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Contents

INTRODUCTION

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1021F INT, 1121F INT

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1021F INT, 1121F INT

Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

47392461 19/06/2012

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Summary of Contents for 1021F

Page 1: ...right 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 ...

Page 2: ...nal components 21 155 Four Wheel Drive 4WD system 23 Drive shaft 23 314 Front axle system 25 Powered front axle 25 100 Front bevel gear set and differential 25 102 Final drive hub steering knuckles and shafts 25 108 Rear axle system 27 Powered rear axle 27 100 Brakes and controls 33 Parking brake Parking lock 33 110 Hydraulic service brakes 33 202 Hydraulic systems 35 Hydraulic systems 35 000 Vari...

Page 3: ...tem 55 015 Transmission control system 55 024 Service brake electrical system 55 030 Parking brake electrical system 55 031 Hydraulic system control 55 036 Steering control system 55 047 Heating Ventilation and Air Conditioning HVAC control system 55 050 Cab Heating Ventilation and Air Conditioning HVAC controls 55 051 Harnesses and connectors 55 100 Engine starting system 55 201 Cold start aid 55...

Page 4: ... Cab lighting 55 514 Wiper Washer system 55 518 Cab brake controls 55 519 Cab controls Lift arm Boom Dipper Bucket 55 524 FAULT CODES 55 DTC Platform cab bodywork and decals 90 Machine shields and guards 90 105 Protections and footboards 90 118 Pneumatically adjusted operator seat 90 124 Cab 90 150 47392461 19 06 2012 Find manuals at https best manuals com ...

Page 5: ...INTRODUCTION 47392461 19 06 2012 1 Find manuals at https best manuals com ...

Page 6: ...Contents INTRODUCTION Torque 3 1021F INT 1121F INT Capacities 6 1021F INT 1121F INT Consumables Biodiesel Fuel 12 Hydraulic contamination 13 47392461 19 06 2012 2 Find manuals at https best manuals com ...

Page 7: ...b ft Counterweight mounting bolts 1125 1261 N m 830 930 lb ft Lower step support bolts 27 31 N m 20 23 lb ft Battery hold down bolts 651 732 N m 480 540 lb ft Cooling Cooling frame mounting 271 298 N m 200 220 lb ft Fan mounting nut 109 122 N m 80 90 lb ft Drivetrain Flex plate to flywheel bolts 33 41 N m 24 30 lb ft Carrier bearing bolt 149 163 N m 110 120 lb ft Drive line mounting bolts 136 149 ...

Page 8: ... ft Hydraulics Priority valve mounting bolts 85 102 N m 63 75 lb ft Main hydraulic pump elbow 85 102 N m 63 75 lb ft Hydraulic tank sight gauge mounting 3 6 N m 27 53 lb in Surge tank hose clamp mounting 48 N m 35 lb ft Brake pump mounting bolts 149 170 N m 110 125 lb ft Hydraulic oil tank suction hose clamps 10 11 N m 90 100 lb in Split half clamp flange bolts hydraulic tank to pumps and priority...

Page 9: ... 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 RCPH11WHL202AAH 2 Wheel nuts First stage 278 N m 205 lb ft Second stage 640 720 N m 472 531 lb ft 47392461 19 06 2012 5 Find manuals at https best manuals com ...

Page 10: ... Reservoir capacity 134 0 l 35 4 US gal Transmission Type of oil CASE AKCELA NEXPLORE FLUID Service capacity with filter change 45 4 l 48 0 US qt Axles Type of oil CASE AKCELA NEXPLORE FLUID Front axle 42 0 l 44 4 US qt Rear axle 42 0 l 44 4 US qt Front axle with axle cooler 45 7 l 48 3 US qt Rear axle with axle cooler 45 7 l 48 3 US qt Heavy duty front axle 62 0 l 65 5 US qt Heavy duty front axle...

Page 11: ... capacity 134 0 l 35 4 US gal Transmission Type of oil CASE AKCELA NEXPLORE FLUID Service capacity with filter change 45 4 l 48 0 US qt Axles Type of oil CASE AKCELA NEXPLORE FLUID Front axle 64 0 l 67 6 US qt Rear axle 64 0 l 67 6 US qt Front axle with axle cooler 67 7 l 71 5 US qt Rear axle with axle cooler 67 7 l 71 5 US qt Front axle with differential lock 62 0 l 65 5 US qt Front axle with dif...

Page 12: ...ges RCPH11WHL023FAH 1 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 2 47392461 19 06 2012 8 ...

Page 13: ...INTRODUCTION Hydraulic Brake system temperature range RCPH10WHL006EAL 3 47392461 19 06 2012 9 ...

Page 14: ...l cloud point point at which wax begins to form the wax crystals will cause power loss or will prevent the engine from starting In cold weather fill the fuel tank at the end of the day s work in order to prevent the formation of condensation Fuel storage Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel Engine trouble can often be traced to the prese...

Page 15: ...ginning 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 Oil change intervals shown in this man ual are based on tests carried out utilizing Case lubricants RCPH10WHL012AAD 4 47392461 19 06 2012 11 ...

Page 16: ...rs and may cause shortened filter life or filter blockages Blockages are more common in cold weather conditions Consult your dealer for information on cold weather operation and proper maintenance intervals when using any biodiesel fuel blend Biodiesel fuel may degrade natural rubber gaskets and hoses as it is more solvent than petro diesel Frequently inspect hoses and other engine components when...

Page 17: ...wear rapidly F Relief valves or check valves held open by dirt G Quick failure of components that have been repaired H Cycle times are slow machine does not have enough power If your machine has any of these problems check the hydraulic oil for contamination There are two types of contam ination microscopic and visible Microscopic contamination occurs when very fine particles of foreign material a...

Page 18: ...la NEXPLORE fluid Capacities 6 CASE Akcela NEXPLORE fluid Capacities 6 CASE Akcela Moly grease Capacities 6 CASE Akcela Engine oil 15W 40 Capacities 7 CASE Akcela HY TRAN Ultra hydraulic transmission oil Capacities 7 CASE Akcela NEXPLORE fluid Capacities 7 CASE Akcela NEXPLORE fluid Capacities 7 CASE Akcela Moly grease Capacities 7 47392461 19 06 2012 14 ...

Page 19: ...SERVICE MANUAL Engine 1021F 1121F 47392461 19 06 2012 10 ...

Page 20: ... 10 Engine and crankcase 10 001 1021F 1121F Air cleaners and lines 10 202 1021F 1121F Engine lubrication system 10 304 1021F 1121F Aftercooler 10 310 1021F 1121F Fan and drive 10 414 1021F 1121F 47392461 19 06 2012 10 ...

Page 21: ...CONSUMABLES INDEX Consumable IU PAGE DOW 732 RTV Silicone clear Engine Install 10 001 19 47392461 19 06 2012 10 ...

Page 22: ...47392461 19 06 2012 10 ...

Page 23: ...Engine 10 Engine and crankcase 001 1021F 1121F 47392461 19 06 2012 10 001 1 ...

Page 24: ...Contents Engine 10 Engine and crankcase 001 TECHNICAL DATA Engine Speeds 4 SERVICE Engine Remove 5 1021F INT 1121F INT Install 18 1021F INT 1121F INT 47392461 19 06 2012 10 001 2 ...

Page 25: ...CONSUMABLES INDEX Consumable IU 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 Machine idled alternate low idle 570 630 rpm Machine idled cold weather alternate accelerated low idle 1170 1230 rpm 47392461 19 06 2012 10 001 4 ...

Page 27: ...he pilot control switch 1 in the normal operation position RCPH10WHL982FAH 2 3 Move the loader hydraulic control handle to the raise and lower position in order to release any hydraulic pressure in the lift circuit 4 Move the loader control handle in and out of the tilt position several times this will relieve any pressure in the pilot accumulator 5 Release the pressure in the ride control accumul...

Page 28: ...oolant 10 Drain the engine oil 11 Loosen the hose clamp 1 on the air intake hose under the air inlet hood RCPH11WHL053AAR 4 12 Remove the mounting bolts on the exhaust stack hood Attach lifting equipment to the exhaust stack Remove the exhaust stack hood 1 RCPH11WHL010AAR 5 13 Remove the muffler assembly 47392461 19 06 2012 10 001 6 ...

Page 29: ...clamps 1 that secure the overflow hose to the wall and brackets Position the overflow hose away from the engine and engine wall RCPH11WHL012AAR 6 16 Remove the left bracket 1 and right bracket 2 RCPH11WHL012AAR 7 17 Remove the hydraulic oil lines 1 RCPH11WHL013AAR 8 47392461 19 06 2012 10 001 7 ...

Page 30: ...L014AAR 9 20 Remove the oil dipstick P clamp 3 Pull the oil dipstick tube 1 through the wall 21 Label and disconnect the hood lift strut electrical con nector 2 RCPH11WHL015AAR 10 22 Remove the before air cooler tube 1 23 Remove the upper radiator tube 2 RCPH11WHL016AAR 11 47392461 19 06 2012 10 001 8 ...

Page 31: ...bel and disconnect the air filter restriction sensor electrical connector 3 RCPH11WHL017AAR 12 27 Remove the wire harness P clamp 1 28 Loosen the hose clamp on the air intake hose 2 Disconnect the air intake hose 3 RCPH11WHL018AAR 13 29 Remove the lower right panel 1 on the engine wall RCPH11WHL020AAR 14 47392461 19 06 2012 10 001 9 ...

Page 32: ...assembly RCPH11WHL019AAR 15 31 Remove the lower radiator tube 1 RCPH11WHL021AAR 16 32 Attach lifting equipment to the engine wall Remove the engine wall s hold down bolts Lift and remove the engine wall RCPH11WHL039AAR 17 47392461 19 06 2012 10 001 10 ...

Page 33: ... turbo exhaust tube 1 RCPH11WHL022AAR 18 34 Remove two bolts 2 washers 3 and nuts 4 Re move the air intake hose 1 RCPH11WHL023AAR 19 35 Disconnect the inlet and outlet heater core heater hoses 1 RCPH11WHL038AAR 20 47392461 19 06 2012 10 001 11 ...

Page 34: ...ical connector Water sensor electrical connector Ground wire Wire harness P clamp Crank case filter inlet hose Crank case filter outlet hose Crank case filter oil return hose Fuel pump inlet tube Fuel pump outlet tube 38 Remove the crank case ventilation fuel filter bracket assembly RCPH11WHL040AAR 22 39 Label and disconnect the engine control module electrical connector 1 RCPH11WHL041AAR 23 47392...

Page 35: ...41 Disconnect the battery positive wire 2 on the air grid heater RCPH11WHL042AAR 24 42 Disconnect the engine ground wires 1 43 Remove the wire harness P clamp 2 RCPH11WHL043AAR 25 44 Remove the engine serpentine belt 1 RCPH11WHL051AAR 26 47392461 19 06 2012 10 001 13 ...

Page 36: ...al connector 4 47 Remove the alternator power wire 3 48 Label and disconnect the bulk electrical connector 5 RCPH11WHL045AAR 27 49 Remove the A C compressor 2 Position the A C compressor 2 away from the engine 50 Remove the wire harness P clamps 1 RCPH11WHL046AAR 28 51 Remove the engine oil drain tube 1 RCPH11WHL047AAR 29 47392461 19 06 2012 10 001 14 ...

Page 37: ...plate RCPH11WHL050AAR 31 54 For 1021F models do procedure A For 1121F mod els do procedure B A Remove the converter housing cover plate 1 See figure 32 B Remove access cover located above starter then remove plug behind cover Carefully re move torque converter bolts through plug hole Use care to ensure bolts do not fall into en gine housing Supporting figure is currently not available RCPH11WHL034...

Page 38: ...ankcase 55 Remove the flex plate bolts 1 RCPH11WHL035AAR 33 56 Remove the harmonic balancer 1 RCPH11WHL051AAR 34 57 Remove the front engine mounts 1 and engine mount plate 2 RCPH11WHL052AAR 35 47392461 19 06 2012 10 001 16 ...

Page 39: ...Engine Engine and crankcase 58 Remove the bell housing bolts 1 RCPH11WHL036AAR 36 59 Remove the engine RCPH11WHL048AAR 37 47392461 19 06 2012 10 001 17 ...

Page 40: ...t plate 5 and the engine mount brackets 1 but do not tighten the bolts to a torque value 4 Tighten the engine bracket upper bolts 2 to a torque of 171 231 N m 126 170 lb ft Tighten the engine bracket lower bolts 3 to a torque of 69 80 N m 51 59 lb ft Tighten the engine mount plate bolts 4 to a torque of 386 434 N m 285 320 lb ft Tighten the engine bracket to engine mount plate bolts 6 to a torque ...

Page 41: ...lb ft RCPH11WHL035AAR 5 7 For 1021F models do procedure A For 1121F mod els do procedure B A Apply DOW 732 RTV SILICONE CLEAR to the converter housing cover plate 1 See figure 6 B Carefully install torque converter bolts through plug hole Tighten bolts to standard torque In stall plug and housing cover plate Supporting figure is currently not available 8 Install the converter housing cover plate 1...

Page 42: ...ore heater hoses 1 RCPH11WHL038AAR 7 10 Reposition the hydraulic oil return tube Install the hydraulic oil return tube P clamp 1 RCPH11WHL050AAR 8 11 Install the air box snorkel 1 Install two bolts 2 washers 3 and nuts 4 RCPH11WHL023AAR 9 47392461 19 06 2012 10 001 20 ...

Page 43: ...o exhaust tube 1 13 Tighten the turbo muffler clamp 2 to a torque of 5 6 N m 44 53 lb in RCPH11WHL022AAR 10 14 Remove lifting equipment 1 from the engine RCPH11WHL048AAR 11 15 Install the engine wall RCPH11WHL039AAR 12 47392461 19 06 2012 10 001 21 ...

Page 44: ...1 RCPH11WHL021AAR 13 17 Install the air box RCPH11WHL019AAR 14 18 Install the wire harness P clamp 1 19 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 RCPH11WHL018AAR 15 47392461 19 06 2012 10 001 22 ...

Page 45: ... Tighten the air intake hose clamp 3 to a torque of 4 5 N m 35 40 lb in 23 Connect the humidity sensor electrical connector 1 24 Connect the air filter restriction sensor electrical con nector 4 RCPH11WHL017AAR 17 25 Install the upper radiator tube 2 26 Install the before air cooler tube 1 RCPH11WHL016AAR 18 47392461 19 06 2012 10 001 23 ...

Page 46: ...nd crankcase 27 Install the engine oil drain tube 1 RCPH11WHL047AAR 19 28 Install the wire harness P clamps 1 RCPH11WHL046AAR 20 29 Install the engine serpentine belt 1 RCPH11WHL051AAR 21 47392461 19 06 2012 10 001 24 ...

Page 47: ...t the alternator power wire 3 Tighten the nut to a torque of 6 8 N m 55 70 lb in 34 Connect the bulk electrical connector 5 RCPH11WHL045AAR 22 35 Connect the engine ground wires 1 36 Install the wire harness P clamp 2 RCPH11WHL043AAR 23 37 Connect the fuel return line 1 38 Connect the battery positive wire 2 on the air grid heater RCPH11WHL042AAR 24 47392461 19 06 2012 10 001 25 ...

Page 48: ...nk case ventilation fuel filter bracket assembly Fuel pump electrical connector Water sensor electrical connector Ground wire Wire harness P clamp Crankcase filter inlet hose Crankcase filter outlet hose Crankcase filter oil return hose Fuel pump inlet tube Fuel pump outlet tube RCPH11WHL040AAR 26 42 Connect the starter battery cables 1 and starter switch wire 2 RCPH11WHL049AAR 27 47392461 19 06 2...

Page 49: ... 2 44 Slip the oil dipstick tube 1 through the engine wall Install the dipstick tube P clamp 3 RCPH11WHL015AAR 28 45 Install the bulkheads 2 46 Install the after air cooler tube 1 RCPH11WHL014AAR 29 47 Install the hydraulic lines 1 RCPH11WHL013AAR 30 47392461 19 06 2012 10 001 27 ...

Page 50: ... tube 1 to the engine wall left bracket and deaeration tank 3 RCPH11WHL012AAR 32 50 Install the muffler assembly 51 Lower the exhaust stack hood 1 in front of the en gine wall and onto the left bracket right bracket and hydraulic oil tank 52 Install the exhaust stack hood mounting bolts RCPH11WHL010AAR 33 47392461 19 06 2012 10 001 28 ...

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