Case 1021G Service Manual Download

Page: 1 / 61

Part number 51428268

edition English

December 2017

SERVICE MANUAL

1021G
1121G

Tier 4B (final)

Wheel Loader

Printed

in U.S.A.

Case is a trademark registered in the United States and many

other countries, owned or licensed to CNH Industrial N.V.,

its subsidiaries or affiliates.

Summary of Contents for 1021G

Page 1: ... MANUAL 1021G 1121G Tier 4B final Wheel Loader Printed in U S A 2017 CNH Industrial Italia S p A All Rights Reserved Case is a trademark registered in the United States and many other countries owned or licensed to CNH Industrial N V its subsidiaries or affiliates ...

Page 2: ...LOADER XR EH NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA 1121G WHEEL LOADER XR EH NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA 51428268_EN 19 12 2017 EN Find manuals at https best manuals com ...

Page 3: ...Market Product Engine 1021G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA North America F2CFE614H B004 1021G WHEEL LOADER XR EH NEW CAB TIER4B NA North America F2CFE614H B004 51428268_EN 19 12 2017 Find manuals at https best manuals com ...

Page 4: ...ansmission external controls 21 2 21 105 Powershift transmission hydraulic components 21 3 21 155 Powershift transmission internal components 21 4 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...

Page 5: ...1 Front loader arm hydraulic system 35 8 35 723 Front loader bucket hydraulic system 35 9 35 733 Axle lubrication and cooling circuit 35 10 Frames and ballasting 39 39 100 Frame 39 1 Steering 41 41 200 Hydraulic control components 41 1 41 216 Cylinders 41 2 41 910 Auxiliary steering 41 3 Wheels 44 44 511 Front wheels 44 1 44 520 Rear wheels 44 2 Cab climate control 50 50 200 Air conditioning 50 1 ...

Page 6: ... controls 55 6 55 415 Loader arm and bucket control system 55 7 55 530 Camera 55 8 55 DTC FAULT CODES 55 9 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 90 118 Protections and footboards 90 2 90 105 Machine shields and guards 90 3 51428268_EN 19 12 2017 Find manuals at https best manuals com ...

Page 7: ...51428268_EN 19 12 2017 Find manuals at https best manuals com ...

Page 8: ...INTRODUCTION 51428268_EN 19 12 2017 1 Find manuals at https best manuals com ...

Page 9: ...intenance standard and precautions 14 Basic instructions Precaution for disassembly and assembly 16 Basic instructions Electrical equipment precautions 18 Consumables Biodiesel Fuel 19 Consumables 20 Hydraulic contamination 22 Product identification Machine orientation 23 Product identification 24 51428268_EN 19 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 51428268_EN 19 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 51428268_EN 19 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: ... 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 27: ...Service capacity with filter change 45 4 l 48 0 US qt Axles Type of oil CASE AKCELA TRANSAXLE FLUID 80W 140 Technical specifications SAE 80W 140 API GL 4 CASE CONSTRUCTION specifications MAT 3510 Front axle 42 0 l 44 4 US qt Rear axle 42 0 l 44 4 US qt Front axle with axle cooler 51 5 L 54 4 US qt Rear axle with axle cooler 46 7 L 49 3 US qt Heavy duty Front axle 62 0 l 65 5 US qt Heavy duty Front...

Page 28: ...S 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 TRANSAXLE FLUID 80W 140 Technical specifications SAE 80W 140 API GL 4 CASE CONSTRUCTION specifications MAT 3510 Front axle Standard and Heavy Duty 62 L 65 5 US qt Rear axle Standard and Heavy Duty 64 0 l 67 6 US qt Front axle with axle cooler Standard and He...

Page 29: ...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 30: ...INE SIDES The terms right hand left hand front and rear when used in this manual indicate the sides of the ma chine as they are seen from the operator s seat 1 Front side 2 Rear side 3 Left hand side 4 Right hand side ITIL11WC0004C0B 1 51428268_EN 19 12 2017 23 ...

Page 31: ... door and hand holds 6 Roll Over Protection System ROPS cab 2 Steps 7 Loader lift arms 3 Bucket Z bar version 8 Battery access 4 Timed disconnect switch and battery jump post 9 Hand rails 5 Bucket cylinder 10 Fuel DEF ADBLUE fill tanks 51428268_EN 19 12 2017 24 ...

Page 32: ...NTRODUCTION LEIL17WHL1733FB 2 1 Hand rails 5 Battery access 2 Pre cleaner 6 Bucket Z bar version 3 Cab air filter access 7 Windshield washer reservoir 4 Bucket cylinder 8 Steps 51428268_EN 19 12 2017 25 ...

Page 33: ...INTRODUCTION 51428268_EN 19 12 2017 26 ...

Page 34: ...UAL Engine 1021G WHEEL LOADER XR EH NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA 1121G WHEEL LOADER XR EH NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA 51428268_EN 19 12 2017 10 ...

Page 35: ...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 51428268_EN 19 12 2017 10 ...

Page 36: ...ankcase 001 1021G WHEEL LOADER XR EH NEW CAB TIER4B NA 1021G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA 1121G WHEEL LOADER XR EH NEW CAB TIER4B NA 1121G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA 51428268_EN 19 12 2017 10 1 10 001 1 ...

Page 37: ...nkcase 001 TECHNICAL DATA Engine General specification 3 General specification 3 Engine horse power 3 Engine horse power 4 SERVICE Engine Remove 6 Install 28 Test 47 See content for specific models 51428268_EN 19 12 2017 10 1 10 001 2 ...

Page 38: ...ngine with 4 Speed Transmission A Low idle 870 930 RPM Alternate low idle 670 730 RPM Alternate Accelerated Idle 1270 1330 RPM B Maximum No Load RPM 2256 2306 RPM C Converter Stall 1937 2087 RPM D Hydraulic Stall 1885 2195 RPM E Converter Hydraulic Stall 1487 1797 RPM Temperature of the torque converter oil 82 104 C 180 219 F Temperature of the hydraulic oil 54 57 C 129 135 F NOTE hydraulic Stall ...

Page 39: ...power 1121G WHEEL LOADER XR EH NEW CAB TIER4B NA NA 1121G WHEEL LOADER ZBAR EH NEW CAB TIER4B NA NA Design characteristics Displacement 8710 cm 531 5 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 Capability 3000 m 9842 5 ft 51428268_EN 19 12 2017 10 1 10 001 4 ...

Page 40: ... RPM Low Idle Speed 700 RPM Rated Power 235 kW at 2100 RPM Peak Torque 1604 N m at 1400 RPM LEIL17WHL0363GA 1 NOTE performances detected at engine test bench NOTE BSFC indicates the Brake Specific Fuel Consumption 51428268_EN 19 12 2017 10 1 10 001 5 ...

Page 41: ... any service procedure 1 Park the machine on a level surface and lower the bucket to the ground Put the articulation lock 1 in LOCKED position LEIL15WHL1782AA 1 2 Push the hydraulic functions lock out switch in the nor mal operation position LEIL16WHL1125AA 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 ...

Page 42: ... LEIL15WHL0825AA 4 8 Locate the timed disconnect switch in the battery box Put the timed disconnect switch in the OFF position LEIL15WHL0663AA 5 9 Tag and disconnect the positive cable battery to isola tor cable 1 and the positive cable isolator to starter 2 from the battery isolator Disconnect the connector 3 from the timed disconnect switch LEIL16WHL1528AB 6 51428268_EN 19 12 2017 10 1 10 001 7 ...

Page 43: ...n re move the radiator cap and coolant drain plug arrow to drain the engine coolant Reinstall the drain plug and radiator cap after the coolant has drained NOTE see machine specifications for cooling system vol ume LEIL15WHL0719AB 9 12 Open the access cover Place a suitable container below the engine oil drain Remove the drain plug and drain the oil into the con tainer Reinstall drain plug NOTE se...

Page 44: ...e compartment cover and exhaust stack Carefully remove the cover 1 the exhaust stack 2 and the precleaner 3 as an assembly LEIL15WHL0679AB 12 16 Disconnect the dearation tank overflow hose 2 from the coolant tank 1 Remove the P clamps 3 that secure the overflow hose 2 to the wall and brackets Tag and remove the overflow hose 2 from the engine and engine wall Disconnect the hoses 4 5 and 6 from the...

Page 45: ... to separate the P clamps 4 and 6 from the bracket 8 Remove the P clamps 4 and 6 from the DEF ADBLUE bundle 5 21 Remove the two bolts 8 with related washers and the nuts to separate the bracket 7 from the engine wall 9 LEIL15WHL0812AB 17 22 Remove the bolt 2 and the related washers and nut to separate the P clamp 3 from the bracket 1 Remove the P clamp 3 from the sensors wiring har ness 4 LEIL15WH...

Page 46: ...e 4 LEIL15WHL1312AB 20 26 Loosen the bolt 1 and remove the P clamp 2 from the supply module support 3 27 Remove the P clamp 2 from the temperature sensor DOC to SCR wire 4 Cut the tie strap 6 28 Disconnect the sensor from the sensors wiring har ness 5 Loosen the hexagonal nut of the tempera ture sensor 7 DOC to SCR Remove the temperature sensor 7 LEIL15WHL0824AB 21 29 Loosen the P clamp 1 of the a...

Page 47: ...inlet of the Diesel Oxidation Catalyst DOC 3 Loosen the hexagonal nut of the inlet temperature sensor 1 and the inlet NOx sensor 2 Disconnect the sensors 1 and 2 from the inlet of the Diesel Oxidation Catalyst DOC 3 LEIL15WHL0671AB 24 32 Loosen the hexagonal nut 1 with related washer spacer and bolt Separate the P clamp 2 that secure the wiring harness 4 of the DOC inlet temperature sensor from th...

Page 48: ... Reduction muffler SCR 4 LEIL15WHL0836BB 28 37 Remove the two bolts 1 with related washers and nuts to separate the bracket hydraulic to cooling 3 from the engine wall 4 38 Remove the four bolts 2 with related washers and nuts to separate the bracket hydraulic to cooling 3 from the hydraulic tank 5 NOTE left hand side of the machine is shown The oper ations are similar for the right hand side 39 R...

Page 49: ...L15WHL0835AB 31 42 Loosen the clamps 2 from the intercooler tube 1 Remove the intercooler tube 1 through the engine wall NOTE for clarity the engine wall is not shown in the figure LEIL15WHL1165AB 32 43 Loosen the V band clamp 1 Remove the O ring and the air intake elbow 2 of the turbocharger Loosen the clamps 3 Remove the air intake tube 4 of the turbocharger Cover the turbocharger inlet to preve...

Page 50: ...WHL1084AB 34 45 Loosen the clamps 2 to remove the upper radiator tube 1 through the engine wall NOTE for clarity the engine wall is not shown in the figure LEIL15WHL1147AB 35 46 Loosen the clamp of the overflow hose to the radiator LEIL15WHL1288AB 36 47 Remove the oil dipstick P clamp 2 Pull the oil dipstick tube 1 through the wall LEIL15WHL0819AB 37 51428268_EN 19 12 2017 10 1 10 001 15 ...

Page 51: ...e LEIL15WHL0813AB 38 50 Remove the P clamp 1 to separate the coolant inlet hose 3 from the supply module bracket 2 LEIL15WHL0843AB 39 51 Remove the P clamp 1 the coolant by pass line 3 from the supply module bracket 2 LEIL15WHL0844AB 40 52 Remove the P clamp 5 Push inward on the fitting retaining clip and discon nect the coolant outlet 2 the coolant inlet 1 and by pass 3 lines from the heater cont...

Page 52: ...1 to disconnect the wire 2 and related P clamp from the support bracket 3 of the crankcase vent filter LEIL15WHL1139AB 43 55 Tag and disconnect the fuel filter heater wire 1 and the water sensor 2 Drain the fuel filter and disconnect the inlet fuel line 3 and outlet fuel line 4 from the fuel filter head Plug the lines and cap the fittings LEIL15WHL0846AB 44 51428268_EN 19 12 2017 10 1 10 001 17 ...

Page 53: ...s and nuts to separate the bracket 6 from the fuel filter engine breather filter bracket 8 and from the fuel filter 9 Remove the fuel filter 9 LEIL15WHL0845FB 45 58 Loosen the clamp 2 on the crankcase vent hose 1 59 Remove the bolt 3 with related washers and nut to separate the two clamps 4 from the hose support bracket 5 60 Loosen the clamp 6 on the crankcase vent hose 1 61 Cut the straps 7 62 Re...

Page 54: ...7 Loosen the four nuts 2 and related washers 3 that hold the support bracket 1 of the crankcase vent filter to the rear chassis NOTE one of these four nuts 2 is used to secure a P clamp that hold the wiring harness to the support bracket 1 LEIL15WHL1140AB 49 68 Loosen the clamps 1 and 2 69 Separate the upper air intake hose 6 from the air intake pipe 5 Remove the upper air intake hose 6 70 Loosen ...

Page 55: ... the air intake bracket 3 from the hydraulic tank 3 Loosen the clamp 4 Remove the air intake pipe 5 LEIL15WHL1060AB 52 76 Tag and disconnect the engine wiring harness con nector from the air filter sensor 2 77 Tag and disconnect the engine wiring harness con nector from the air inlet humidity sensor 1 LEIL15WHL0848AB 53 78 Loosen the clamps 2 on the turbocharger 79 Loosen the clamp 3 on the air fi...

Page 56: ...3 Disconnect the elbow 1 Remove the P clamp 3 Cut the straps 4 Remove the hose fill 2 84 Remove the P clamps 7 and 6 85 Disconnect the tube 5 LEIL15WHL1071AB 56 86 Disconnect and remove the tubes 1 and 2 LEIL15WHL1072AB 57 87 Disconnect the engine coolant line 2 from the zinc lower radiator tube 1 Disconnect the dosing module coolant line 3 from the lower radiator tube 1 LEIL15WHL1053AB 58 5142826...

Page 57: ... drive belt from the engine LEIL15WHL0772AA 61 91 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 Recovery the refrigerant as indicated in Air condi tioning Service instruction 50 200 Disconnect the low pressure line 3 from the suction port compressor to condenser hose and hose 2 of...

Page 58: ...he starter switch wire 1 Remove the starter switch wire 1 from the en gine starter LEIL15WHL1299AB 64 95 Place identification tags on the cables Remove the negative cable starter to ground 1 the negative cable battery to starter 2 from the engine starter Remove the positive cable battery isolator to starter and the connectors 4 and 5 from the engine starter LEIL16WHL1527AB 65 51428268_EN 19 12 201...

Page 59: ... Remove the engine starter LEIL15WHL1331BB 66 97 Tag and disconnect the electrical connector from the engine control unit LEIL15WHL1085AA 67 98 Disconnect the hydraulic fittings 2 and 3 from the hydraulic oil supply tube 1 LEIL15WHL0833AB 68 51428268_EN 19 12 2017 10 1 10 001 24 ...

Page 60: ...1 Loosen and remove the bolts 1 that fasten the cen ter drive shaft 2 to the transmission NOTICE the bolts 1 that fasten the center drive shaft 2 to the transmission must be replaced when removed LEIL15WHL1207AB 71 NOTE steps 102 and 103 are related only to CASE CONSTRUCTION 1021G 102 Remove the bolts 1 and related washers Remove the converter housing cover plate 2 and remove the flex plate bolts ...

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