Case 821E User manual
SERVICE MANUAL
WHEEL LOADER
821E
TIER 3
84299244
(Replaces 87364100)
Revised December 2009
Issued September 2006
Copyright © 2006 CNH Ameica LLC.
All rights reserved.
Printed in U.S.A.
Issued August, 2006
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A. Bur 5-3090
SECTION INDEX
GENERAL
Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Section Title Section Number
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1001-2
Bur 8-71603 Revised 7-05 Printed in U.S.A.
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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1001-3
Bur 8-71603 Revised 7-05 Printed in U.S.A.
TORQUE SPECIFICATIONS - DECIMAL HARDWARE
Use the torques in this chart when special torques
are not given. These torques apply to fasteners with
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
used.
Grade 5 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
1/4 inch 108 to 132 12 to 15
5/16 inch 204 to 252 23 to 28
3/8 inch 420 to 504 48 to 57
Size
Pound-
Feet
Newton
metres
7/16 inch 54 to 64 73 to 87
1/2 inch 80 to 96 109 to 130
9/16 inch 110 to 132 149 to 179
5/8 inch 150 to 180 203 to 244
3/4 inch 270 to 324 366 to 439
7/8 inch 400 to 480 542 to 651
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983
Grade 8 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
1/4 inch 144 to 180 16 to 20
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Size
Pound-
Feet
Newton
metres
7/16 inch 70 to 84 95 to 114
1/2 inch 110 to 132 149 to 179
9/16 inch 160 to 192 217 to 260
5/8 inch 220 to 264 298 to 358
3/4 inch 380 to 456 515 to 618
7/8 inch 600 to 720 814 to 976
1.0 inch 900 to 1080 1220 to 1465
1-1/8 inch 1280 to 1440 1736 to 1953
1-1/4 inch 1820 to 2000 2468 to 2712
1-3/8 inch 2380 to 2720 3227 to 3688
1-1/2 inch 3160 to 3560 4285 to 4827
NOTE: Use thick nuts with Grade 8 bolts.
1001-4
Bur 8-71603 Revised 7-05 Printed in U.S.A.
TORQUE SPECIFICATIONS - METRIC HARDWARE
Use the following torques when specifications are not
given.
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is
used.
Grade 12.9 Bolts, Nuts, and Studs
Usually the torque values specified for grade 10.9
fasteners can be used satisfactorily on grade 12.9
fasteners.
Grade 8.8 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
M4 24 to 36 3 to 4
M5 60 to 72 7 to 8
M6 96 to 108 11 to 12
M8 228 to 276 26 to 31
M10 456 to 540 52 to 61
Size
Pound-
Feet
Newton
metres
M12 66 to 79 90 to 107
M14 106 to 127 144 to 172
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
M36 1600 to 1950 2175 to 2600
8.8
Grade 10.9 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
M4 36 to 48 4 to 5
M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
M8 324 to 384 37 to 43
Size
Pound-
Feet
Newton
metres
M10 54 to 64 73 to 87
M12 93 to 112 125 to 150
M14 149 to 179 200 to 245
M16 230 to 280 310 to 380
M20 450 to 540 610 to 730
M24 780 to 940 1050 to 1275
M30 1470 to 1770 2000 to 2400
M36 2580 to 3090 3500 to 4200
10.9
12.9
1001-5
Bur 8-71603 Revised 7-05 Printed in U.S.A.
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting
Tube OD
Hose ID
Thread
Size
Pound-
Inches
Newton
metres
1/4 inch
6.4 mm
7/16-20 72 to 144 8 to 16
5/16 inch
7.9 mm
1/2-20 96 to 192 11 to 22
3/8 inch
9.5 mm
9/16-18 120 to 300 14 to 34
1/2 inch
12.7 mm
3/4-16 180 to 504 20 to 57
5/8 inch
15.9 mm
7/8-14 300 to 696 34 to 79
Tube OD
Hose ID
Thread
Size
Pound-
Feet
Newton
metres
3/4 inch
19.0 mm
1-1/16-12 40 to 80 54 to 108
7/8 inch
22.2 mm
1-3/16-12 60 to 100 81 to 135
1.0 inch
25.4 mm
1-5/16-12 75 to 117 102 to 158
1-1/4 inch
31.8 mm
1-5/8-12 125 to 165 169 to 223
1-1/2 inch
38.1 mm
1-7/8-12 210 to 250 285 to 338
Split Flange Mounting Bolts
Size
Pound-
Inches
Newton
metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Size
Pound-
Feet
Newton
metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
Straight Threads with O-ring
Tube OD
Hose ID
Thread
Size
Pound-
Inches
Newton
metres
1/4 inch
6.4 mm
7/16-20 144 to 228 16 to 26
5/16 inch
7.9 mm
1/2-20 192 to 300 22 to 34
3/8 inch
9.5 mm
9/16-18 300 to 480 34 to 54
1/2 inch
12.7 mm
3/4-16 540 to 804 57 to 91
Tube OD
Hose ID
Thread
Size
Pound-
Feet
Newton
metres
5/8 inch
15.9 mm
7/8-14 58 to 92 79 to 124
3/4 inch
19.0 mm
1-1/16-12 80 to 128 108 to 174
7/8 inch
22.2 mm
1-3/16-12 100 to 160 136 to 216
1.0 inch
25.4 mm
1-5/16-12 117 to 187 159 to 253
1-1/4 inch
31.8 mm
1-5/8-12 165 to 264 224 to 357
1-1/2 inch
38.1 mm
1-7/8-12 250 to 400 339 to 542
1001-6
Bur 8-71603 Revised 7-05 Printed in U.S.A.
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Face Seal End
O-ring Boss End
Fitting or Lock Nut
Nom.
SAE
Dash
Size Tube OD
Thread
Size
Pound-
Inches
Newton
metres
Thread
Size
Pound-
Inches
Newton
metres
-4 1/4 inch
6.4 mm
9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
-6 3/8 inch
9.5 mm
11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
-8 1/2 inch
12.7 mm
13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
Thread
Size
Pound-
Feet
Newton
metres
-10 5/8 inch
15.9 mm
1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
Nom.
SAE
Dash
Size Tube OD
Thread
Size
Pound-
Feet
Newton
metres
1-1/16-12 85 to 90 115 to 122
1-3/16-12 95 to 100 129 to 136
-12 3/4 inch
19.0 mm
1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
-14 7/8 inch
22.2 mm
1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
-16 1.0 inch
25.4 mm
1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
-20 1-1/4 inch
31.8 mm
1-11/16-12 125 to 140 170 to 190
-24 1-1/2 inch
38.1 mm
2-12 150 to 180 200 to 254
Section
1002
1002
Copyright © 2006 CNH Ameica LLC.
All rights reserved.
Printed in U.S.A.
Issued August, 2006
CNH America LLC.
700 State Street
Racine, WI 53404 U.S.A. Bur 5-3100
FLUIDS AND LUBRICANTS
1002-2
Bur 5-3100 Issued 8-06 Printed in U.S.A.
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1002-3
Bur 5-3100 Issued 8-06 Printed in U.S.A.
CAPACITIES AND LUBRICANTS
Engine Oil
Capacity with Filter Change ............................................................................................ 21 liters (22 U.S. quarts)
Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity...................................................................................................................40.9 liters (10.8 U.S. Gallons)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
Hydraulic System
Hydraulic Reservoir Refill Capacity.............................................................................90 liters (23.8 U.S. Gallons)
Total System Capacity............................................................................................... 176 liters (46.5 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ............................................................................39.7 litres (10.5 U.S. Gallons)
Type of Oil ................................................................................................................ Case AKCELA No. 1 15W-40
Axles
Capacity
Front...................................................................................................................... 37.4 litres (39.5 U.S. Quarts)
Rear ......................................................................................................................... 23.7 litres (25 U.S. Quarts)
Type of Lubricant .................................................................................................... Case AKCELA Transaxle Fluid
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System)................................................................Case AKCELA Hy-Tran Ultra®
1002-4
Bur 5-3100 Issued 8-06 Printed in U.S.A.
ENGINE OIL RECOMMENDATIONS
Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CH-4 (preferred) or CG-4.
See the chart below for
recommended viscosity at
ambient air temperature
ranges.
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
intervals given in this manual
are according to tests with Case
AKCELA lubricants.
BD03A102
BC02N250
RH99K130
1002-5
Bur 5-3100 Issued 8-06 Printed in U.S.A.
TRANSMISSION TEMPERATURE CHART
BC04F193
DIESEL FUEL SYSTEM
Use No. 2 diesel fuel in the engine of this machine.
The use of other fuels can cause the loss of engine
power and high fuel consumption.
In very cold temperatures, a mixture of No. 1 and No.
2 diesel fuels is temporarily permitted. See the
following Note.
NOTE: See your fuel dealer for winter fuel
requirements in your area. If the temperature of the
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel
filter and cause the engine to lose power or not start.
The diesel fuel used in this machine must meet the
specifications as shown below in, “Specifications for
Acceptable No. 2 Diesel Fuel”, or “Specification
D975-81” of the American Society for Testing and
Materials.
Fuel Storage
If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
tank. Many engine problems are caused by water in
the fuel.
Keep the fuel storage tank outside and keep the fuel
as cool as possible. Remove water from the storage
container at regular periods of time.
Fill the fuel tank at the end of the daily operating
period to prevent condensation in the fuel tank.
Specifications for Acceptable No. 2 Diesel Fuel
API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%
1002-6
Bur 5-3100 Issued 8-06 Printed in U.S.A.
MAINTENANCE SCHEDULE
Model 821E
SERVICE
INTERVAL
ITEM
NUMBER
SERVICE POINTS
Initial Service
FREQUENCY IN HOURS
CHECK
CLEAN
CHANGE
DRAIN
LUBRICATE
REPLACE
ADJUST
Variable
Periodic
(*)
13 Radiator Coolant Level *
14 Tires *
19 Hydraulic Filter *
22 Alternator, AC, Drive Belt *
29 Air cleaner **
XX Fire extinguisher *
Every 10 Hours 1 Check Engine Oil Level 10
Every 50 Hours
2 Check Engine Coolant Level 50
3 Check Transmission Oil Level 50
4 Check Hydraulic Oil Level 50
5 & 6 Grease Bucket Mounting Fittings 50
18 Bleed Fuel Filter of Condensation 50
First 100 Hours
17 Change Engine Oil and Filters 100
18 & 26 Replace Fuel Filters 100
19 Change Hydraulic Filter 100
21 Change Oil in Axles 100
Every 100 Hours
8Lubricate The Steering Cylinder Pivots - Rod And
Closed End (4 Fittings) 100
9 Grease Front Drive Shaft Support Bearing 100
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
11 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
Every 250
Hours
12 & 23 Check Cab Air Filter 250
13 Check Radiator Coolant Level 250
14 Check Tire Pressure & Wheel Torque 4 250
22 Check Drive Belt 250
XX Trans Clutch Calibration (See Section 6002) 250 1000
Every 500
Hours
15 Check Axle Oil Level 500
16 Check Battery Electrolyte Level 500
17 Change Engine Oil and Filter 500
17 Change Crankcase Filter 500
18 Drain Fuel Tank Condensation & Water Separator 500
26 Replace Fuel Filter 500
Every 1000
Hours
19 Replace Hydraulic Oil filter 1000
20 Grease Articulation Fittings 1000
21 Change Front & Rear Axle Oil 1000
22 Replace Drive Belt 1000
23 Replace Cab Air Filter 1000
25 Change Transmission Oil and Filter 1000
XX Check Injector Calibration 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 1000
Every 2000
Hours
27 Change Hydraulic Oil 2000
28 Change Coolant 2000
29 Replace Engine Air Cleaner 2000
XX Valve Clearance (Engine Manual) 2000
Every 6000
hours
XX Engine Injectors (Engine Manual) 6000
XX Fuel Pump (Engine Manual) 6000 6000
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