Case 1021G Service Manual
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Case 1021G Service Manual

Wheel loader
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1021G
1121G
Tier 2
Wheel Loader
SERVICE MANUAL
Part number 48083742
English
July 2018
© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.

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  • Page 1 1021G 1121G Tier 2 Wheel Loader SERVICE MANUAL Part number 48083742 English July 2018 © 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL 1021G ZBAR - EH, NEW CAB TIER2 1121G ZBAR - EH, NEW CAB TIER2 48083742_EN 31/07/2018 Find manuals at https://best-manuals.com...
  • Page 3 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
  • Page 4 [33.110] Parking brake or parking lock ............33.2 Hydraulic systems...............
  • Page 5 [55.301] Alternator ................55.3 [55.512] Cab controls.
  • Page 6 INTRODUCTION 48083742_EN 31/07/2018 Find manuals at https://best-manuals.com...

  • Page 7: Table Of Contents

    Contents INTRODUCTION Safety rules ..................3 Personal safety .
  • Page 8 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 9: Personal Safety

    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 10 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 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18: 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 19: 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 20 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 21: 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 22 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 23: 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 24: 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 25: 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 26 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 27: 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 28: 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 29: Product Identification

    INTRODUCTION Product identification LEIL16WHL2581FA 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 30 INTRODUCTION LEIL16WHL2582FA 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 48083742_EN 31/07/2018...
  • Page 31 INTRODUCTION 48083742_EN 31/07/2018...
  • Page 32 SERVICE MANUAL Engine 1021G ZBAR - EH, NEW CAB TIER2 1121G ZBAR - EH, NEW CAB TIER2 48083742_EN 31/07/2018...
  • Page 33 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.216] Fuel tanks .
  • Page 34 Engine - 10 Engine and crankcase - 001 1021G ZBAR - EH, NEW CAB TIER2 1121G ZBAR - EH, NEW CAB TIER2 48083742_EN 31/07/2018 10.1 [10.001] / 1...
  • Page 35 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine General specification (*) ..............3 General specification (*) .
  • Page 36 Engine - Engine and crankcase Engine - General specification 1021G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA Engine with 4 Speed Transmission A. Low idle 870-930 RPM Alternate low idle 670-730 RPM Alternate accelerated idle...
  • Page 37 Engine - Engine and crankcase Engine - Remove Prior operation: Engine hood - Remove (90.105) 1. Park the machine on a level surface and lower the bucket to the ground. Put the articulation lock (1) in LOCKED position. LEIL15WHL1782AA 2. Push the hydraulic functions lock-out switch in the nor- mal operation position.
  • Page 38 Engine - Engine and crankcase 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. LEIL15WHL0663AA 9.
  • Page 39 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 40 Engine - Engine and crankcase 14. Remove the mounting bolts (arrows) from engine compartment top cover (1). 15. Attach a suitable lifting device and lift strap to the en- gine compartment cover and exhaust stack. Carefully remove the cover (1), the exhaust stack (2) and the precleaner (3) as an assembly.
  • Page 41 Engine - Engine and crankcase 19. Loosen the clamp (2) to disconnect the exhaust sys- tem pipe (1) from the engine. LEIL17WHL0301AB 20. Remove the two bolts, washers and nuts (3) to un- fix from the muffler the bracket (1) that supports the check valve (2).
  • Page 42 Engine - Engine and crankcase 23. Loosen the clamps (3) to disconnect the air intake tube (4). NOTE: for clarity, the engine wall is not shown in the figure. LEIL17WHL0260AB 24. Loosen the clamps (2) to disconnect the upper radia- tor tube (1).
  • Page 43 Engine - Engine and crankcase 27. Tag and disconnect the cable (grid heater power relay to heater) (1) and cable (ground heater) (2). LEIL17WHL0303AB 28. Tag and disconnect the WSH connector (1) from the fuel pre-filter. Remove the bolt, washer and nut (2) to unfix the P-clamp securing the wire to the support bracket.
  • Page 44 Engine - Engine and crankcase 31. Remove the bolts, washers and nuts (2), (3) to unfix fuel pre-filter (1) from the support bracket. NOTE: pay attention to the GRD_WIF wire release at the location (2); tag the wire. LEIL17WHL0298AB 32. Loosen the clamp (2) on the crankcase vent hose (1). 33.
  • Page 45 Engine - Engine and crankcase 41. Loosen the four nuts (2) and related washers (3) that hold the support bracket (1) of the crankcase vent filter to the rear chassis. NOTE: one of these four nuts (2) is used to secure a P-clamp that hold the wiring harness to the support bracket (1).
  • Page 46 Engine - Engine and crankcase 49. Remove the bolts, washers and nuts (1) to unfix the air cleaner bracket (2) from the engine wall. 50. Remove the four nuts and washers (3) to unfix the air cleaner bracket (2) from the rear chassis. Move the air cleaner (4) with the air cleaner bracket (2) out of the machine.
  • Page 47 Engine - Engine and crankcase 59. Remove the bolt, washer (6) and two P-clamps (4) to separate the heater supply and return tubes (3), (2) from the bracket (5). Remove the bolts and washers (7), (8) to unfix the bracket (5) from the engine. Disconnect the heater supply tube (3) from the engine.
  • Page 48 Engine - Engine and crankcase 63. Tag and disconnect the ALT_B and ALT_5 connectors (4), (5). Remove the bolts, washers and nut (2), (3) to discon- nect the alternator (1) from the engine. LEIL17WHL0265AB 64. Cut the cable strap (5). Tag and disconnect the ACT_10 connector from air compressor clutch con- nector (4).
  • Page 49 Engine - Engine and crankcase 67. Tag and disconnect the ST wire (1) from the engine starter. LEIL15WHL1299AB 68. Tag and disconnect the negative cable (starter to ground) (1), the negative cable (battery to starter) (2) from the engine starter. Tag and disconnect the positive cable (battery isolator to starter) (3) and CPWR, XM1C connectors (4), (5) from the engine starter.
  • Page 50 (2) to the transmission. NOTICE: the bolts (1) that fasten the center drive shaft (2) to the transmission must be replaced when removed. LEIL15WHL1207AB NOTE: steps 74 and 75 are related only to CASE CONSTRUCTION 1021G. 48083742_EN 31/07/2018 10.1 [10.001] / 17...
  • Page 51 LEIL15WHL1330AB 75. Remove the twelve flex plate bolts (1). LEIL15WHL1019AB NOTE: steps 76 and 77 are related only to CASE CONSTRUCTION 1121G. 76. Remove the cover (1). Remove the plug (2) to gain access to the flywheel. 77. Turn the flywheel (clockwise as seen from the engine front) until one of the torque converter bolts is visible through the hole, and remove the bolt.
  • Page 52 Engine - Engine and crankcase 79. Loosen the oil drain hose (15) and the O-ring (14) from the elbow (13). 80. Separate the engine mounting brackets (8) from the engine. Remove the engine bracket upper bolts (11) and the related washers (12). Remove the engine bracket upper bolts (9) and the related washers (10).
  • Page 53 5. Install the twelve bell housing bolts (1). Tighten the bell housing bolts (1) to a torque of 54 – 60 N·m (40 – 44 lb ft). LEIL15WHL1020AB NOTE: steps 6 and 7 are related only to CASE CONSTRUCTION 1021G. 48083742_EN 31/07/2018 10.1 [10.001] / 20...
  • Page 54 (1). Install the converter housing cover plate (2). LEIL15WHL1330AB NOTE: step 8 is related only to CASE CONSTRUCTION 1121G. 8. Turn the flywheel (clockwise as seen from the engine front) until one of the torque converter bolts location is visible through the hole, and install the bolt.
  • Page 55 Engine - Engine and crankcase 10. Use two clamps to connect the hydraulic oil return tube (2) to the lower hose (1) and secure them. LEIL17WHL0257AB 11. Connect the hydraulic fittings (2) and (3) to the hy- draulic oil return tube (1). LEIL17WHL0258AB 12.
  • Page 56 Engine - Engine and crankcase 13. Install the negative cable (starter to ground) (1), the negative cable (battery to starter) (2) on the engine starter. Tighten the related nut. Use existing hardware to mount the positive cable (battery isolator to starter) (3) and CPWR, XM1C con- nectors (4), (5) to the engine starter.
  • Page 57 Engine - Engine and crankcase 17. Install the air conditioning compressor (1) with the mounting bolts (6). Connect the low-pressure line (3) to the suction port (compressor to condenser hose). Connect the high- pressure line (2) to the discharge port (cab to com- pressor hose) of the air-conditioning compressor.
  • Page 58 Engine - Engine and crankcase 21. Connect the zinc lower radiator tube (2) to the elbow radiator hose with the clamp (1). Torque the clamp to 10.1 – 11.3 N·m (7.4 – 8.3 lb ft). Install the zinc lower radiator tube (2) to the engine with two bolts and washers (arrows).
  • Page 59 Engine - Engine and crankcase 30. Connect the engine heater cable to the engine. LEIL17WHL0305AB 31. Place the air cleaner (4) with the air cleaner bracket (2) in the correct position. Install the four nuts and washers (3) to fix the air cleaner bracket (2) to the rear chassis.
  • Page 60 Engine - Engine and crankcase 37. Install the air intake bracket (1) to the hydraulic tank with two washers and nuts (5). 38. Install and tighten the clamp (2) to air intake bracket (1). 39. Connect the air intake upper hose (3) with clamp (4). Torque the clamp to 4 –...
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