Case 1021G User manual

1/2 SERVICE MANUAL
1021G
1121G
Tier 2
Wheel Loader
Part number 48083742
English
July 2018
© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
1021G
1121G
Wheel Loader
Part number 48083742
SERVICE MANUAL

SERVICEMANUAL
1021GZBAR-EH,NEWCABTIER2
1121GZBAR-EH,NEWCABTIER2
48083742_EN31/07/2018EN
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.216]Fueltanks..........................................................................10.2
[10.202]Aircleanersandlines..............................................................10.3
[10.400]Enginecoolingsystem.............................................................10.4
[10.414]Fananddrive......................................................................10.5
[10.310]Aftercooler..........................................................................10.6
[10.304]Enginelubricationsystem..........................................................10.7
Transmission..............................................................................21
[21.113]Powershifttransmission............................................................21.1
[21.135]Powershifttransmissionexternalcontrols..........................................21.2
[21.105]Powershifttransmissionhydrauliccomponents....................................21.3
[21.155]Powershifttransmissioninternalcomponents......................................21.4
Four-WheelDrive(4WD)system..................................................23
[23.314]Driveshaft..........................................................................23.1
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
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[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.106]Variabledisplacementpump.......................................................35.3
[35.359]Maincontrolvalve..................................................................35.4
[35.357]Pilotsystem........................................................................35.5
[35.204]Remotecontrolvalves.............................................................35.6
[35.752]Hydraulicfandrivecoolingsystem.................................................35.7
[35.701]Frontloaderarmhydraulicsystem.................................................35.8
[35.723]Frontloaderbuckethydraulicsystem..............................................35.9
Framesandballasting.................................................................39
[39.100]Frame..............................................................................39.1
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
[41.216]Cylinders...........................................................................41.3
[41.910]Auxiliarysteering...................................................................41.4
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.100]Harnessesandconnectors.........................................................55.1
[55.201]Enginestartingsystem.............................................................55.2
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[55.301]Alternator...........................................................................55.3
[55.512]Cabcontrols........................................................................55.4
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.5
[55.415]Loaderarmandbucketcontrolsystem............................................55.6
[55.530]Camera.............................................................................55.7
[55.518]Wiperandwashersystem..........................................................55.8
[55.DTC]FAULTCODES....................................................................55.9
Frontloaderandbucket...............................................................82
[82.100]Arm.................................................................................82.1
[82.300]Bucket..............................................................................82.2
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.118]Protectionsandfootboards.........................................................90.2
[90.120]Mechanically-adjustedoperatorseat...............................................90.3
[90.124]Pneumatically-adjustedoperatorseat..............................................90.4
[90.105]Machineshieldsandguards.......................................................90.5
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INTRODUCTION
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Contents
INTRODUCTION
Safetyrules.....................................................................................3
Personalsafety.................................................................................4
Basicinstructions-Importantnoticeregardingequipmentservicing.........................13
Basicinstructions-Howtousethemaintenancestandardandprecautions.................14
Basicinstructions-Precautionfordisassemblyandassembly...............................16
Basicinstructions-Electricalequipmentprecautions........................................18
Consumables-BiodieselFuel................................................................19
Consumables.................................................................................20
Hydrauliccontamination......................................................................22
Productidentication-Machineorientation..................................................23
Productidentication..........................................................................24
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Personalsafety
CarefullyreadthisManualbeforeproceedingwithmain-
tenance,repairs,refuellingorothermachineoperations.
Repairshavetobecarriedoutonlybyauthorizedandin-
structedstaff;specicprecautionshavetobetakenwhen
grinding,weldingorwhenusingmalletsorheavyham-
mers.
Non-authorizedpersonsarenotallowedtorepairorcarry
outmaintenanceonthismachine.Donotcarryoutany
workontheequipmentwithoutpriorauthorization.
Askyouremployeraboutthesafetyinstructionsinforce
andsafetyequipment.
Nobodyshouldbeallowedinthecabduringmachine
maintenanceunlessheisaqualiedoperatorhelping
withthemaintenancework.
Ifitisnecessarytomovetheequipmenttocarryoutre-
pairsormaintenance,donotliftorlowertheequipment
fromanyotherpositionthantheoperator’sseat.
TULI12WEX2004AA1
Nevercarryoutanyoperationonthemachinewhenthe
engineisrunning,exceptwhenspecicallyindicated.
Stoptheengineandensurethatallpressureisrelieved
fromhydrauliccircuitsbeforeremovingcaps,covers,
valves,etc.
Allrepairandmaintenanceoperationsshouldbecarried
outwiththegreatestcareandattention.
Servicestairsandplatformsusedinaworkshoporinthe
eldshouldbebuiltincompliancewiththesafetyrulesin
force.
Anyfunctionaldisorders,especiallythoseaffectingthe
safetyofthemachine,shouldthereforeberectiedim-
mediately.
DANGER
Unexpectedmovement!
Makesureparkingbrakeisapplied.Secure
machinewithwheelchocks.
Failuretocomplywillresultindeathorserious
injury.D0013A
TULI12WEX2005AA2
Beforeperforminganyworkonthemachine,attacha
maintenanceinprogresstag.Thistagcanbeappliedon
theleft-handcontrollever,safetyleverorcabdoor.
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INTRODUCTION
Emergency
Bepreparedforemergencies.Alwayskeepareextin-
guisherandrstaidkitreadilyavailable.Ensurethatthe
reextinguisherisservicedinaccordancewiththeman-
ufacturer’sinstructions.
SMIL12WEX0174AA3
Equipment
Wearclosettingclothingandsafetyequipmentappropri-
ateforthejob:
•Safetyhelmet
•Safetyshoes
•Heavygloves
•Reectiveclothing
•Wetweatherclothing
Ifworkingconditionsrequire,thefollowingpersonalsafety
equipmentshouldbeonhand:
•Respirators(ordustproofmasks)
•Earplugsoracousticearsprotections
•Goggleswithlateralshieldormasksforeyeprotection
Donotwearrings,wristwatches,jewelry,unbuttonedor
appingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtinto
movingparts.
TULI12WEX2008AA4
Engine-Radiator
Neverleavetheenginerunninginenclosedspaceswith-
outproperventilationwhichisabletoevacuatetoxicex-
haustgases-Keeptheexhaustmanifoldandtubefree
fromcombustiblematerials.
Donotrefuelwiththeenginerunning,especiallyifhot,as
thisincreasesrehazardincaseoffuelspillage.
Neverattempttocheckoradjustthebeltswhentheen-
gineisrunning.
Neverlubricatethemachinewiththeenginerunning.
TULI12WEX2009AA5
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