Case 1021F User manual

PrintedinU.S.A.
Copyright © 2012 CNHAmerica LLC. All Rights Reserved.
CaseisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 47392461
1st edition English
July 2012
SERVICE MANUAL
1021F
1121F
Tier 2
Wheel Loader

Contents
INTRODUCTION
Engine.......................................................................................10
Engineandcrankcase....................................................................10.001
Aircleanersandlines.....................................................................10.202
Enginelubricationsystem................................................................10.304
Aftercooler................................................................................10.310
Fananddrive.............................................................................10.414
Transmission..............................................................................21
Powershifttransmission..................................................................21.113
Powershifttransmissionexternalcontrols................................................21.135
Gearboxinternalcomponents............................................................21.145
Powershifttransmissioninternalcomponents............................................21.155
Four-WheelDrive(4WD)system..................................................23
Driveshaft................................................................................23.314
Frontaxlesystem.......................................................................25
Poweredfrontaxle.......................................................................25.100
Frontbevelgearsetanddifferential......................................................25.102
Finaldrivehub,steeringknuckles,andshafts...........................................25.108
Rearaxlesystem........................................................................27
Poweredrearaxle........................................................................27.100
Brakesandcontrols....................................................................33
Parkingbrake/Parkinglock..............................................................33.110
Hydraulicservicebrakes.................................................................33.202
Hydraulicsystems.......................................................................35
Hydraulicsystems........................................................................35.000
Variabledisplacementpump.............................................................35.106
Reservoir,cooler,andlters..............................................................35.300
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Pilotsystem...............................................................................35.357
Maincontrolvalve........................................................................35.359
Auxiliaryhydraulicvalvesandlines......................................................35.525
Frontloaderarmhydraulicsystem.......................................................35.701
Steering.....................................................................................41
Auxiliarysteering.........................................................................41.910
Wheels......................................................................................44
Frontwheels..............................................................................44.511
Cabclimatecontrol.....................................................................50
Airconditioning...........................................................................50.200
Electricalsystems.......................................................................55
Electricalsystem.........................................................................55.000
Fueltanksystem.........................................................................55.011
Enginecoolingsystem...................................................................55.012
Enginecontrolsystem....................................................................55.015
Transmissioncontrolsystem.............................................................55.024
Servicebrakeelectricalsystem..........................................................55.030
Parkingbrakeelectricalsystem..........................................................55.031
Hydraulicsystemcontrol.................................................................55.036
Steeringcontrolsystem..................................................................55.047
Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.......................55.050
CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.........................55.051
Harnessesandconnectors...............................................................55.100
Enginestartingsystem...................................................................55.201
Coldstartaid.............................................................................55.202
Alternator.................................................................................55.301
Battery....................................................................................55.302
Externallighting..........................................................................55.404
Externallightingswitchesandrelays.....................................................55.405
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Warningindicators,alarms,andinstruments.............................................55.408
Loaderarmandbucketcontrolsystem...................................................55.415
Cab/Platformharnessesandconnectors.................................................55.510
Cabcontrols..............................................................................55.512
Cablighting...............................................................................55.514
Wiper/Washersystem....................................................................55.518
Cabbrakecontrols.......................................................................55.519
Cabcontrols(Liftarm,Boom,Dipper,Bucket)...........................................55.524
FAULTCODES..........................................................................55.DTC
Platform,cab,bodywork,anddecals.............................................90
Machineshieldsandguards..............................................................90.105
Protectionsandfootboards...............................................................90.118
Pneumatically-adjustedoperatorseat....................................................90.124
Cab.......................................................................................90.150
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INTRODUCTION
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Contents
INTRODUCTION
Torque..........................................................................................3
1021FINT,1121FINT
Capacities.......................................................................................6
1021FINT,1121FINT
Consumables-BiodieselFuel................................................................12
Hydrauliccontamination......................................................................13
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INTRODUCTION
Torque
1021FINT ,1121FINT
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)
Startermotormountingbolts41-48N·m(30-35lbft)
Enginesupportbracket-to-rearchassisbolts386-434N·m(285-320lbft)
Engineshockmountnuts397-447N·m(293-330lbft)
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INTRODUCTION
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)
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INTRODUCTION
Wheels
Tightenthewheelnutsintwostages.First,tightenthewheelnutsinthesequenceasshownintheimage(1)toa
torqueof278N·m(205lbft).Second,tightenthewheelnutsinthesequenceasshownintheimage(1)toatorque
of640-720N·m(472-531lbft).
RCPH11WHL202AAH2
WheelnutsFirststage:278N·m(205lbft).Secondstage:640-
720N·m(472-531lbft)
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INTRODUCTION
Capacities
1021FINT ,1121FINT
1021FCapacitiesandspecications
Engine
TypeofoilCASEAKCELAENGINEOIL15W-40
Capacity(withlterchange)28.5l(30.1USqt)
Coolingsystem
Systemcapacity56.8l(60.0USqt)
Fuelsystem
Systemcapacity473.0l(125.0USgal)
Hydraulicsystem
TypeofuidCASEAKCELAHY-TRAN®ULTRA™
HYDRAULICTRANSMISSIONOIL
Totalsystemcapacity250.0l(66.0USgal)
Reservoircapacity134.0l(35.4USgal)
Transmission
TypeofoilCASEAKCELANEXPLORE™FLUID
Servicecapacity-withlterchange45.4l(48.0USqt)
Axles
TypeofoilCASEAKCELANEXPLORE™FLUID
Frontaxle42.0l(44.4USqt)
Rearaxle42.0l(44.4USqt)
Frontaxlewithaxlecooler45.7l(48.3USqt)
Rearaxlewithaxlecooler45.7l(48.3USqt)
Heavydutyfrontaxle62.0l(65.5USqt)
Heavydutyfrontaxlewithcooler65.7l(69.4USqt)
Greasettings,asrequiredCASEAKCELAMOLYGREASE
*Machinesareshippedfromthefactorywithbreak-inoil.
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INTRODUCTION
1121FCapacitiesandspecications
Engine
TypeofoilCASEAKCELAENGINEOIL15W-40
Capacity(withlterchange)28.5l(30.1USqt)
Coolingsystem
Systemcapacity56.8l(60.0USqt)
Fuelsystem
Systemcapacity473.0l(125.0USgal)
Hydraulicsystem
TypeofuidCASEAKCELAHY-TRAN®ULTRA™
HYDRAULICTRANSMISSIONOIL
Totalsystemcapacity250.0l(66.0USgal)
Reservoircapacity134.0l(35.4USgal)
Transmission
TypeofoilCASEAKCELANEXPLORE™FLUID
Servicecapacity-withlterchange45.4l(48.0USqt)
Axles
TypeofoilCASEAKCELANEXPLORE™FLUID
Frontaxle64.0l(67.6USqt)
Rearaxle64.0l(67.6USqt)
Frontaxlewithaxlecooler67.7l(71.5USqt)
Rearaxlewithaxlecooler67.7l(71.5USqt)
Frontaxlewithdifferentiallock62.0l(65.5USqt)
Frontaxlewithdifferentiallockandaxlecooler65.7l(69.4USqt)
Greasettings,asrequiredCASEAKCELAMOLYGREASE
*Machinesareshippedfromthefactorywithbreak-inoil.
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INTRODUCTION
Engineoilviscosity/Temperatureranges
RCPH11WHL023FAH1
NOTE:Useofanengineoilpanheateroranenginecoolantheatermayberequiredwhenoperatingtemperatures
areinWinterorArcticconditions.
Transmissionoilviscosity/Temperatureranges
RCPH10WHL453BAH2
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INTRODUCTION
Hydraulic/Brakesystem-temperaturerange
RCPH10WHL006EAL3
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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.
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INTRODUCTION
Engineoil
CaseAkcelaengineoilisrecommendedforyourengine.
Thisoilinsurescorrectlubricationofyourengineinall
workingconditions.Seechartsatthebeginningofthis
sectiontochoosethecorrectoilforclimate/temperatures.
IfCaseAkcelaengineoilcannotbeobtained,useonlyoil
oftheAPISERVICECI-4category.
NOTE:DonotputanyPerformanceAdditiveorotherad-
ditiveinthesump.Oilchangeintervalsshowninthisman-
ualarebasedontestscarriedoututilizingCaselubricants.
RCPH10WHL012AAD4
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INTRODUCTION
Consumables-BiodieselFuel
FattyAcidMethylEsterBiodiesel(BiodieselFuel)consistsofafamilyoffuelsderivedfromvegetableoilstreatedwith
methylesters.
NOTICE:BiodieselfuelblendsareapprovedforyourengineonlyiftheycomplywithSpecicationStandardsEN
14214orASTMD6751.
NOTICE:Verifywithyourlocaldealerwhichblendsareapprovedforyourengine.Useofbiodieselfuelthatdoesnot
complywiththeStandardsEN14214orASTMD6751couldleadtoseveredamagetoengineandfuelsystem.Use
ofnon-approvedbiodieselfuelsmayvoidwarrantycoverage.
BiodieselFuelUsageConditions
Biodieselfuelsmustbepurchasedfromatrustedsupplierthatunderstandstheproductandmaintainsgoodfuel
quality.Biodieselfuelsmustbepre-blendedbythesupplier.Mixingbiodieselfuelsonsitecanresultinanincorrect
mixturewhichcandamageengineandfuelsystem.
Engineperformanceiseffectedbytheuseofbiodieselfuels.Theremaybeupto12percentreductioninpoweror
torquedependingontheblendused.
NOTICE:DONOTmodifytheengineand/orfuelinjectionpumpsettingstorecoverreducedperformance.
Thereducedpowermustbeacceptedifusinganybiodieselfuelblends.
NOTICE:Theuseofhighbiodieselfuelblendsisnotrecommendedincoldweatherconditions.
Usingbiodieselfuelsmayrequirechangingengineoil,engineoillters,andfuellterelementsmorefrequently.
Biodieselfuelscanremoverustandotherparticlesthatadheretotheinsideofthefueltank.Theseparticlesare
trappedbyvehicleltersandmaycauseshortenedlterlifeorlterblockages.Blockagesaremorecommonincold
weatherconditions.Consultyourdealerforinformationoncoldweatheroperationandpropermaintenanceintervals
whenusinganybiodieselfuelblend.
Biodieselfuelmaydegradenaturalrubbergasketsandhoses,asitismoresolventthanpetro-diesel.Frequently
inspecthosesandotherenginecomponentswhenusingbiodieselfuel.
DONOTallowwatertocollectinthefuelorstoragetanks.Biodieselfuelattractsmoisturefromtheatmosphere.
Keepfueltanksandstoragetanksasfullaspossibletolimittheamountofairandwatervapors.Itmaybenecessary
todrainmachinefuelltermorefrequently.Potentialoxidationandstabilitycouldcreateaproblemwithfuelstoredin
themachine.
BiodieselStorage
NOTICE:DONOTstoremachinesformorethanthreemonthswithbiodieselblendsinthefuelsystem.DONOT
storebiodieselfuelinon-sitestoragetanksformorethanthreemonths.
Iflongperiodsofstoragearerequired,runthemachinefor20hoursusingregulardieselfueltoushthebiodiesel
fuelfromtheenginefuelsystem.
NOTICE:Biodieselfuelsmustnotbestoredinon-sitestoragetanksformorethan3months.Anyspillageofbiodiesel
fuelsmustbecleanedupimmediatelybeforeitcancausedamagetotheenvironmentorthepaintnishofthema-
chine.Beforeusingbiodieselfuelblends,youshouldconsultwithyourdealertoreceivefullinformationaboutthe
approvedblendforyourmachineandanydetailedconditionsofitsusage.Failuretofollowtherequirementsand
conditionsofbiodieselfuelusagewillvoidyourmachine’swarranty.
NOTE:B7isthehighestbiodiesel(7%blend)thatshouldbeusedinthismachine.
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INTRODUCTION
Hydrauliccontamination
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.
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CONSUMABLESINDEX
ConsumableIUPAGE
CASEAkcelaEngineoil
15W-40
Capacities6
CASEAkcelaHY-TRAN®
Ultra™hydraulictransmission
oil
Capacities6
CASEAkcelaNEXPLORE™
uid
Capacities6
CASEAkcelaNEXPLORE™
uid
Capacities6
CASEAkcelaMolygreaseCapacities6
CASEAkcelaEngineoil
15W-40
Capacities7
CASEAkcelaHY-TRAN®
Ultra™hydraulictransmission
oil
Capacities7
CASEAkcelaNEXPLORE™
uid
Capacities7
CASEAkcelaNEXPLORE™
uid
Capacities7
CASEAkcelaMolygreaseCapacities7
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SERVICEMANUAL
Engine
1021F
1121F
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Contents
Engine-10
Engineandcrankcase......................................................................10.001
1021F,1121F
Aircleanersandlines.......................................................................10.202
1021F,1121F
Enginelubricationsystem..................................................................10.304
1021F,1121F
Aftercooler..................................................................................10.310
1021F,1121F
Fananddrive...............................................................................10.414
1021F,1121F
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