Case 48083741 Service Manual
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Case 48083741 Service Manual

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821G
921G
Tier 2
Wheel Loader
SERVICE MANUAL
Part number 48083741
English
July 2018
© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.

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Summary of Contents for Case 48083741

  • Page 1 821G 921G Tier 2 Wheel Loader SERVICE MANUAL Part number 48083741 English July 2018 © 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL 821G ZBAR - EH, NEW CAB TIER2 921G ZBAR - EH, NEW CAB TIER2 48083741_EN 31/07/2018 Find manuals at https://best-manuals.com...
  • Page 3 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.202] Air cleaners and lines .
  • Page 4 [35.000] Hydraulic systems..............35.1 [35.300] Reservoir, cooler, and filters.
  • Page 5 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system....55.5 [55.415] Loader arm and bucket control system ..........55.6 [55.530] Camera.
  • Page 6 INTRODUCTION 48083741_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: Torque - Minimum Tightening Torques For Normal Assembly

    INTRODUCTION Torque - Minimum tightening torques for normal assembly Use the torques in this chart when special torques are not given. These torques apply to plain and zinc-dichromate fasteners as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubri- cants, Molydisulfide greases, or other extreme pressure lubricants are used.
  • Page 25 INTRODUCTION Grade 12.9 bolts, nuts, and studs Torque values specified for grade 10.9 hardware can be used for grade 12.9 hardware. Markings for Grade 12.9 hardware 48083741_EN 31/07/2018...

  • Page 26: 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) 13.25 L (14 US qt)
  • Page 27 CASE AKCELA UNITEK NO. 1™ SBL CJ-4 Technical specifications SAE 10W40 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) 13.25 L (14 US qt)

  • Page 28: 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 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

    INTRODUCTION Product identification The terms right-hand, left-hand, front, and rear are used in this manual to indicate the sides as they are seen from the operator's seat. 1. Front 2. Right-hand 3. Rear 4. Left-hand RCPH10WHL003BAH 48083741_EN 31/07/2018...

  • Page 31: Product Identification

    INTRODUCTION Product identification LEIL16WHL2487FA 1. Roll Over Protection System (ROPS) cab 5. Steps 2. Cab door handle 6. Bucket (Z-bar version) 3. Timed disconnect switch and optional battery jump post 7. Loader lift arms 4. Battery access 8. Bucket cylinder 48083741_EN 31/07/2018...
  • Page 32 INTRODUCTION LEIL16WHL2486FA 1. Pre-cleaner 5. Bucket (Z-bar version) 2. Sliding access panel 6. Cab air filter door 3. Cab side window 7. Windshield washer reservoir 4. Driving lights 48083741_EN 31/07/2018...
  • Page 33 INTRODUCTION 48083741_EN 31/07/2018...
  • Page 34 SERVICE MANUAL Engine 821G ZBAR - EH, NEW CAB TIER2 921G ZBAR - EH, NEW CAB TIER2 48083741_EN 31/07/2018...
  • Page 35 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.202] Air cleaners and lines .
  • Page 36 Engine - 10 Engine and crankcase - 001 821G ZBAR - EH, NEW CAB TIER2 921G ZBAR - EH, NEW CAB TIER2 48083741_EN 31/07/2018 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 821G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA Engine with 4 Speed Transmission A. Low idle 870 RPM to 930 RPM Alternate low idle 670 RPM to 730 RPM Alternate accelerated idle 1270 RPM to 1330 RPM Working idle (setting from factory)
  • Page 39 Engine - Engine and crankcase Temperature of the hydraulic oil 54 – 57 °C (129 – 135 °F) NOTE: hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode with transmission in manual mode and in 3rd gear.
  • Page 40 Engine - Engine and crankcase Engine - Remove 1. Park the machine on a level surface and lower the bucket to the ground. Put the articulation lock in LOCKED position and stop the engine. LEIL16WHL0048AB 2. Actuate the brake pedal several times to discharge the brake accumulators.
  • Page 41 Engine - Engine and crankcase 5. Locate the timed disconnect switch and hood raise switch in the battery box. Raise the engine hood and put the timed disconnect switch to OFF position. RCPH10WHL106AAH 6. Unhook the rubber T-handle (1) and raise the upper panel (2).
  • Page 42 Engine - Engine and crankcase 9. Place a suitable container below the engine oil drain plug. Remove the engine oil drain plug and drain oil into container. Then reinstall the engine oil drain plug. NOTE: see machine specifications for engine oil sump vol- ume.
  • Page 43 Engine - Engine and crankcase 13. Remove the support bracket of the engine coolant overflow tank. LEIL16WHL0575AB 14. Remove the cooling fan guard. LEIL17WHL0137AB 15. Loosen the four bolts to remove the engine guard (1). LEIL17WHL0118AB 16. Disconnect the crankcase vent hose from the engine. LEIL17WHL0136AB 48083741_EN 31/07/2018 10.1 [10.001] / 8...
  • Page 44 Engine - Engine and crankcase 17. Remove the clamps (3) that secure the crankcase vent hose (2) to the brackets (1). Remove the brack- ets (1) from the engine. LEIL17WHL0133AB LEIL17WHL0119AB 18. Remove the clamp to disconnect the air cleaner from the engine.
  • Page 45 Engine - Engine and crankcase 20. Remove the drive belt from the engine. LEIL17WHL0117AB 21. Tag and disconnect the ACT connector from the air- conditioning compressor clutch and ALT_5, ALT_B connectors from the alternator. Remove the alternator (2) and air-conditioning com- pressor (1).
  • Page 46 Engine - Engine and crankcase 24. Tag and disconnect the ST, CPWR and battery posi- tive cables (1) from the engine starter. Tag and disconnect the negative battery cable (2), ground strap (3) and XM1C cable (4) from the engine starter.
  • Page 47 Engine - Engine and crankcase 28. Remove the clamp (2) to disconnect the bottom en- gine coolant line (1) from the engine. Tag the hose. LEIL17WHL0092AB 29. Remove the clamps (2) to disconnect the turbo outlet air cooling line (1) from the charge air cooler and en- gine.
  • Page 48 Engine - Engine and crankcase 31. Tag and disconnect the fuel pre-filter to engine hose (8) from the engine. 32. Remove the clamp (7) that secures the fuel tank suc- tion hose to the rear muffler support. 33. Tag and disconnect the WIF connector (9) and WSH connector (6) from the fuel pre-filter (4).
  • Page 49 Engine - Engine and crankcase 38. Attach a suitable lifting device to the exhaust system assembly (1) (including muffler, pipe, support brack- ets). Remove the hardware at the noted six locations to unfix the exhaust system assembly (1) from the rear chassis.
  • Page 50 Engine - Engine and crankcase 40. Tag and disconnect the EDC7 connector from the En- gine Controller Unit (ECU). LEIL17WHL0050AB 41. Tag and disconnect the FFH connector from the fuel filter. LEIL17WHL0049AB 42. Remove the clamp (1) to release the fuel return hose (2).
  • Page 51 Engine - Engine and crankcase 44. Remove the upper and lower drive shaft dust covers. LEIL17WHL0048AB 45. Remove the bolts to disengage the drive shaft from the engine coupling. LEIL17WHL0047AB 46. Connect a vacuum pump to the hydraulic reservoir and turn it on. Tag and disconnect the suction hose (2), pressure hose (4) and attenuator hose (3) from the brake pump (1).
  • Page 52 Engine - Engine and crankcase 47. Connect a suitable lifting equipment to the engine mounts (1). Take up all slack in lifting equipment. Remove the engine mount bolts (2). 48. Slowly raise the engine from the rear chassis. Make sure all wire harness connections and hoses have been disconnected and are clear of the engine.
  • Page 53 Engine - Engine and crankcase Engine - Install WARNING Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap.
  • Page 54 Engine - Engine and crankcase 2. Attach a suitable lifting device to the engine mounts (1) and slowly move the engine into position over the rear chassis. Make sure all harness connections and hoses are out of the way or positioned correctly for reconnecting, before lowering the engine.
  • Page 55 Engine - Engine and crankcase 7. Position the drive shaft on the engine coupling. In- stall the six bolts (4–speed transmission) or eight bolts (5–speed transmission) to secure the drive shaft to the engine coupling. NOTE: the figure shows the machine with 5–speed trans- mission.
  • Page 56 Engine - Engine and crankcase 11. At the noted location install additional spacer and clamp to route the fuel tank suction hose. LEIL17WHL0086AB 12. Install the clamp (1) to secure the fuel return hose (2). 13. Connect the fuel line (2) to the top of the fuel filter. LEIL17WHL0046AB 14.
  • Page 57 Engine - Engine and crankcase 16. Mount the engine starter (1). Firstly install the short threaded portion of the three studs (2) into the flywheel housing. Apply Loctite 747 primer to the studs and holes. Apply two drops of L ®...
  • Page 58 Engine - Engine and crankcase 19. Fix the end of the exhaust system pipe (1) to the en- gine with a new clamp (2). Tighten the clamp to 5.7 – 6.3 N·m (4.2 – 4.6 lb ft). LEIL17WHL0054AB 20. Install the alarm back-up (1) to the rear muffler support with four bolts, washers (under bolt head and nut) and nuts.
  • Page 59 Engine - Engine and crankcase 27. Install the turbo outlet air cooling line (1) with clamps. Torque the clamp at the end mating the charge air cooler to 10.1 – 11.3 N·m (7.4 – 8.3 lb ft). Install a new O-ring at the end mating the engine and torque the clamp (2) to 5.8 –...
  • Page 60 Engine - Engine and crankcase 31. Install the breather line (hose and venting check valve) to the engine. Tighten the clamp to 3.4 N·m (2.5 lb ft) LEIL17WHL0094AB 32. Install the ST, CPWR and battery positive cables (1) to the engine starter. Torque the nut to 22.5 – 29.4 N·m (16.6 –...
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