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Case 1021F Service Manual
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Case 1021F Service Manual

Wheel loader
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1021F
1121F
Tier 2
Wheel Loader
SERVICE MANUAL
Part number 47392461
1st edition English
July 2012

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Summary of Contents for Case 1021F

  • Page 1 1021F 1121F Tier 2 Wheel Loader SERVICE MANUAL Part number 47392461 1st edition English July 2012...
  • Page 2 Contents INTRODUCTION Engine..................10 Engine and crankcase ..............10.001 Air cleaners and lines.
  • Page 3 Pilot system................35.357 Main control valve .
  • Page 4 Warning indicators, alarms, and instruments ..........55.408 Loader arm and bucket control system.
  • Page 5 INTRODUCTION 47392461 19/06/2012 Find manuals at https://best-manuals.com...
  • Page 6 Torque ..................3 1021F INT, 1121F INT Capacities .
  • Page 7 INTRODUCTION Torque 1021F INT, 1121F INT Alternator Alternator pulley retaining nut 95 - 109 N·m (70 - 80 lb ft) Battery terminal nut 6 - 8 N·m (55 - 72 lb in) Indicator light terminal nut 2 - 3 N·m (16 - 24 lb in)
  • Page 8 INTRODUCTION Fuel tank Tighten the fuel sender bolts in the sequence as shown in the image (2) to a torque of 6 - 8 N·m (53 - 71 lb in). RCPH11WHL117AAR Fuel sender mounting bolts 6 - 8 N·m (53 - 71 lb in) Fuel tank skid plate bolts (bolts and nuts are to be 122 - 164 N·m (90 - 121 lb ft) torqued only one time.
  • Page 9 INTRODUCTION Wheels Tighten the wheel nuts in two stages. First, tighten the wheel nuts in the sequence as shown in the image (1) to a torque of 278 N·m (205 lb ft). Second, tighten the wheel nuts in the sequence as shown in the image (1) to a torque of 640 - 720 N·m (472 - 531 lb ft).
  • Page 10 INTRODUCTION Capacities 1021F INT, 1121F INT 1021F Capacities and specifications Engine Type of oil CASE A 15W-40 KCELA NGINE OIL Capacity (with filter change) 28.5 l (30.1 US qt) Cooling system System capacity 56.8 l (60.0 US qt) Fuel system System capacity 473.0 l (125.0 US gal)
  • Page 11 INTRODUCTION 1121F Capacities and specifications Engine Type of oil CASE A 15W-40 KCELA NGINE OIL Capacity (with filter change) 28.5 l (30.1 US qt) Cooling system System capacity 56.8 l (60.0 US qt) Fuel system System capacity 473.0 l (125.0 US gal)
  • Page 12 INTRODUCTION Engine oil viscosity/Temperature ranges RCPH11WHL023FAH NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions. Transmission oil viscosity/Temperature ranges RCPH10WHL453BAH 47392461 19/06/2012...
  • Page 13 INTRODUCTION Hydraulic/Brake system - temperature range RCPH10WHL006EAL 47392461 19/06/2012...
  • Page 14 Transmission component oil Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for your climate/temperature conditions such as Case Nexplore or CNH F200A. See charts at the beginning of this section. Grease...
  • Page 15 See charts at the beginning of this section to choose the correct oil for climate/temperatures. If Case Akcela engine oil cannot be obtained, use only oil of the API SERVICE CI-4 category. NOTE: Do not put any Performance Additive or other ad- ditive in the sump.
  • Page 16 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 17 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. (A) When you drain the oil or disconnect any line. (B) When you disassemble a component.
  • Page 18 CONSUMABLES INDEX Consumable PAGE CASE Akcela Engine oil Capacities 15W-40 CASE Akcela HY-TRAN® Capacities Ultra™ hydraulic transmission CASE Akcela NEXPLORE™ Capacities fluid CASE Akcela NEXPLORE™ Capacities fluid CASE Akcela Moly grease Capacities CASE Akcela Engine oil Capacities 15W-40 CASE Akcela HY-TRAN®...
  • Page 19 SERVICE MANUAL Engine 1021F 1121F 47392461 19/06/2012...
  • Page 20 Engine and crankcase ..............10.001 1021F , 1121F Air cleaners and lines.
  • Page 21 CONSUMABLES INDEX Consumable PAGE DOW 732 RTV Silicone clear Engine - Install 10.001 / 19 47392461 19/06/2012...
  • Page 22 47392461 19/06/2012...
  • Page 23 Engine - 10 Engine and crankcase - 001 1021F 1121F 47392461 19/06/2012 10.001 / 1...
  • Page 24 Remove ................. . 5 1021F INT, 1121F INT Install .
  • Page 25 CONSUMABLES INDEX Consumable PAGE DOW 732 RTV Silicone clear Engine - Install 10.001 / 19 47392461 19/06/2012 10.001 / 3...
  • Page 26 Engine - Engine and crankcase Engine - Speeds 1021F \ 1121F 570 - 630 rpm Machine idled (alternate low idle) Machine idled (cold weather alternate accelerated low idle) 1170 - 1230 rpm 47392461 19/06/2012 10.001 / 4...
  • Page 27 Engine - Engine and crankcase Engine - Remove 1021F INT, 1121F INT Prior operation: Engine hood - Remove (90.105) NOTE: Put caps on the fittings and plugs in the hoses to prevent foreign material from entering the system when disconnecting fuel lines or hydraulic hoses.
  • Page 28 Engine - Engine and crankcase Put the master disconnect switch (1) in the off posi- tion. RCPH11WHL094AAH Drain the engine radiator coolant. Drain the engine oil. Loosen the hose clamp (1) on the air intake hose under the air inlet hood. RCPH11WHL053AAR Remove the mounting bolts on the exhaust stack hood.
  • Page 29 Engine - Engine and crankcase Disconnect the deaeration tank overflow hose (2). Remove the P-clamps (1) that secure the overflow hose to the wall and brackets. Position the overflow hose away from the engine and engine wall. RCPH11WHL012AAR Remove the left bracket (1) and right bracket (2). RCPH11WHL012AAR Remove the hydraulic oil lines (1).
  • Page 30 Engine - Engine and crankcase Remove the after air cooler tube (1) . Remove the bulkheads (2). RCPH11WHL014AAR Remove the oil dipstick P-clamp (3) . Pull the oil dipstick tube (1) through the wall. Label and disconnect the hood lift strut electrical con- nector (2).
  • Page 31 Engine - Engine and crankcase Label and disconnect the humidity sensor electrical connector (1). Remove the turbo inlet tube (2). Label and disconnect the air filter restriction sensor electrical connector (3). RCPH11WHL017AAR Remove the wire harness P-clamp (1). Loosen the hose clamp on the air intake hose (2). Disconnect the air intake hose (3).
  • Page 32 Engine - Engine and crankcase Remove the air box assembly. RCPH11WHL019AAR Remove the lower radiator tube (1) . RCPH11WHL021AAR Attach lifting equipment to the engine wall. Remove the engine wall’s hold-down bolts. Lift and remove the engine wall. RCPH11WHL039AAR 47392461 19/06/2012 10.001 / 10...
  • Page 33 Engine - Engine and crankcase Remove the turbo exhaust tube (1). RCPH11WHL022AAR Remove two bolts (2), washers (3), and nuts (4). Re- move the air intake hose (1) . RCPH11WHL023AAR Disconnect the inlet and outlet heater core heater hoses (1). RCPH11WHL038AAR 47392461 19/06/2012 10.001 / 11...
  • Page 34 Engine - Engine and crankcase Disconnect the starter battery cables (1) and starter switch wire (2). RCPH11WHL049AAR Disconnect the following from the crank case venti- lation/fuel filter bracket assembly: Fuel pump electrical connector • Water sensor electrical connector • Ground wire •...
  • Page 35 Engine - Engine and crankcase Disconnect the fuel return line (1). Disconnect the battery positive wire (2) on the air grid heater. RCPH11WHL042AAR Disconnect the engine ground wires (1). Remove the wire harness P-clamp (2). RCPH11WHL043AAR Remove the engine serpentine belt (1). RCPH11WHL051AAR 47392461 19/06/2012 10.001 / 13...
  • Page 36 Engine - Engine and crankcase Label and disconnect the A/C compressor electrical connector (1). Label and disconnect the A/C pressure switch elec- trical connector (4). Remove the alternator power wire. (3). Label and disconnect the bulk electrical connector (5). RCPH11WHL045AAR Remove the A/C compressor (2).
  • Page 37 Remove the hydraulic oil return tube P-clamp (1). Position the hydraulic oil return tube away from the converter housing cover plate. RCPH11WHL050AAR For 1021F models, do procedure A. For 1121F mod- els, do procedure B. Remove the converter housing cover plate (1). See figure 32.
  • Page 38 Engine - Engine and crankcase Remove the flex plate bolts (1). RCPH11WHL035AAR Remove the harmonic balancer (1). RCPH11WHL051AAR Remove the front engine mounts (1) and engine mount plate (2). RCPH11WHL052AAR 47392461 19/06/2012 10.001 / 16...
  • Page 39 Engine - Engine and crankcase Remove the bell housing bolts (1). RCPH11WHL036AAR Remove the engine. RCPH11WHL048AAR 47392461 19/06/2012 10.001 / 17...
  • Page 40 Engine - Engine and crankcase Engine - Install 1021F INT, 1121F INT Carefully lower the engine into the chassis. RCPH11WHL048AAR Install the bell housing bolts (1). Tighten the bell housing bolts (1) to a torque of 54 - 60 N·m (40 - 44 lb ft).
  • Page 41 Install the flex plate bolts (1). Tighten the flex plate bolts (1) to a torque of 33 - 41 N·m (24 - 30 lb ft). RCPH11WHL035AAR For 1021F models, do procedure A. For 1121F mod- els, do procedure B. Apply DOW 732 RTV S...
  • Page 42 Engine - Engine and crankcase Connect the inlet and outlet heater core heater hoses (1). RCPH11WHL038AAR Reposition the hydraulic oil return tube. Install the hydraulic oil return tube P-clamp (1). RCPH11WHL050AAR Install the air box snorkel (1). Install two bolts (2), washers (3), and nuts (4).
  • Page 43 Engine - Engine and crankcase Install the turbo exhaust tube (1). Tighten the turbo muffler clamp (2) to a torque of 5 - 6 N·m (44 - 53 lb in). RCPH11WHL022AAR Remove lifting equipment (1) from the engine. RCPH11WHL048AAR Install the engine wall. RCPH11WHL039AAR 47392461 19/06/2012 10.001 / 21...
  • Page 44 Engine - Engine and crankcase Install the lower radiator tube (1). RCPH11WHL021AAR Install the air box. RCPH11WHL019AAR Install the wire harness P-clamp (1) . Connect the air intake hose (3). Tighten the hose clamp on the air intake hose (2) to a torque of 4 - 5 N·m (35 - 40 lb in).
  • Page 45 Engine - Engine and crankcase Install the lower, right panel (1) on the engine wall. RCPH11WHL020AAR Install the turbo inlet tube (2). Tighten the air intake hose clamp (3) to a torque of 4 - 5 N·m (35 - 40 lb in). Connect the humidity sensor electrical connector (1).
  • Page 46 Engine - Engine and crankcase Install the engine oil drain tube (1). RCPH11WHL047AAR Install the wire harness P-clamps (1). RCPH11WHL046AAR Install the engine serpentine belt (1). RCPH11WHL051AAR 47392461 19/06/2012 10.001 / 24...
  • Page 47 Engine - Engine and crankcase Install the A/C compressor (2). Connect the A/C compressor electrical connector (1). Connect the A/C pressure switch electrical connector (4). Connect the alternator power wire (3). Tighten the nut to a torque of 6 - 8 N·m (55 - 70 lb in). Connect the bulk electrical connector (5).
  • Page 48 Engine - Engine and crankcase Connect the engine control module electrical con- nector (1). RCPH11WHL041AAR Install the crank case ventilation/fuel filter bracket as- sembly. Connect the following on the crank case ventilation/ fuel filter bracket assembly: Fuel pump electrical connector •...
  • Page 49 Engine - Engine and crankcase Connect the hood lift strut electrical connector (2). Slip the oil dipstick tube (1) through the engine wall. Install the dipstick tube P-clamp (3). RCPH11WHL015AAR Install the bulkheads (2). Install the after air cooler tube (1). RCPH11WHL014AAR Install the hydraulic lines (1).
  • Page 50 Engine - Engine and crankcase Install the left bracket (1) and right bracket (2). RCPH11WHL012AAR Install the P-clamps (2) and overflow tube (1) to the engine wall, left bracket, and deaeration tank (3). RCPH11WHL012AAR Install the muffler assembly. Lower the exhaust stack hood (1) in front of the en- gine wall and onto the left bracket, right bracket, and hydraulic oil tank.
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