Case 821G Service Manual
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Case 821G Service Manual

Wheel loader
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821G
921G
Stage IV
Wheel Loader
SERVICE MANUAL
Part number 51428216
English
November 2017
© 2017 CNH Industrial Italia S.p.A. All Rights Reserved.

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  • Page 1 821G 921G Stage IV Wheel Loader SERVICE MANUAL Part number 51428216 English November 2017 © 2017 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL 821G WHEEL LOADER XR-EH, NEW CAB TIER4B, 821G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B, 821G Wheel Loader XR-EH, New cab, Tier 4B, Multipurpose, 821G Wheel Loader ZBAR-EH, New cab, Tier 4B, Multipurpose, 921G WHEEL LOADER XR-EH, NEW CAB TIER4B, 921G WHEEL LOADER...
  • Page 3 821G Wheel Loader ZBAR-EH, Europe F4HFE613S*B004 New cab, Tier 4B, Multipurpose 821G WHEEL LOADER XR-EH, Europe F4HFE613S*B004 NEW CAB TIER4B 821G Wheel Loader XR-EH, New Europe F4HFE613S*B004 cab, Tier 4B, Multipurpose 921G WHEEL LOADER ZBAR-EH, Europe F4HFE613R*B006 NEW CAB TIER4B...
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
  • Page 5 [33.110] Parking brake or parking lock ............33.2 Hydraulic systems...............
  • Page 6 [55.302] Battery................55.4 [55.988] Selective Catalytic Reduction (SCR) electrical system .
  • Page 7 51428216_EN 14/12/2017 Find manuals at https://best-manuals.com...
  • Page 8 INTRODUCTION 51428216_EN 14/12/2017 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Safety rules ..................3 Personal safety .
  • Page 10 INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.
  • Page 11 INTRODUCTION Personal safety Carefully read this Manual before proceeding with main- tenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and in- structed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy ham- mers.
  • Page 12 Keep the exhaust manifold and tube free from combustible materials. Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage. Never attempt to check or adjust the belts when the en- gine is running.
  • Page 13 INTRODUCTION Pay attention to rotating components and do not allow anyone to approach these areas to avoid becoming en- tangled. Hands, clothing or tools getting caught in the fan blades or engine belts, can cause amputations, violent hemorrages and generate conditions of grave danger. For this reason avoid touching or approaching all rotating or moving parts.
  • Page 14 INTRODUCTION When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital. If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid penetrating the skin must be removed within a few hours to avoid serious infections.
  • Page 15 INTRODUCTION Hoses and tubes Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the correct position be- fore tightening the connections.
  • Page 16 INTRODUCTION Battery Batteries give off explosive gases. Never handle open flames and unshielded light sources near batteries. (No smoking is addressed in the next in- struction). To prevent any risk of explosion, observe the following instructions: • When disconnecting the battery cables, always discon- nect the negative (-) cable first.
  • Page 17 INTRODUCTION Flammable liquids When handling flammable liquids: • Do not smoke. • Keep away from unshielded light sources and open flames. Fuels often have a low flash point and are readily ignited. Never attempt to extinguish burning liquids with water. Use: •...

  • Page 18: Personal Safety

    INTRODUCTION Tires Before inflating the tires, always check the condition of rims and the outer condition of tires for the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tire, make sure that there are no nearby persons, then position yourself at tread side.
  • Page 19 INTRODUCTION Waste disposal Improperly disposing of waste can threaten the environ- ment. Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

  • Page 20: Basic Instructions - Important Notice Regarding Equipment Servicing

    In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

  • Page 21: Basic Instructions - How To Use The Maintenance Standard And Precautions

    INTRODUCTION Basic instructions - How to use the maintenance standard and precautions Application WHEN THE MACHINE IS NEW Confirm that the performances are in accordance with standard specifications as compared to the performance stan- dards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY) Use the data for the criterion, for the purpose of correction, adjustment and replacement.
  • Page 22 INTRODUCTION PARTS REQUIRING REGULAR REPLACEMENT Critical hoses that are necessary to secure safety, we designate as Very Important Parts (V.I.P.) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize themselves with the machine and handle safely. Use caution when inspecting and replacing oils and grease.

  • Page 23: Basic Instructions - Precaution For Disassembly And Assembly

    • Confirm ready access to a first-aid kit and fire extinguisher, as well as appropriate emergency personnel contacts in the case of a medical accident or fire. • Before performing any work on the machine, follow lockout/tagout procedures by attaching a “maintenance in progress tag”.
  • Page 24 INTRODUCTION Reassembling hydraulic equipment • Clean parts in a well ventilated room. • Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly. • Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling. •...

  • Page 25: Basic Instructions - Electrical Equipment Precautions

    INTRODUCTION Basic instructions - Electrical equipment precautions WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. An- tidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk.

  • Page 26: Consumables

    Capacity (with filter change) 13.25 l (14.0 US qt) Total capacity in system 15.1 l (16 US qt) Cooling system Type of coolant CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT CASE CONSTRUCTION specifications MAT3624 System capacity 30.0 l (32.0 US qt)
  • Page 27 INTRODUCTION level in the tank reaches the bottom of the fill neck. Adequate air volume must be present in the top of the tank for proper functionality of the after treatment system. 51428216_EN 14/12/2017...
  • Page 28 INTRODUCTION 921G Capacities and Engine Type of oil AMBRA UNITEK 10W-40/AKCELA UNITEK 10W-40 Technical SAE 10W-40 API CJ-4 [Brand] MAT3521 Type of oil AMBRA UNITEK SSL 0W-40/AKCELA UNITEK SSL 0W-40 (cold weather) Technical SAE 0W-40 API CJ-4 [Brand] MAT3521 Capacity (with change) 13.25 l (14.0 US qt) Total capacity in system...

  • Page 29: Consumables - Biodiesel Fuel

    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 30: Hydraulic Contamination

    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: • When you drain the oil or disconnect any line •...

  • Page 31: Product Identification

    INTRODUCTION Product identification The terms right-hand, left-hand, front, and rear are used in this manual to indicate the sides as they are seen from the operator's seat. 1. Front 2. Right-hand 3. Rear 4. Left-hand RCPH10WHL003BAH 51428216_EN 14/12/2017...
  • Page 32 INTRODUCTION Product identification LEIL17WHL1703FB 1. Roll Over Protection System (ROPS) cab 5. Steps 2. Cab door handle 6. Bucket 3. Timed disconnect switch and optional battery jump post 7. Loader lift arms 4. Battery access 8. Bucket cylinder 51428216_EN 14/12/2017...
  • Page 33 INTRODUCTION LEIL17WHL1701FB 1. Pre-cleaner 6. Cab air filter door 2. Sliding access panel 7. Windshield washer reservoir 3. Cab side window 8. Diesel Exhaust Fluid (DEF)/AdBlue® fill tank 4. Driving lights 9. Tool box 5. Handrail 51428216_EN 14/12/2017...
  • Page 34 INTRODUCTION Waste Handler (WH) models LEIL17WHL2018FB 1. Windshield guard 6. Transmission guard 2. Driving light guard 7. Fuel tank guard 3. Chassis side cover 8. Front chassis guard 4. Front articulation joint cover 9. Upper articulation cover 5. Rear articulation joint cover 51428216_EN 14/12/2017...
  • Page 35 INTRODUCTION LEIL17WHL2017FB 1. Windshield guard 6. Transmission guard 2. Driving light guard 7. Fuel tank guard 3. Chassis side cover 8. Front chassis guard 4. Front articulation joint cover 9. Upper articulation cover 5. Rear articulation joint cover 51428216_EN 14/12/2017...
  • Page 36 Engine 821G WHEEL LOADER XR-EH, NEW CAB TIER4B, 821G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B, 821G Wheel Loader XR-EH, New cab, Tier 4B, Multipurpose, 821G Wheel Loader ZBAR-EH, New cab, Tier 4B, Multipurpose, 921G WHEEL LOADER XR-EH, NEW CAB TIER4B, 921G WHEEL LOADER...
  • Page 37 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.216] Fuel tanks .
  • Page 38 Engine and crankcase - 001 821G WHEEL LOADER XR-EH, NEW CAB TIER4B, 821G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B, 821G Wheel Loader XR-EH, New cab, Tier 4B, Multipurpose, 821G Wheel Loader ZBAR-EH, New cab, Tier 4B, Multipurpose, 921G WHEEL LOADER XR-EH, NEW CAB TIER4B, 921G WHEEL LOADER...
  • Page 39 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine General specification (*) ..............3 General specification (*) .
  • Page 40 Engine - General specification 821G WHEEL LOADER XR-EH, NEW CAB TIER4B 821G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B 821G Wheel Loader XR-EH, New cab, Tier 4B, Multipurpose 821G Wheel Loader ZBAR-EH, New cab, Tier 4B, Multipurpose Engine with 4 Speed Transmission A.
  • Page 41 Engine - Engine horse power 821G WHEEL LOADER XR-EH, NEW CAB TIER4B 821G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B 821G Wheel Loader XR-EH, New cab, Tier 4B, Multipurpose 821G Wheel Loader ZBAR-EH, New cab, Tier 4B, Multipurpose Design characteristics Displacement 6728 cm³...
  • Page 42 Engine - Engine and crankcase LEIL17WHL0358GA NOTE: performances detected at engine test bench. NOTE: BSFC indicates the Brake Specific Fuel Consumption. Engine - Engine horse power 921G WHEEL LOADER XR-EH, NEW CAB TIER4B 921G WHEEL LOADER ZBAR-EH, NEW CAB TIER4B 921G Wheel Loader XR-EH, New cab, Tier 4B, Multipurpose 921G Wheel Loader ZBAR-EH, New cab, Tier 4B, Multipurpose Design characteristics...
  • Page 43 Engine - Engine and crankcase Performance Altitude Capability 3000 m (9842.5 ft) 2175 RPM High Idle Speed Low Idle Speed 700 RPM Rated Power 183 kW at 2000 RPM Peak Torque 1300 kW at 1300 RPM LEIL17WHL0359GA NOTE: performances detected at engine test bench. NOTE: BSFC indicates the Brake Specific Fuel Consumption.
  • Page 44 Engine - Engine and crankcase Engine - Remove NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen- erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors.
  • Page 45 Engine - Engine and crankcase 4. Raise the grill located above the cooler box just behind the cab. Then slowly loosen the hydraulic reservoir filler cap to release pressure in the reservoir. RCPH10WHL099BAL 5. Locate the timed disconnect switch and the hood raise switch in the battery box.
  • Page 46 Engine - Engine and crankcase 8. Place a suitable container below the radiator drain plug, remove the radiator cap and the radiator drain plug (see the arrow in figure) to drain the engine coolant. Then reinstall the radiator drain plug and the radiator cap after coolant has drained.
  • Page 47 Engine - Engine and crankcase 12. Place a solid steel bar or pipe through the strap loop inside the engine hood and attach the strap to a suit- able lifting device. Raise the engine hood with the strap to release ten- sion on the lifting motor.
  • Page 48 Engine - Engine and crankcase 16. Tag and disconnect the engine hood wiring harness connector (1) from the rear chassis wiring harness connector. Remove the engine hood wire harness clamp (2) from the fan guard. LEIL13WHL0150AB 17. Have another person to balance the hood and LOOSEN the hood hinge mounting bolts (see the arrows in figure) from the cooler frame.
  • Page 49 Engine - Engine and crankcase 19. Put the timed disconnect switch (1) in OFF position. Remove the battery cover and disconnect ground lead from the batteries (2). RAPH12WEL0608AA 20. Have another person to balance the hood and remove the hood hinge mounting bolts (see the arrows in fig- ure) from the cooler frame.
  • Page 50 Engine - Engine and crankcase 23. Tag and disconnect the engine wiring harness con- nector from the air inlet humidity sensor (1). LEIL13WHL0143AB 24. Loosen the clamp (1) on the crankcase ventilation hose (2) and disconnect the hose. LEIL13WHL0144AB 25. Loosen the clamps on the turbocharger and air filter housing.
  • Page 51 Engine - Engine and crankcase 27. Loosen the clamp on the hose at the after cooler inlet and remove the tube. LEIL13WHL0147AB 28. Loosen the clamp on the air inlet hose at the air filter housing. LEIL13WHL0148AB 29. Loosen the clamp (1) on the air inlet hose (2) at the exhaust support bracket.
  • Page 52 Engine - Engine and crankcase 31. Remove the four mounting bolts from the belt cover. Then remove the cover. NOTE: after removing the belt cover, remove the cover mounting bracket from the left rear side of machine frame. LEIL16WHL0566AB 32. Remove the drive belt from the engine. LEIL13WHL0155AB 33.
  • Page 53 Engine - Engine and crankcase 35. Remove the return line of the SCR coolant. LEIL16WHL0568AB 36. Tag and remove the wires from the starter solenoid (1), the ground cable (2), and ground strap (3) from the starter. NOTE: move the starter cables away from the engine. LEIL16WHL0569AB 37.
  • Page 54 Engine - Engine and crankcase 39. If the machine is so equipped, unplug the engine block heater and set it aside. LEIL15WHL0016AB 40. Loosen the clamp (see the arrow in figure) and dis- connect the pipe. LEIL15WHL0015AB 41. Loosen the clamps and remove the lower coolant hose from the engine.
  • Page 55 Engine - Engine and crankcase 43. Remove the return radiator hose (1) and the engine coolant vent hose from the top of the radiator. LEIL13WHL0141AB 44. Remove the overflow tank of the engine coolant. LEIL16WHL0574AB 45. Remove the bracket of the overflow tank. LEIL16WHL0575AB 46.
  • Page 56 Engine - Engine and crankcase 47. Loosen the clamp (1) on the intake manifold for the output hose of the after cooler. Loosen the clamp (2) from the body of the DEF/A ® tank vent filter. LEIL13WHL0613AA 48. Loosen the clamp on the after cooler, and remove the output hose of the after cooler from the machine.
  • Page 57 Engine - Engine and crankcase 51. Remove wire harness support clamp. LEIL16WHL0490AB 52. Remove the P-clamp and cut the cable ties by the sup- ply module. Disconnect the end of the jumper harness (near the supply module) from the Diesel Oxidation Catalyst (DOC) support.
  • Page 58 Engine - Engine and crankcase 55. Tag and disconnect the wire harness of the tempera- ture sensor (1) for the Selective Catalytic Reduction muffler (SCR) and cut the connector wire clamps. Loosen the screws and remove the bar (2). LEIL14WHL0407AB 56.
  • Page 59 Engine - Engine and crankcase 59. Remove the DEF/A ® storage tank cover lo- cated on the right-hand side of the machine. LEIL13WHL0170AB 60. Tag and disconnect the wire harness and DEF/ ® supply return lines from DEF/A ® storage tank. Install a protective cap in the supply lines.
  • Page 60 Engine - Engine and crankcase 63. Disconnect the main connector of the supply module. LEIL13WHL0171AB 64. Attach suitable lifting straps to the support structure (1) of the Diesel Oxidation Catalyst (DOC). The sup- ply module and the coolant control valve are also at- tached to this support structure.
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