Case 821G Service Manual Download Page 1

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821G

921G

Wheel Loader

SERVICE MANUAL

Wheel Loader

821G

921G

Stage IV

Part number 51428216

English

November 2017

SER
VICE MANU

Part number 51428216

Summary of Contents for 821G

Page 1: ...2 821G 921G Wheel Loader SERVICE MANUAL Wheel Loader 821G 921G Stage IV Part number 51428216 English November 2017 2017 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL Part number 51428216 ...

Page 2: ...Tier 4B Multipurpose 821G Wheel Loader ZBAR EH New cab Tier 4B Multipurpose 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 51428216_EN 14 12 2017 EN Find manuals at https best manuals com ...

Page 3: ...rope F4HFE613S B004 821G Wheel Loader XR EH New cab Tier 4B Multipurpose Europe F4HFE613S B004 921G WHEEL LOADER ZBAR EH NEW CAB TIER4B Europe F4HFE613R B006 921G Wheel Loader ZBAR EH New cab Tier 4B Multipurpose Europe F4HFE613R B006 921G WHEEL LOADER XR EH NEW CAB TIER4B Europe F4HFE613R B006 921G Wheel Loader XR EH New cab Tier 4B Multipurpose Europe F4HFE613R B006 51428216_EN 14 12 2017 Find m...

Page 4: ...1 21 155 Powershift transmission internal components 21 2 21 700 Torque converter 21 3 Four Wheel Drive 4WD system 23 23 314 Drive shaft 23 1 Front axle system 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 108 Final drive hub steering knuckles and shafts 25 3 Rear axle system 27 27 100 Powered rear axle 27 1 27 106 Rear bevel gear set and differential 27 2 ...

Page 5: ...723 Front loader bucket hydraulic system 35 9 35 734 Tool quick coupler hydraulic system 35 10 Frames and ballasting 39 39 100 Frame 39 1 Steering 41 41 101 Steering control 41 1 41 200 Hydraulic control components 41 2 41 216 Cylinders 41 3 41 910 Auxiliary steering 41 4 Wheels 44 44 511 Front wheels 44 1 44 520 Rear wheels 44 2 Cab climate control 50 50 200 Air conditioning 50 1 Electrical syste...

Page 6: ...m and bucket control system 55 8 55 530 Camera 55 9 55 DTC FAULT CODES 55 10 Front loader and bucket 82 82 100 Arm 82 1 82 300 Bucket 82 2 Platform cab bodywork and decals 90 90 150 Cab 90 1 90 120 Mechanically adjusted operator seat 90 2 90 124 Pneumatically adjusted operator seat 90 3 90 105 Machine shields and guards 90 4 51428216_EN 14 12 2017 Find manuals at https best manuals com ...

Page 7: ...51428216_EN 14 12 2017 Find manuals at https best manuals com ...

Page 8: ...INTRODUCTION 51428216_EN 14 12 2017 1 Find manuals at https best manuals com ...

Page 9: ...use the maintenance standard and precautions 14 Basic instructions Precaution for disassembly and assembly 16 Basic instructions Electrical equipment precautions 18 Consumables 19 Consumables Biodiesel Fuel 22 Hydraulic contamination 23 Product identification 24 Product identification 25 51428216_EN 14 12 2017 2 Find manuals at https best manuals com ...

Page 10: ...CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Machine safety NOTICE Notice indicates a situation that if not avoided could result in machine or property damage Throughout this manual you will find the signal word Notice followed by special instruction...

Page 11: ...rom any other position than the operator s seat TULI12WEX2004AA 1 Never carry out any operation on the machine when the engine is running except when specifically indicated Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps covers valves etc All repair and maintenance operations should be carried out with the greatest care and attention Service st...

Page 12: ...otections Goggles with lateral shield or masks for eye protection Do not wear rings wristwatches jewelry unbuttoned or flapping clothing such as ties torn clothes scarves open jackets or shirts with open zips which could get caught into moving parts TULI12WEX2008AA 4 Engine Radiator Never leave the engine running in enclosed spaces with out proper ventilation which is able to evacuate toxic ex hau...

Page 13: ...e cap while engine is hot wear safety clothes and equipment then loosen the cap slowly to relieve the pressure gradually When checking the fuel oil and coolant levels use lights and lamps explicitly designated as explosion proof If these types of lamps are not used fires or explosions may occur TULI12WEX2011AA 7 Hydraulic systems Jets of fluids under pressure can penetrate the skin caus ing seriou...

Page 14: ...entally be pierced when the heat expands beyond the area immediately heated Arrange for temporary fire resistant shields to protect hoses or other components during welding or torch use Have any visible leakage repaired immediately Discharged oil pollutes the environment Soak up any oil that has spilled with a proper binding agent Sweep up binding agent and dispose of it separately from other wast...

Page 15: ...d outer sheath will allow water penetra tion Concealed corrosion of the wire reinforcement could subsequently occur along the hose length with resultant hose failure Ballooning of the hose indicates an internal leakage due to structural failure This condition rapidly deteriorates and total hose failure soon occurs Kinked crushed stretched or deformed hoses generally suffer internal structural dama...

Page 16: ...id vomiting Drink water to rinse your mouth Consult a doctor EYES Rinse abundantly with water for 15 min and con sult a doctor When the electrolyte of a battery is frozen it can ex plode if you attempt to charge the battery or if you try to start the engine using a booster battery Always keep the battery charged to prevent the electrolyte freezing Provide good ventilation when changing a battery o...

Page 17: ...il or fuel Fuel or oil spills can cause slipping hazards thoroughly contain and clean affected areas Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly Never use fuel to clean machine parts that will be exposed to dirt or debris Use a non flammable product for cleaning parts Always perform fuel or oil refilling in well aired and venti lated areas TULI12WEX2018AA 15 During r...

Page 18: ...y means of an inflation pistol complete with extension and pressure control valve Use an inflation cage TULI12WEX2020AA 17 Cleaning Clean the exterior of all components before carrying out any form of repair Dirt and dust can reduce the efficient working life of a component and lead to costly replace ment Solvents should be checked that they are suitable for the cleaning of components and also tha...

Page 19: ...nd pure an tifreeze Fuel Filter elements oil and fuel filters Filter elements air filters Battery Also polluted rags paper sawdust and gloves must be disposed in compliance with the same procedures Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping int...

Page 20: ...nsibility for damages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer 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 The info...

Page 21: ...e at which reconditioning is impossible without replacement of parts If the value is expected to exceed the service limit before next inspection and correction are performed replace the parts immediately The operation over the specified values causes increase of damage and requires the down time of machine and also causes safety problems Cautions to be exercised at judgment EVALUATION OF MEASURED ...

Page 22: ... 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 Refer to the Operators Manuals as well 51428216_EN 14 12 2017 15 ...

Page 23: ...sassembling and assembling hydraulic equipment Before removing lines release the pressure of hydraulic oil tank or open the cover on the return side to tank and take out the filter Drain the oil in removed lines into an appropriate container to prevent oil contamination Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system Thoroughly clean...

Page 24: ...emoved o rings back up rings and oil seals with new ones Apply gear oil on them before reassembling Thoroughly clean and dry surfaces on which liquid sealant must be reapplied Before assembling remove rust preventives on new parts Use special tools to fit bearings bushing and oil seal Assemble parts matching to the marks After completion check that there is no omission of parts 51428216_EN 14 12 2...

Page 25: ...e equipment with care so as not to drop it or bump it Connector should be removed by unlocking while hold ing the connector Never disconnect electrical plugs by pulling on the wires Always use only the electrical connectors to make the disconnection Check that connector is connected and locked com pletely Engine key off before removing and connecting connec tor Engine key off before touching termi...

Page 26: ...O VG 46 MS 1230 DIN 51524 HVLP Total system capacity 178 0 l 47 0 US gal Reservoir capacity 90 8 l 24 0 US gal Transmission Type of oil CASE AKCELA NEXPLORE FLUID Technical specifications SAE 10W 30 API GL 4 ISO VG 32 46 CASE CONSTRUCTION specifications MAT 3525 Service capacity with filter change 34 1 l 36 0 US qt Axles Type of oil CASE AKCELA TRANSAXLE FLUID 80W 140 Technical specifications SAE ...

Page 27: ...TRODUCTION 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 20 ...

Page 28: ...ir capacity 110 0 l 29 0 US gal Transmission Type of oil AMBRA MULTI G 134 HYDRAULIC TRANSMISSION OIL AKCELA NEXPLORE FLUID Technical SAE 10W 30 API GL 4 ISO VG 32 46 Brand MAT 3525 Service capacity with change 34 1 l 36 0 US qt Axles Type of oil AMBRA TRX 80W 140 AKCELA TRANSAXLE FLUID 80W 140 Technical SAE 80W 140 API GL 4 Brand MAT 3510 Front axle 42 0 l 44 4 US qt Rear axle 40 0 l 42 3 US qt D...

Page 29: ... 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 u...

Page 30: ...ear rapidly Relief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times or a lack of power If your machine has any of these problems check the hydraulic oil for contamination There are two types of contamination microscopic and visible Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydrauli...

Page 31: ...ification 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 1 51428216_EN 14 12 2017 24 ...

Page 32: ...tion LEIL17WHL1703FB 1 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 25 ...

Page 33: ...1701FB 2 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 26 ...

Page 34: ...018FB 3 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 27 ...

Page 35: ...ndshield 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 28 ...

Page 36: ...l 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 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 51428216_EN 14 12 2017 10 ...

Page 37: ...uel tanks 10 2 10 202 Air cleaners and lines 10 3 10 500 Selective Catalytic Reduction SCR exhaust treatment 10 4 10 400 Engine cooling system 10 5 10 414 Fan and drive 10 6 10 310 Aftercooler 10 7 10 304 Engine lubrication system 10 8 51428216_EN 14 12 2017 10 ...

Page 38: ...el 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 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 51428216_EN 14 12 2017 10 1 10 001 1 ...

Page 39: ...nkcase 001 TECHNICAL DATA Engine General specification 3 General specification 3 Engine horse power 4 Engine horse power 5 SERVICE Engine Remove 7 Install 27 Test 49 See content for specific models 51428216_EN 14 12 2017 10 1 10 001 2 ...

Page 40: ...OTE hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open Throttle WOT in max power mode with transmission in manual mode and in 3rd gear Engine General specification 921G WHEEL LOADER XR EH NEW CAB TIER4B WE 921G WHEEL LOADER ZBAR EH NEW CAB TIER4B WE 921G Wheel Loader XR EH New cab Tier 4B...

Page 41: ...ER XR EH NEW CAB TIER4B WE 821G WHEEL LOADER ZBAR EH NEW CAB TIER4B WE 821G Wheel Loader XR EH New cab Tier 4B Multipurpose WE 821G Wheel Loader ZBAR EH New cab Tier 4B Multipurpose WE Design characteristics Displacement 6728 cm 410 6 in Engine Configuration 6 cylinder in line 4 stroke Intake Air Turbocharged 4 valves cyl Fuel injection High pressure common rail EGR No Performance Altitude Capabil...

Page 42: ... NEW CAB TIER4B WE 921G WHEEL LOADER ZBAR EH NEW CAB TIER4B WE 921G Wheel Loader XR EH New cab Tier 4B Multipurpose WE 921G Wheel Loader ZBAR EH New cab Tier 4B Multipurpose WE Design characteristics Displacement 6728 cm 410 6 in Engine Configuration 6 cylinder in line 4 stroke Intake Air Turbocharged 4 valves cyl Fuel injection High pressure common rail EGR No 51428216_EN 14 12 2017 10 1 10 001 5...

Page 43: ...5 ft High Idle Speed 2175 RPM Low Idle Speed 700 RPM Rated Power 183 kW at 2000 RPM Peak Torque 1300 kW at 1300 RPM LEIL17WHL0359GA 1 NOTE performances detected at engine test bench NOTE BSFC indicates the Brake Specific Fuel Consumption 51428216_EN 14 12 2017 10 1 10 001 6 ...

Page 44: ... the sensors using extreme caution prior to performing any service procedure 1 Park the machine on a level surface and lower the bucket to the ground Put the articulation lock in LOCKED position and stop the engine LEIL16WHL0048AB 1 2 Actuate the brake pedal several times to discharge the brake accumulators LEIL15WHL0564AA 2 3 Put the key switch in ON position Put the control switch in ON position...

Page 45: ...n the battery box Raise the engine hood and put the timed disconnect switch in the OFF position RCPH10WHL106AAH 5 6 Unhook the rubber T handle 1 and raise the upper panel 2 Make sure that the security levers are blocked LEIL13WHL0137AB 6 7 Raise both side panels 1 Then remove the thumb screws 2 and inner fender panels 3 NOTE right hand side of the machine is shown The op eration is similar for the...

Page 46: ...ng system vol ume LEIL16WHL0198AA 8 9 Place a suitable container below the engine oil drain plug see the arrow in figure Remove the engine oil drain plug and drain oil into container Then reinstall the engine oil drain plug NOTE see machine specifications for engine oil sump vol ume LEIL16WHL0198AA 9 10 Remove the drain hose 1 from the frame bracket 2 LEIL16WHL1250AB 10 11 Double up a nylon liftin...

Page 47: ...he connector 1 of the rearview cam era wire harness 3 Cut the wire ties 2 that hold the rearview camera wire harness 3 to the rear grill LEIL16WHL0849AB 13 14 Cut the wire ties and remove the rearview camera wire harness from the engine hood Place the rearview camera wire harness off to the side in a safe location LEIL13WHL0140AB 14 15 Remove the engine hood wire harness clamp 1 from the cooler ho...

Page 48: ...ounting bolts see the arrows in figure from the cooler frame NOTE do not remove the engine hood hinge mounting bolts at this time LEIL13WHL0142AB 17 18 Disconnect the wiring harness 5 Put the timed disconnect switch in the ON position Retract the lifting motor cylinder 1 and remove the clevis pin 3 and the cotter pin 4 from the bottom of the lifting motor cylinder 1 Separate the lifting motor cyli...

Page 49: ...re from the cooler frame LEIL13WHL0142AB 20 21 Carefully raise and remove the engine hood from the machine Lower the engine hood onto a suitable plat form and disconnect lifting equipment from the ex haust stack 1 NOTE radiator overflow hose may interfere with left hand hood hinge movement and hood removal LEIL13WHL0552AB 21 22 Tag and disconnect the engine wiring harness con nector from the air f...

Page 50: ... on the crankcase ventilation hose 2 and disconnect the hose LEIL13WHL0144AB 24 25 Loosen the clamps on the turbocharger and air filter housing Remove the intake air hose 1 Cover the turbocharger inlet to prevent debris entry LEIL13WHL0145AB 25 26 Loosen the clamp from the elbow connected to the turbocharger LEIL14WHL0203AB 26 51428216_EN 14 12 2017 10 1 10 001 13 ...

Page 51: ...nlet hose at the air filter housing LEIL13WHL0148AB 28 29 Loosen the clamp 1 on the air inlet hose 2 at the exhaust support bracket Remove the air inlet hose 2 LEIL13WHL0151AB 29 30 Remove the securing bolts 1 with the related wash ers and nuts Remove the bracket 2 with the air filter 3 as an assembly LEIL15WHL0037AB 30 51428216_EN 14 12 2017 10 1 10 001 14 ...

Page 52: ...om the engine LEIL13WHL0155AB 32 33 If machine is equipped with the air conditioning sys tem identify tag and disconnect the engine wiring harness connectors from the air compressor clutch connector 1 and high pressure switch 2 Then re move the three mounting bolts 3 for the compressor and carefully set it on the left battery cover LEIL13WHL0156AB 33 34 Tag and disconnect the wiring from the alter...

Page 53: ...ound cable 2 and ground strap 3 from the starter NOTE move the starter cables away from the engine LEIL16WHL0569AB 36 37 Remove the bolts securing the wiring harness clamps to the engine LEIL16WHL0570AB 37 38 Remove the ground wires from the engine NOTE move the wiring harness away from the engine LEIL16WHL0572AB 38 51428216_EN 14 12 2017 10 1 10 001 16 ...

Page 54: ... aside LEIL15WHL0016AB 39 40 Loosen the clamp see the arrow in figure and dis connect the pipe LEIL15WHL0015AB 40 41 Loosen the clamps and remove the lower coolant hose from the engine RAPH12WEL0629AA 41 42 Remove the radiator hose from the engine LEIL13WHL0159AB 42 51428216_EN 14 12 2017 10 1 10 001 17 ...

Page 55: ...olant vent hose from the top of the radiator LEIL13WHL0141AB 43 44 Remove the overflow tank of the engine coolant LEIL16WHL0574AB 44 45 Remove the bracket of the overflow tank LEIL16WHL0575AB 45 46 Remove the cooling fan guard LEIL13WHL0160AB 46 51428216_EN 14 12 2017 10 1 10 001 18 ...

Page 56: ...hine LEIL13WHL0162AB 48 49 Tag and disconnect the fuel filter heater wire 1 and the water sensor 2 Then drain fuel filter and discon nect the inlet 3 and outlet 4 fuel lines from the fuel filter head Plug the lines and cap the fittings Remove the ground wire and the attachment bolt 5 of the fuel filter head LEIL13WHL0163AB 49 50 Tag and remove the grid heater cable 1 NOTE hold the rear nut with a ...

Page 57: ...es by the sup ply module Disconnect the end of the jumper harness near the supply module from the Diesel Oxidation Catalyst DOC support LEIL15WHL0034AB 52 53 Loosen the clamp 1 on the Diesel Oxidation Catalyst DOC LEIL13WHL0166AB 53 54 Tag and disconnect the connector 1 LEIL13WHL0167AB 54 51428216_EN 14 12 2017 10 1 10 001 20 ...

Page 58: ...t the front 1 and rear 2 part of the structure Use a suitable lifting device and carefully lift the support structure of the Selective Catalytic Reduction muffler SCR from the machine NOTE pay particular attention to the connection between the SCR muffler and the Diesel Oxidation Catalyst DOC LEIL13WHL0169AB 56 57 Tag and disconnect the wire harness from the buzzer Remove the bolts 1 securing the ...

Page 59: ...ag and disconnect the wire harness and DEF ADBLUE supply and return lines from the DEF ADBLUE storage tank Install a protective cap in the supply lines RAPH12WEL0070AA 60 61 Remove the support bracket of the hood lift cylinder RAPH12WEL0071AA 61 62 Remove the heater hose from the engine LEIL15WHL0009AB 62 51428216_EN 14 12 2017 10 1 10 001 22 ...

Page 60: ...ant control valve are also at tached to this support structure LEIL14WHL0212AB 64 65 Loosen the two hexagonal nuts of the sensors 3 and 4 and disconnect the sensors 3 and 4 Loosen the clamp 1 on the Diesel Oxidation Catalyst DOC and disconnect the exhaust pipe 2 from the Diesel Oxidation Catalyst DOC LEIL13WHL0229AA 65 66 Remove the SCR coolant supply line from the engine LEIL15WHL0008AB 66 514282...

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