Case 1021F User manual

PrintedinU.S.A.
Copyright © 2011 CNHAmerica LLC. All Rights Reserved.
CaseisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 84555573
1st edition English
October 2011
SERVICE MANUAL
1021F
1121F
Tier 4
Wheel Loader

Contents
INTRODUCTION
HYDRAULIC,PNEUMATIC,ELECTRICAL,ELECTRONICSYSTEMSA
PRIMARYHYDRAULICPOWERSYSTEM..............................................A.10.A
ELECTRICALPOWERSYSTEM........................................................A.30.A
LIGHTINGSYSTEM......................................................................A.40.A
ELECTRONICSYSTEM.................................................................A.50.A
FAULTCODES...........................................................................A.50.A
ENGINEANDPTOIN...................................................................B
ENGINE..................................................................................B.10.A
FUELANDINJECTIONSYSTEM........................................................B.20.A
AIRINTAKESYSTEM....................................................................B.30.A
EXHAUSTSYSTEMEmissionscontrol..................................................B.40.B
ENGINECOOLANTSYSTEM...........................................................B.50.A
LUBRICATIONSYSTEM.................................................................B.60.A
STARTINGSYSTEM.....................................................................B.80.A
TRANSMISSION,DRIVEANDPTOOUT........................................C
POWERCOUPLINGFixedcoupling.....................................................C.10.B
TRANSMISSIONPowershift.............................................................C.20.E
AXLES,BRAKESANDSTEERING.................................................D
FRONTAXLE............................................................................D.10.A
REARAXLE..............................................................................D.12.A
STEERINGHydraulic.....................................................................D.20.C
SERVICEBRAKEHydraulic..............................................................D.30.C
PARKINGBRAKEHydraulic.............................................................D.32.C
WHEELSANDTRACKSWheels.........................................................D.50.C
FRAMEANDCAB........................................................................E
SHIELD...................................................................................E.20.A
USERCONTROLSANDSEAT..........................................................E.32.A
8455557311/10/2011

USERCONTROLSANDSEATOperatorseat...........................................E.32.C
USERPLATFORM.......................................................................E.34.A
ENVIRONMENTCONTROLHeatingsystem............................................E.40.B
ENVIRONMENTCONTROLAir-conditioningsystem....................................E.40.C
ENVIRONMENTCONTROLHeating,ventilationandair-conditioning...................E.40.D
SAFETYSECURITYACCESSORIESSafety............................................E.50.B
HITCHANDWORKINGTOOL.......................................................H
SINGLEARMLift.........................................................................H.40.B
8455557311/10/2011

8455557311/10/2011

Thanks very much for your reading,
Want to get more information,
Please click here, Then get the complete
manual
NOTE:
If there is no response to click on the link above,
please download the PDF document first, and then
click on it.
Have any questions please write to me:
[e-mail]

INTRODUCTION
8455557311/10/2011
1

Contents
INTRODUCTION
Torque..........................................................................................3
Hydrauliccontamination........................................................................6
21F
Capacities.......................................................................................7
8455557311/10/2011
2

INTRODUCTION
Torque
Alternator
Alternatorpulleyretainingnut95-109N·m(70-80lbft)
Batteryterminalnut6-8N·m(55-72lbin)
Indicatorlightterminalnut2-3N·m(16-24lbin)
Axle
Planetarycarrierlockscrews200N·m(148lbft)
Brakespringretainercover34N·m(25lbft)
Axlewheelendscrewplug50N·m(37lbft)
NutSecuringBrakeTubetoConnector100N·m(74lbft)
BrakeTubeFittingtoWheelEndFitting36N·m(27lbft)
Axlehousingbolts560N·m(413lbft)
Inputangeslottednut1200N·m(885lbft)
Differentialreleasinghousingcoverbolts185N·m(136lbft)
Differentialhousingcoverbolts400N·m(295lbft)
Wheelmountingbolts644-719N·m(475-530lbft)
Axlebreathervalve4-6N·m(35-53lbin)
Frontaxlemountingbolts1519-1708N·m(1120-1260lbft)
Reartrunnioncoverbolts103-115N·m(76-85lbft)
Reartrunnionspacerbolts285-319N·m(210-235lbft)
Trunnioncastingmounting651-732N·m(480-540lbft)
Chassis
Cabandcanopymountingbolts773-854N·m(570-630lbft)
Counterweightmountingbolts1125-1261N·m(830-930lbft)
Lowerstepsupportbolts27-31N·m(20-23lbft)
Batteryholddownbolts651-732N·m(480-540lbft)
Cooling
Coolingframemounting271-298N·m(200-220lbft)
Fanmountingnut109-122N·m(80-90lbft)
Drivetrain
Flexplatetoywheelbolts33-41N·m(24-30lbft)
Carrierbearingbolt149-163N·m(110-120lbft)
Drivelinemountingbolts136-149N·m(100-110lbft)
Transmissionsightgaugemountingbolts3-5N·m(24-48lbin)
Transmissionshockmountnuts929-1044N·m(685-770lbft)
Transmission-to-bracketbolts1125-1275N·m(830-940lbft)
Transmission-to-ywheelhousingbolts54-60N·m(40-44lbft)
Transmissionlltubebolts17-33N·m(151-292lbin)
Banjotubebolt160N·m(118lbft)
Bypassvalvehoseclamps10-11N·m(90-100lbin)
Engine
Airintakehoseclamps4-5N·m(35-44lbin)
Aspiratorhoseclamps3N·m(30lbin)
Muferextubeclamp18-22N·m(13-16lbft)
Muferclampatturbo5-6N·m(44-53lbin)
8455557311/10/2011
3

INTRODUCTION
Startermotormountingbolts41-48N·m(30-35lbft)
Enginesupportbracket-to-rearchassisbolts386-434N·m(285-320lbft)
Engineshockmountnuts397-447N·m(293-330lbft)
Fueltank
Tightenthefuelsenderboltsinthesequenceasshownintheimage(2)toatorqueof6-8N·m(53-71lbin).
RCPH11WHL117AAR1
Fuelsendermountingbolts6-8N·m(53-71lbin)
Fueltankskidplatebolts(boltsandnutsaretobe
torquedonlyonetime.Replaceasnecessary)
122-164N·m(90-121lbft)
Fueltankmountingbolts(boltsandnutsaretobe
torquedonlyonetime.Replaceasnecessary)
301-407N·m(222-300lbft)
Hydraulics
Priorityvalvemountingbolts85-102N·m(63-75lbft)
Mainhydraulicpumpelbow85-102N·m(63-75lbft)
Hydraulictanksightgaugemounting3-6N·m(27-53lbin)
Surgetankhoseclampmounting48N·m(35lbft)
Brakepumpmountingbolts149-170N·m(110-125lbft)
Hydraulicoiltanksuctionhoseclamps10-11N·m(90-100lbin)
Split,halfclampangebolts(hydraulictank-to-pumps
andpriorityvalve-to-pump)
73-90N·m(54-67lbft)
Split,halfclampangebolts(priorityvalve-to-loader
valve)
198-242N·m(146-179lbft)
Pumpmountingbolts149-170N·m(110-125lbft)
Wheels
Tightenthewheelnutsintwostages.First,tightenthewheelnutsinthesequenceasshownintheimage(2)toa
torqueof278N·m(205lbft).Second,tightenthewheelnutsinthesequenceasshownintheimage(2)toatorque
of640-720N·m(472-531lbft).
8455557311/10/2011
4

INTRODUCTION
RCPH11WHL202AAH2
WheelnutsFirststage:278N·m(205lbft).Secondstage:640-
720N·m(472-531lbft)
8455557311/10/2011
5

INTRODUCTION
Hydrauliccontamination
21F
Contaminationinthehydraulicsystemisamajorcauseofthemalfunctionofhydrauliccomponents.Contamination
isanyforeignmaterialinthehydraulicoil.Contaminationcanenterthehydraulicsysteminseveralways.
(A)Whenyoudraintheoilordisconnectanyline.
(B)Whenyoudisassembleacomponent.
(C)Fromnormalwearofthehydrauliccomponents.
(D)Fromdamagedorwornseals.
(E)Fromadamagedcomponentinthehydraulicsystem.
Allhydraulicsystemsoperatewithsomecontamination.Thedesignofthecomponentsinthishydraulicsystemper-
mitsefcientoperationwithasmallamountofcontamination.Anincreaseinthisamountofcontaminationcancause
problemsinthehydraulicsystem.Thefollowinglistincludessomeoftheseproblems.
(A)Cylinderrodsealsleak.
(B)Controlvalvespoolsdonotreturntoneutral.
(C)Movementofcontrolvalvespoolsisdifcult.
(D)Hydraulicoilbecomestoohot.
(E)Pumpgears,housing,andotherpartswearrapidly.
(F)Reliefvalvesorcheckvalvesheldopenbydirt.
(G)Quickfailureofcomponentsthathavebeenrepaired.
(H)Cycletimesareslow;machinedoesnothaveenoughpower.
Ifyourmachinehasanyoftheseproblems,checkthehydraulicoilforcontamination.Therearetwotypesofcontam-
ination,microscopicandvisible.
Microscopiccontaminationoccurswhenveryneparticlesofforeignmaterialareinsuspensioninthehydraulicoil.
Theseparticlesaretoosmalltoseeorfeel.Microscopiccontaminationcanbefoundbyidenticationofthefollowing
problemsorbytestinginalaboratory.Examplesoftheproblems:
(A)Cylinderrodsealleak.
(B)ControlvalvespoolsdonotreturntoNEUTRAL.
(C)Thehydraulicsystemhasahighoperatingtemperature.
Visiblecontaminationisforeignmaterialthatcanbefoundbysight,touch,orodor.Visiblecontaminationcancause
asuddenfailureofcomponents.Examplesofvisiblecontamination:
(A)Particlesofmetalordirtintheoil.
(B)Airintheoil.
(C)Theoilisdarkandthick.
(D)Theoilhasanodorofburnedoil.
(E)Waterintheoil.
Ifyoundcontamination,useaPortableFiltertocleanthehydraulicsystem.
8455557311/10/2011
6

INTRODUCTION
Capacities
1021FCapacitiesandspecications
Engine
TypeofoilCaseAkcela(SAE15W-40)
Capacity(withlterchange)28.5l(30.1USqt)
Coolingsystem
Systemcapacity56.8l(60.0USqt)
Fuelsystem
Systemcapacity473.0l(125.0USgal)
Hydraulicsystem
TypeofuidCaseAkcelaHy-TranUltra
Totalsystemcapacity250.0l(66.0USgal)
Reservoircapacity134.0l(35.4USgal)
Transmission
TypeofoilCaseNexplore
Servicecapacity-withlterchange45.4l(48.0USqt)
Axles
TypeofoilCaseNexplore
Frontaxle42.0l(44.4USqt)
Rearaxle42.0l(44.4USqt)
Frontaxlewithaxlecooler45.7l(48.3USqt)
Rearaxlewithaxlecooler45.7l(48.3USqt)
Heavydutyfrontaxle62.0l(65.5USqt)
Heavydutyfrontaxlewithcooler65.7l(69.4USqt)
DEF(DieselExhaustFluid)
Totalcapacity90.8l(24.0USgal)
Greasettings,asrequiredCaseAkcelaMolydisulde
*Machinesareshippedfromthefactorywithbreak-inoil.
8455557311/10/2011
7

INTRODUCTION
1121FCapacitiesandspecications
Engine
TypeofoilCaseAkcela(SAE15W-40)
Capacity(withlterchange)28.5l(30.1USqt)
Coolingsystem
Systemcapacity56.8l(60.0USqt)
Fuelsystem
Systemcapacity473.0l(125.0USgal)
Hydraulicsystem
TypeofuidCaseAkcelaHy-TranUltra
Totalsystemcapacity250.0l(66.0USgal)
Reservoircapacity134.0l(35.4USgal)
Transmission
TypeofoilCaseNexplore
Servicecapacity-withlterchange45.4l(48.0USqt)
Axles
TypeofoilCaseNexplore
Frontaxle64.0l(67.6USqt)
Rearaxle64.0l(67.6USqt)
Frontaxlewithaxlecooler67.7l(71.5USqt)
Rearaxlewithaxlecooler67.7l(71.5USqt)
Frontaxlewithdifferentiallock62.0l(65.5USqt)
Frontaxlewithdifferentiallockandaxlecooler65.7l(69.4USqt)
DEF(DieselExhaustFluid)
Totalcapacity90.8l(24.0USgal)
Greasettings,asrequiredCaseAkcelaMolydisulde
*Machinesareshippedfromthefactorywithbreak-inoil.
8455557311/10/2011
8

INTRODUCTION
Engineoilviscosity/Temperatureranges
RCPH11WHL023FAH1
NOTE:Useofanengineoilpanheateroranenginecoolantheatermayberequiredwhenoperatingtemperatures
areinWinterorArcticconditions.
Transmissionoilviscosity/Temperatureranges
RCPH10WHL453BAH2
8455557311/10/2011
9

INTRODUCTION
Hydraulic/Brakesystem-temperaturerange
RCPH10WHL006EAL3
8455557311/10/2011
10

INTRODUCTION
Coolantsolution
Putonlyethylene-glycolcoolantsolutioninthecoolingsystem.Usegoodqualityethylene-glycolthathasahigh
boilingpointwithnoadditivestopreventleakage.Donotusenon-approvedanti-rustadditives.Anti-rustadditives
andethylene-glycolcanmixandworkagainsteachother,reducinganti-corrosionprotection,formingdepositsinthe
coolingsystem,andcausingdamagetothecoolingsystemandradiator.Contactyourdealerwhocansupplyyou
withthesuitablecoolantsolution.
Anti-freeze/Anti-corrosion
Useanti-freezeinallseasonstoprotectthecoolingsystemfromcorrosionandriskoffreezing.Forareaswherethe
ambienttemperatureisover-36°C(-32.8°F)useablendof50%ethylene-glycolbasedanti-freeze.
Forareaswherethetemperatureisbelow-36°C(-32.8°F)-itisadvisabletouseablendof40%waterand60%
anti-freeze.
Fuel
Usedieselfuelsuitablefortheambienttemperatureconditions(ASTM-D-975).
UsefuelwhichistoASTM(AmericanSocietyforT estingandMaterials)D975standard.
UsegradeNo.2fuel.Theuseofothertypesoffuelcanresultinalossofpoweroftheengineandmaycausehigh
fuelconsumption.
Inverylowambienttemperatures,useamixtureoffuelsNo.1andNo.2asnecessary.Consultyourfuelsupplier
forappropriatefuelsupply.
Ifthetemperaturefallsbelowthefuelcloudpoint(pointatwhichwaxbeginstoform)thewaxcrystalswillcausepower
lossorwillpreventtheenginefromstarting.
Incoldweather,llthefueltankattheendoftheday'sworkinordertopreventtheformationofcondensation.
Fuelstorage
Prolongedstorageoffuelcanleadtotheaccumulationofimpuritiesandcondensationinthefuel.Enginetroublecan
oftenbetracedtothepresenceofwaterinthefuel.
Thestoragetankmustbeplacedoutsideandthetemperatureofthefuelshouldbekeptaslowaspossible.Drainoff
waterandimpuritiesregularly.
Hydraulicuid
CaseAkcelaHy-TranUltrahydraulicuidisspecicallydesignedforhighpressureapplicationsandforCasehydraulic
systems.YourCaseDealercanprovidehydraulicuidtofullldifferentclimate/temperatureconditions.Refertothe
chartsatthebeginningofthissection.
Transmissioncomponentoil
Extremepressureoilshouldbeusedforenclosedtransmissioncomponents.Chooseanoilthatismanufactured
foryourclimate/temperatureconditionssuchasCaseNexploreorCNHF200A.Seechartsatthebeginningofthis
section.
Grease
Thetypeofgreasetousedependsonambienttemperaturesuchas:CaseAkcelaMolydisuldeGrease
Environment
Beforeyouservicethismachineanddisposeofoil,uids,andlubricants,obeyenvironmentalregulations.Donot
drainoiloruidsontothegroundorintocontainersthatleak.Checkwithyourlocalenvironmental,recyclingcenter
oryourdealerforcorrectdisposalinformation.
8455557311/10/2011
11

INTRODUCTION
Engineoil
CaseAkcelaengineoilisrecommendedforyourengine.
Thisoilinsurescorrectlubricationofyourengineinall
workingconditions.Seechartsatthebeginningofthis
sectiontochoosethecorrectoilforclimate/temperatures.
IfCaseAkcelaengineoilcannotbeobtained,useonlyoil
oftheAPISERVICECI-4category.
NOTE:DonotputanyPerformanceAdditiveorotherad-
ditiveinthesump.Oilchangeintervalsshowninthisman-
ualarebasedontestscarriedoututilizingCaselubricants.
RCPH10WHL012AAD4
8455557311/10/2011
12

SERVICEMANUAL
HYDRAULIC,PNEUMATIC,ELECTRICAL,ELECTRONICSYSTEMS
21F
8455557311/10/2011
A

Contents
HYDRAULIC,PNEUMATIC,ELECTRICAL,
ELECTRONICSYSTEMS-A
PRIMARYHYDRAULICPOWERSYSTEM................................................A.10.A
21F
ELECTRICALPOWERSYSTEM..........................................................A.30.A
21F
LIGHTINGSYSTEM........................................................................A.40.A
21F
ELECTRONICSYSTEM...................................................................A.50.A
21F
FAULTCODES.............................................................................A.50.A
1021F,1121F
8455557311/10/2011
A

HYDRAULIC,PNEUMATIC,ELECTRICAL,
ELECTRONICSYSTEMS-A
PRIMARYHYDRAULICPOWERSYSTEM-10.A
21F
8455557311/10/2011
A.10.A/1