the P-clamp (4) from the DEF/ ®...
  • Page 54 Engine - Engine and crankcase 63. Loosen the P-clamps (2) on the engine to crankcase vent filter hose (1). 64. Remove the engine to the crankcase vent filter hose (1). 65. Remove the drain hose filter (3) from the crankcase vent filter.
  • Page 55 Engine - Engine and crankcase 71. Remove the P-clamp (1). Remove the air intake aspirator hose (2). LEIL15WHL1059AB 72. Loosen the clamp (6) to separate the air intake aspi- rator hose (7) from the check valve. 73. Remove the P-clamp (8) to separate the rear chassis harness (9) from the air intake bracket (3).
  • Page 56 Engine - Engine and crankcase 81. Remove the bolts (1) with related washers and nuts to separate the air cleaner bracket (2) engine wall. 82. Remove the four nuts and washers (3). Estract the air cleaner (4) as an assembly. LEIL15WHL1057AB 83.
  • Page 57 Engine - Engine and crankcase 88. Remove the bolts (2) and the washers (3). Loosen the clamp (5) to separate the zinc lower radi- ator tube (1) from the elbow radiator hose (6). Remove the zinc lower radiator tube (1) and discard the O-ring (4).
  • Page 58 Engine - Engine and crankcase 93. Disconnect the wires from the alternator. Identify and tag the wires to aid in reassembly. NOTE: move the wires away from the engine. LEIL15WHL0818AB 94. Place an identification tag on the starter switch wire (1).
  • Page 59 Engine - Engine and crankcase 96. Remove the three nuts (1) from the engine starter. Remove the engine starter. LEIL15WHL1331BB 97. Tag and disconnect the electrical connector from the engine control unit. LEIL15WHL1085AA 98. Disconnect the hydraulic fittings (2) and (3) from the hydraulic oil supply tube (1).
  • Page 60 NOTICE: the bolts (1) that fasten the center drive shaft (2) to the transmission must be replaced when removed. LEIL15WHL1207AB NOTE: steps 102 and 103 are related only to CASE CONSTRUCTION 1021G. 102. Remove the bolts (1) and related washers. Remove the converter housing cover plate (2) and remove the flex plate bolts.
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