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Case 621F, Service Manual

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Case 621F Service Manual Download Page 4

621F Wheel Loader

Repair Manual

47387703

Table of Contents

Description

Section No.

General

Tab 1

Section Index - General
General Torque Specifications

1001

Fluids and Lubricants

1002

Metric Conversion Chart

1003

Engines

Tab 2

Section Index - Engines
Engine and Radiator Removal and Installation

2000

Stall Tests

2002

After Cooler

2003

SCR System Sensors

2020

SCR Catalyst

2030

Engine Intake Temperature/Humidity Sensor

2040

DEF/ADBLUE Heater Control Valve

2050

DEF/ADBLUE DNOx Supply Module

2060

DEF/ADBLUE Dosing Injector

2070

DEF/ADBLUE Supply Tank

2080

DEF/ADBLUE Supply Tank Level and Temperature Sensor/Pick-up and Heater

2090

DEF/ADBLUE Supply Filters

2100

For Engine Repair, See the Engine Service Manual (sold separately)

84392428

Fuel System

Tab 3

Section Index - Fuel System
For Fuel System Repair, See the Engine Service Manual (sold separately)

84392428

Electrical

Tab 4

Section Index - Electrical
Removal and Installation of Starter and Alternator

4001

Electrical Specifications and Troubleshooting

4002

Batteries

4003

Instrument Cluster

4005

Find manuals at http://best-manuals.com/search?&s=CASE-47387703

Summary of Contents for 621F

Page 1: ...621F TIER 4 Print No 47387703 Service Manual Wheel Loader ...

Page 2: ...621F Loader 47387703 Use for Repair Manual Find manuals at http best manuals com search s CASE 47387703 ...

Page 3: ...Find manuals at http best manuals com search s CASE 47387703 ...

Page 4: ... 2050 DEF ADBLUE DNOx Supply Module 2060 DEF ADBLUE Dosing Injector 2070 DEF ADBLUE Supply Tank 2080 DEF ADBLUE Supply Tank Level and Temperature Sensor Pick up and Heater 2090 DEF ADBLUE Supply Filters 2100 For Engine Repair See the Engine Service Manual sold separately 84392428 Fuel System Tab 3 Section Index Fuel System For Fuel System Repair See the Engine Service Manual sold separately 843924...

Page 5: ...6004 Rear Axle 6004 Drive Shafts Center Bearing and Universal Joints 6005 Wheels and Tires 6006 Brakes Tab 7 Section Index Brakes Removal and Installation of Brake Components 7001 Hydraulic Brake Troubleshooting 7002 Brake Pump 7003 Brake Accumulators 7004 Parking Brake 7008 Hydraulics Tab 8 Section Index Hydraulics How to Read Hydraulic Schematics 8000 Removal and Installation of Hydraulic Compon...

Page 6: ... Conditioner System Service 9003 Removal And Installation Of Air Conditioning And Heater Components 9004 Loader 9006 Roll Over Protective Structure ROPS Cab Structural Frame CSF 9007 Cab Glass Installation 9010 Rear View Camera Installation and Removal 9020 Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 621F Wheel Loader Repair Manual 47387703 Table of Contents Descri...

Page 7: ...Find manuals at http best manuals com search s CASE 47387703 ...

Page 8: ...ECTION INDEX GENERAL Standard Torque Specifications 1001 Fluids and Lubricants 1002 Metric Conversion Chart 1003 Section Title Section Number Find manuals at http best manuals com search s CASE 47387703 ...

Page 9: ...Find manuals at http best manuals com search s CASE 47387703 ...

Page 10: ...Section 1001 1001 GENERAL TORQUE SPECIFICATIONS Find manuals at http best manuals com search s CASE 47387703 ...

Page 11: ...001 2 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 ...

Page 12: ...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 S...

Page 13: ...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 ...

Page 14: ...5 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 2...

Page 15: ...o 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 1...

Page 16: ...Section 1002 1002 FLUIDS AND LUBRICANTS ...

Page 17: ...NDATIONS 4 TRANSMISSION TEMPERATURE CHART 5 DIESEL FUEL SYSTEM 5 Fuel Storage 5 Specifications for Acceptable No 2 Diesel Fuel 5 What is Selective Catalytic Reduction SCR 6 Selective Catalytic Reduction SCR Basic instructions 8 MAINTENANCE SCHEDULE 9 MAINTENANCE POINTS 11 ...

Page 18: ...stem Capacity 147 6 liters 39 U S Gallons Type of Oil Case AKCELA Hy Tran Ultra Transmission Refill Capacity with Filter Change 26 7 litres 28 2 U S quarts Type of Oil Case Nexplore Axles Capacity Standard Front 22 litres 23 2 U S Quarts Standard Rear 22 litres 23 2 U S Quarts Optional Front 22 litres 23 2 U S Quarts Optional Rear 22 litres 23 2 U S Quarts Type of Lubricant Case Nexplore DEF Diese...

Page 19: ...A 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 B...

Page 20: ...fication 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 t...

Page 21: ...6 F greatly reduce the shelf life of DEF AdBlue DEF AdBlue has a typical shelf life of 6 12 months Refer to the SHELF LIFE table below In order for DEF AdBlue to remain in a usable condition stor age requirements need to be met Store between 11 C 12 F and 30 C 86 F Use only an approved DEF AdBlue container Keep container tightly closed Keep container in a cool well ventilated area Keep away from h...

Page 22: ...ol system to fail to conform to the emission control performance level it was verified to or to the requirements in the California Code of Regulations Title 13 Sections 2700 to 2706 and 2710 for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your diesel emission control system vehicle or equipment as specified in the owner s manuals Where a war...

Page 23: ...d diameter triggered by the magnet in the tank filler neck and with overfill flow cut out This will ensure that The screen in the filler neck will not be damaged Impurities are not entering the DEF AdBlue tank The standardized DEF AdBlue nozzle matches the filler neck diameter The DEF AdBlue tank is not overfilled as the DEF AdBlue pump will stop when the DEF AdBlue tank is full DEF AdBlue is not ...

Page 24: ...sure Wheel Torque 100 250 14 Check Drive Belt 250 Every 500 Hours 15 Check Battery Electrolyte Level 500 16 Check Axle Oil Level 500 17 Drain Fuel Tank Condensation Water Separator 500 18 Change Engine Oil and Filter 100 500 18 Change Crankcase Filter 500 19 27 Replace Fuel Filter 100 500 XX ROPS CSF and seat belt torques 500 Every 1000 Hours 20 Change Front Rear Axle Oil 100 1000 21 Replace Hydra...

Page 25: ...ntenance of safety related items and for detailed information of the service items on this chart Operators and service manuals are available for this machine from your dealer If you operate the machine in severe conditions lubricate and service the machine more frequently ...

Page 26: ...Section 1003 1003 METRIC CONVERSION CHART ...

Page 27: ...1003 2 TABLE OF CONTENTS CONVERSION FACTORS 3 Metric to U S 3 U S to Metric 4 ...

Page 28: ...bic yd Power kilowatt 1 341 02 horsepower Pressure kilopascal bar 0 145 038 14 50385 lb sq inch lb sq inch Temperature degree C 1 8 x C 32 degree F Torque newton meter newton meter 8 850 748 0 737 562 lb inch lb foot Velocity kilometer hr 0 621 371 miles hr Volume cubic centimeter cubic meter cubic meter milliliter litre litre litre litre 0 061 024 35 314 66 1 307 950 0 033 814 1 056 814 0 879 877...

Page 29: ... 276 kg cubic meter Power horsepower 0 745 700 kilowatt Pressure lbs sq in lbs sq in lbs sq in 6 894 757 0 069 0 070 303 kilopascal bar kg sq cm Temperature degree F 1 8 F 32 degree C Torque pound inch pound foot 0 112 985 1 355 818 newton meter newton meter Velocity miles hr 1 609 344 kilometer hr Volume cubic inch cubic foot cubic yard ounce US fluid quart US liquid quart Imperial gallon US gall...

Page 30: ...t 2030 Engine Intake Temperature Humidity Sensor 2040 DEF AdBlue Heater Control Valve 2050 DEF AdBlue DNOx Supply Module 2060 DEF AdBlueDosing Injector 2070 DEF AdBlue Supply Tank 2080 DEF AdBlue Supply Tank Level and Temperature Sensor Pick up and Heater 2090 DEF AdBlue Supply Filters 2100 FOR ENGINE REPAIR SEE THE ENGINE REPAIR MANUAL 84392428 Section Title Section Number ...

Page 31: ......

Page 32: ...Section 2000 2000 ENGINE AND RADIATOR REMOVAL AND INSTALLATION ...

Page 33: ...2000 2 TABLE OF CONTENTS Engine 3 Removal 3 Installation 10 Radiator 18 Removal 18 Installation 20 ...

Page 34: ...draulic reservoir STEP 4 BD06F108 The master and hood raise switch are located by the battery box Raise the hood with the hood lift motor Put master disconnect switch in OFF position Remove both battery covers and disconnect batteries from the machine STEP 5 BD02N160 Put a 28 4 liter 30 U S quart container below radiator drain Remove radiator cap Remove cap and drain coolant into container Install...

Page 35: ...he lifting motor STEP 9 BD03A228 Remove the pin from the top of the lifting motor STEP 10 BD06F109 Tag and disconnect hood wiring harness connector from rear chassis wiring harness connector STEP 11 BD03A227 BD03A226 Remove mount bolt 1 and backup alarm wiring harness clamp from cooler housing Have another person balance the hood and remove the hood hinge mounting bolts 2 from the cooler frame 1 2...

Page 36: ...air filter restriction switch STEP 14 BD03A225 Loosen clamp on air cleaner intake hose and remove the crankcase ventilation hose STEP 15 BD06F110 Loosen clamps on turbocharger and air cleaner remove the intake hose STEP 16 BD06F110 Loosen the clamp on the turbocharger for the after cooler inlet hose STEP 17 BD03A115 Loosen the clamp on the after cooler and remove the after cooler inlet hose from t...

Page 37: ...he after cooler outlet hose from the machine STEP 20 BD06F110 Loosen the exhaust clamp from the turbocharger STEP 21 BD06F112 Remove the air cleaner and muffler from the bracket STEP 22 BD06F113 BD06F114 Remove the four mounting bolts from the belt cover remove the cover NOTE After removing the belt cover remove the cover mounting brackets from the machine frame ...

Page 38: ... engine wiring harness connectors from air compressor clutch connector 1 Remove the three mounting bolts 2 for the compressor and set the compressor on the left battery cover STEP 26 BD06F118 Tag and disconnect the wiring from the alternator STEP 27 BD06F119 Remove bolt securing wiring harness clamp to engine STEP 28 BD06F120 Remove bolt securing wiring harness clamp 1 to the engine Remove ground ...

Page 39: ...the engine STEP 31 BD06F122 Remove the radiator hose 1 from the rear of the engine remove the heater hose from the rear of the engine 2 remove the clamp bolts and clamps 3 from the bell housing STEP 32 BD06F111 Tag and remove the grid heater cable STEP 33 BD03A142 Disconnect the wiring harness from the EDC 7 controller NOTE Lifting up on the lever will release the connector from the controller STE...

Page 40: ...TEP 38 BD06F127 Remove the lower cover for the drive shaft STEP 39 BD03A172 Remove the drive shaft bolts from the flywheel Move the drive shaft clear of the flywheel STEP 40 Connect suitable lifting equipment to engine lifting brackets Take up all slack in lifting equipment Remove the engine mounting bolts and lift the engine enough to gain access to the drain hose pull the drain hose with the eng...

Page 41: ...er 2 bolt 1 washer 6 and nut 7 in engine isolators Lower engine into position STEP 44 Tighten engine mounting bolts to a torque of 244 to 298 Nm 180 to 220 lb ft STEP 45 Disconnect lifting equipment from engine lifting brackets STEP 46 Connect engine oil drain hose to frame bracket STEP 47 BD03A172 At front of engine position drive shaft on engine coupling Install six bolts to secure drive shaft t...

Page 42: ...vacuum pump from hydraulic reservoir STEP 50 BD06F125 Install bolt and clamp for fuel return hose STEP 51 BD06F124 Remove cap from fitting and plug from the hose connect fuel line 2 Connect fuel filter heater wires 1 Remove and discard tag STEP 52 BD06F123 Remove cap from fitting and plug from the hose connect fuel line to EDC 7 STEP 53 BD03A142 Connect wiring harness to EDC 7 controller NOTE Star...

Page 43: ...e 1 STEP 56 BD06F146 Connect the engine coolant vent hose STEP 57 BD06F121 Install the wires to the starter solenoid 3 install the ground cable 2 and ground strap 1 to the starter Remove and discard tags STEP 58 BD06F120 Install bolt securing wiring harness 1 clamp to the engine Install ground wires 2 to the engine STEP 59 BD06F119 Install bolt securing wiring harness clamp to engine 2 1 3 3 1 2 1...

Page 44: ...ne wiring harness connectors to air compressor clutch connector 1 Remove and discard tags STEP 62 BD06F116 Install lower cooler hose to the engine and tighten the clamps to a torque of 10 1 to 11 3 Nm 90 to 100 lb inch STEP 63 BD06F115 Install the drive belt STEP 64 BD06F113 BD06F114 Install the cover mounting brackets to the machine frame Install the belt cover install the four mounting bolts for...

Page 45: ...lamp on the turbocharger tighten the muffler mounting bolts STEP 67 BD03A118 Place the after cooler outlet hose on the machine Tighten the clamp on the after cooler STEP 68 BD06F111 Tighten the clamp on the intake manifold for the after cooler output hose STEP 69 BD03A115 Place the after cooler inlet hose on the machine Tighten the clamp on the after cooler STEP 70 BD06F110 Tighten the clamp on th...

Page 46: ...24 Connect engine wiring harness connector to air filter restriction switch Remove and discard tag STEP 74 BD03A232 Carefully raise and place hood over loader NOTE Refer to step 7 and 8 of removal for lifting procedure STEP 75 BD03A227 BD03A226 Have another person balance the hood install the hood hinge mounting bolts 2 to the cooler frame Install mount bolt 1 and backup alarm wiring harness clamp...

Page 47: ... mm X With the motor down to its lowest point take a measurement between the left hand side hood bumper and the counter weight record this measurement Y Use the following table to adjust the strut X Hood Adjustment Table Y MM X MM Y MM X MM Y MM X MM Y MM X MM 1 19 21 14 41 9 61 5 2 19 22 14 42 9 62 5 3 18 23 14 43 9 63 4 4 18 24 13 44 9 64 4 5 18 25 13 45 9 65 4 6 18 26 13 46 8 66 4 7 17 27 13 47...

Page 48: ...k on the reservoir STEP 83 Connect the batteries install battery covers put master disconnect switch in ON position STEP 84 Start engine and run the engine at low idle Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol and water When the coolant is at operating temperature stop the engine When engine has cooled check the coolant level at th...

Page 49: ...move the two mounting screws for the side panel remove the panel NOTE Photo is of the oil cooler side of the machine the procedure is the same STEP 5 BD06F128 Remove bolt and washer securing LH fender Remove LH fender STEP 6 BD02N160 Put a 28 4 liter 30 0 U S quart container below radiator drain Remove radiator cap then remove cap and drain coolant into container Install cap after coolant has drai...

Page 50: ...e lower radiator hose from the radiator STEP 10 BD03A113 Disconnect overflow hose from radiator Disconnect connector from coolant level sender STEP 11 BD03A106 Remove screws and install lifting eyes 1 Attach suitable lifting equipment to lifting eyes Remove four mounting bolts 2 remove radiator from machine 1 2 2 ...

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