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CASE 821F TIER 4 WHEEL LOADER Service Repair Manual

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Printed in U.S.A.
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC...

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Section
1001
1001
GENERAL TORQUE SPECIFICATIONS

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1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

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CASE 821F TIER 4 WHEEL LOADER Service Repair Manual

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This is the Highly Detailed factory service repair manual for theCASE 821F TIER 4 WHEEL LOADER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CASE 821F TIER 4 WHEEL LOADER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
General Information
Engine
Electrical System
Undercarriage
Drive Train
Undercarriage Hydraulics
Upperstructure Hydraulics
Upperstructure
Electrical Schematic
Hydraulic Schematic – 821F
Hydraulic Schematic – 921F
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCASE 821F TIER 4 WHEEL LOADER Service Repair Workshop Manual.

Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/

Thanks for visiting!






This is the Highly Detailed factory service repair manual for theCASE 821F TIER 4 WHEEL LOADER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CASE 821F TIER 4 WHEEL LOADER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
General Information
Engine
Electrical System
Undercarriage
Drive Train
Undercarriage Hydraulics
Upperstructure Hydraulics
Upperstructure
Electrical Schematic
Hydraulic Schematic – 821F
Hydraulic Schematic – 921F
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCASE 821F TIER 4 WHEEL LOADER Service Repair Workshop Manual.

Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/

Thanks for visiting!

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CASE 821F TIER 4 WHEEL LOADER Service Repair Manual

  1. 1. Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A. Part number 84487565 1st edition English April 2011 SERVICE MANUAL 821F 921F Tier 4 Wheel Loader
  2. 2. Section 1001 1001 GENERAL TORQUE SPECIFICATIONS
  3. 3. 1001-2 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
  4. 4. 1001-3 TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used. Grade 5 Bolts, Nuts, and Studs Size Pound- Inches Newton metres 1/4 inch 108 to 132 12 to 15 5/16 inch 204 to 252 23 to 28 3/8 inch 420 to 504 48 to 57 Size Pound- Feet Newton metres 7/16 inch 54 to 64 73 to 87 1/2 inch 80 to 96 109 to 130 9/16 inch 110 to 132 149 to 179 5/8 inch 150 to 180 203 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 Size Pound- Feet Newton metres 7/16 inch 70 to 84 95 to 114 1/2 inch 110 to 132 149 to 179 9/16 inch 160 to 192 217 to 260 5/8 inch 220 to 264 298 to 358 3/4 inch 380 to 456 515 to 618 7/8 inch 600 to 720 814 to 976 1.0 inch 900 to 1080 1220 to 1465 1-1/8 inch 1280 to 1440 1736 to 1953 1-1/4 inch 1820 to 2000 2468 to 2712 1-3/8 inch 2380 to 2720 3227 to 3688 1-1/2 inch 3160 to 3560 4285 to 4827 NOTE: Use thick nuts with Grade 8 bolts.
  5. 5. 1001-4 TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used. Grade 12.9 Bolts, Nuts, and Studs Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners. Grade 8.8 Bolts, Nuts, and Studs Size Pound- Inches Newton metres M4 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 4 to 5 M5 84 to 96 9 to 11 M6 132 to 156 15 to 18 M8 324 to 384 37 to 43 Size Pound- Feet Newton metres M10 54 to 64 73 to 87 M12 93 to 112 125 to 150 M14 149 to 179 200 to 245 M16 230 to 280 310 to 380 M20 450 to 540 610 to 730 M24 780 to 940 1050 to 1275 M30 1470 to 1770 2000 to 2400 M36 2580 to 3090 3500 to 4200 10.9 12.9
  6. 6. 1001-5 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting Tube OD Hose ID Thread Size Pound- Inches Newton metres 1/4 inch 6.4 mm 7/16-20 72 to 144 8 to 16 5/16 inch 7.9 mm 1/2-20 96 to 192 11 to 22 3/8 inch 9.5 mm 9/16-18 120 to 300 14 to 34 1/2 inch 12.7 mm 3/4-16 180 to 504 20 to 57 5/8 inch 15.9 mm 7/8-14 300 to 696 34 to 79 Tube OD Hose ID Thread Size Pound- Feet Newton metres 3/4 inch 19.0 mm 1-1/16-12 40 to 80 54 to 108 7/8 inch 22.2 mm 1-3/16-12 60 to 100 81 to 135 1.0 inch 25.4 mm 1-5/16-12 75 to 117 102 to 158 1-1/4 inch 31.8 mm 1-5/8-12 125 to 165 169 to 223 1-1/2 inch 38.1 mm 1-7/8-12 210 to 250 285 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 22 to 34 3/8 inch 9.5 mm 9/16-18 300 to 480 34 to 54 1/2 inch 12.7 mm 3/4-16 540 to 804 57 to 91 Tube OD Hose ID Thread Size Pound- Feet Newton metres 5/8 inch 15.9 mm 7/8-14 58 to 92 79 to 124 3/4 inch 19.0 mm 1-1/16-12 80 to 128 108 to 174 7/8 inch 22.2 mm 1-3/16-12 100 to 160 136 to 216 1.0 inch 25.4 mm 1-5/16-12 117 to 187 159 to 253 1-1/4 inch 31.8 mm 1-5/8-12 165 to 264 224 to 357 1-1/2 inch 38.1 mm 1-7/8-12 250 to 400 339 to 542
  7. 7. 1001-6 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS O-ring Face Seal End O-ring Boss End Fitting or Lock Nut Nom. SAE Dash Size Tube OD Thread Size Pound- Inches Newton metres Thread Size Pound- Inches Newton metres -4 1/4 inch 6.4 mm 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27 -6 3/8 inch 9.5 mm 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41 -8 1/2 inch 12.7 mm 13/16-16 384 to 480 43 to 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 1-5/8-12 150 to 160 203 to 217 -16 1.0 inch 25.4 mm 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271 -20 1-1/4 inch 31.8 mm 1-11/16-12 125 to 140 170 to 190 -24 1-1/2 inch 38.1 mm 2-12 150 to 180 200 to 254
  8. 8. Section 1002 1002 FLUIDS AND LUBRICANTS
  9. 9. 1002-2 TABLE OF CONTENTS 821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
  10. 10. 1002-3 821F - CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts) Type of oil .........................................Case AKCELA No. 1 engine oil see engine oil recommendations on page 4 Engine Cooling System Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel.............................................................................................See Diesel fuel specifications on page 5 DEF (Diesel Exhaust Fluid) Tank Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts) Hydraulic System Hydraulic Reservoir Refill Capacity..........................................................................90.8 liters (24.0 U.S. Gallons) Total System Capacity...............................................................................................178 liters (47.0 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Front...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Type of Lubricant............................................................................................................................. Case Nexplore NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil. Brake System Type of Fluid (Same as Hydraulic System)................................................................Case AKCELA Hy-Tran Ultra®
  11. 11. 1002-4 921F - CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts) Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts) Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4 Engine Cooling System Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 DEF (Diesel Exhaust Fluid) Tank Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts) Hydraulic System Hydraulic Reservoir Refill Capacity...........................................................................110 liters (29.0 U.S. Gallons) Total System Capacity...............................................................................................200 liters (53.0 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Front...................................................................................................................... 42.0 liters (44.4 U.S. Quarts) Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Type of Lubricant............................................................................................................................. Case Nexplore NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil.
  12. 12. 1002-5 ENGINE OIL RECOMMENDATIONS Case AKCELA No. 1 Engine oil is recommended for use in your Case engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions. If Case AKCELA 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 char t 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 BC02N250 RH99K130
  13. 13. 1002-6 TRANSMISSION TEMPERATURE CHART RCPH10WHL435BAH3 DIESEL FUEL SYSTEM Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption. In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following Note. NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will restrict the fuel filter and cause the engine to lose power or not start. The diesel fuel used in this machine must meet the specifications as shown below in, “Specifications for Acceptable No. 2 Diesel Fuel”, or “Specification 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 tank at the end of the daily operating period to prevent condensation in the fuel tank. Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum ............................................................................................................................................. 34 Flash point, minimum ............................................................................................................................60°C (140°F) Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F) Viscosity, at 38°C (100°F) Centistokes ......................................................................................................................................... 2.0 to 4.3 Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum ..................................................................................................... 0.05%
  14. 14. 1002-7 What is Selective Catalytic Reduction (SCR)? The main components of the SCR system include the SCR catalyst, the Diesel Exhaust Fluid (DEF)/ AdBlue® injection unit, the DEF/AdBlue® tank, and the DEF/AdBlue® dosing control unit. How does Selective Catalytic Reduction (SCR) work? During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue® solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue® solution. During cold engine operation at low engine coolant and ambient air temperatures, water vapor will be visible from the exhaust when the engine operates. This water vapor will resemble steam or light white smoke and will dissipate as the engine and machine components warm and is considered normal. NOTE: After engine shutdown, the SCR system will perform a purge cycle, which permits the supply module to continue to run for up to 70 seconds. This is to be considered normal and requires no action from the operator. What is Diesel Exhaust Fluid (DEF)/AdBlue®? DEF/AdBlue® is a non-toxic aqueous urea solution ( 32.5 %) with a slight ammonia odor used to chemically reduce NOx emissions from heavy-duty diesel powered vehicles. DEF/AdBlue® is neither explosive nor harmful to the environment and is classified under the minimum-risk category of transportable fluids. DEF/AdBlue® quality is defined by ISO 22241-1. The American Petroleum Institute (API®) has a voluntary certification program for DEF/AdBlue®. To ensure DEF/ AdBlue® satisfies the requirements of ISO 22241. DEF/AdBlue®. API Diesel Exhaust Fluid Certification Mark is a registered trademark of API in the United States and or other countries. Storage, handling, and transport NOTICE: Storage temperatures above 30 °C (86 °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 heat and direct sunlight. Thawing • The machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue®. The machine will still function until the DEF/AdBlue® begins to flow. The SCR system will then function normally. • Do not heat DEF/AdBlue® for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life. NOTICE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue®. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjust- ing of the DEF/AdBlue® mixture will lessen its ability to perform correctly and may cause damage to the SCR components. Handling and supply of additives, if any. • Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, impervious gloves are recommended. Follow the precautions listed in the SAFETY INFORMATION chapter when handling any service fluid. • No additives are required. NOTICE: Contaminated DEF/AdBlue® can affect the performance of your machine. Follow all instructions in this manual when handling DEF/AdBlue®. Shelf life Constant ambient storage temperature and minimum shelf life Less than or equal to 10 °C (50 °F) 36 months Less than or equal to 25 °C (77 °F) ¹ 18 months Less than or equal to 30 °C (86 °F) 12 months Less than or equal to 35 °C (95 °F) 6 months Greater than 35 °C (95 °F) -² ¹ To prevent decomposition of DEF/AdBlue®, prolonged transportation or storage above 25 °C (77 °F) should be avoided. ² Significant loss of shelf life: check every batch before use. See your [Brand] dealer for more information on testing.
  15. 15. 1002-8 NOTE: The main factors taken into account to define the shelf life in the previous figures are the ambient storage temperature and the initial alkalinity of DEF/AdBlue®. The difference in evaporation between vented and non-vented storage containers is an additional factor. NOTE: The information in this table is for reference only and has been provided by the International Organization for Standardization, Document number ISO 22241-3 Diesel engines - NOx reduction agent AUS 32 - Part 3: Handling, transportation and stor- age. Disposal • Dispose of DEF/AdBlue® and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal. For machines sold in California CNH must warrant the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control 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 warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owner’s manual for other warranty information. The diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, and other emission-related assemblies. Glossary Acronym Definition DEF Diesel Exhaust Fluid ISO International Organization for Standardization MSDS Material Safety Data Sheet NOx Nitrogen Oxide PPE Personal Protective Equipment SCR Selective Catalytic Reduction ULSD Ultra Low Sulfur Diesel
  16. 16. 1002-9 SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS Requirements The operator must maintain appropriate DEF/AdBlue® levels at all times. The SCR system is compatible with up to 7% bio-diesel fuel. Diesel Exhaust Fluid (DEF)/AdBlue® refilling The DEF/AdBlue® tank cap (1) can be identified by the “blue” color of the cap. A fitting under the cap prevents the insertion of a diesel fill nozzle. NOTE: If any DEF/AdBlue® spills or contacts any surface other than the storage tanks, immediately clean the affected surface with clear water. DEF/AdBlue® will cause corrosion on painted and unpainted metallic surfaces, and may distort some plastic and rubber components. It is recommended that DEF/AdBlue® filling equipment should be used having a fill nozzle/pump with the correct length and 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 pumped in the fuel tank, as the DEF/AdBlue® nozzle cannot pump when the magnet is not sensed. NOTICE: Refilling with a funnel is not recommended as this may lead to damage of the screen in the filler neck. NOTE: The information above has been provided by the International Organization for Standardization (ISO), Document number ISO 22241-4 Diesel engines - NOx reduction agent AUS 32 - Part 4: Refilling interface. Diesel Exhaust Fluid (DEF)/AdBlue® consumption NOTE: DEF/AdBlue® consumption is highly dependent on engine loads, humidity levels, DEF/AdBlue® fluid concentration, and engine speed. The “typical” consumption is only a guideline to verify proper function of the SCR system. CNH recommends to fill the DEF/AdBlue® tanks at every fuel refilling interval.
  17. 17. 1002-10 MAINTENANCE SCHEDULE SERVICE INTERVAL ITEM NUMBER SERVICE POINTS InitialService FREQUENCY IN HOURS CHECK CLEAN CHANGE DRAIN LUBRICATE REPLACE ADJUST Variable Periodic (*) 2 Radiator Coolant Level * 13 Tires * 16 Hydraulic Filter * 12 Alternator, AC, Drive Belt * 31 Air cleaner * * 19 Bleed Fuel Filter of Condensation * 28 Clean SCR system DEF tank filter * XX Fire extinguisher * Every 10 Hours 1 Check Engine Oil Level 10 Every 50 Hours 13 Check Engine Coolant Level 50 3 Check Transmission Oil Level 50 4 Check Hydraulic Oil Level 50 5 & 6 Grease Bucket Mounting Fittings 50 7 Grease machine and attachments 50 First 100 Hours 16 Change Engine Oil and Filters 100 18 Replace Fuel Filters 100 20 Change Hydraulic Filter 100 25 Change Oil in Axles 100 13 Check wheel torque 100 28 Clean in-line DEF supply filter 100 Every 100 Hours 8 Lubricate The Steering Cylinder Pivots - Rod And Closed End (4 Fittings) 100 9 Grease Front Drive Shaft Support Bearing 100 10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100 10 Lubricate Loader Lift & Cylinder Pivots (18) XT 100 Every 250 Hours 11 Check Cab Air Filter 250 14 Check Tire Pressure & Wheel Torque 4 250 12 Check Drive Belt 250 XX Trans Clutch Calibration (See Section 6002) 250 1000 Every 500 Hours 14 Check Axle Oil Level 500 15 Check Battery Electrolyte Level 500 16 Change Engine Oil and Filter 500 XX Check ROPS 500 18 Drain Fuel Tank Condensation & Water Separator 500 19 Replace Fuel Filter 500
  18. 18. 1002-11 Every 1000 Hours 20 Replace Hydraulic Oil filter 1000 21 Grease Articulation Fittings 1000 24 Change crankcase filter 1000 1000 23 Replace Drive Belt 11 Replace Cab Air Filter 1000 26 Change Transmission Oil and Filter 1000 XX Check Injector Calibration 1000 XX Check Valve Adjustment (Engine Manual) 1000 XX Trans Clutch Calibration (See Section 6002) 1000 Every 1500 Hours 21 Change Front & Rear Axle Oil 1500 26 Change Transmission Oil and Filter 1500 28 Clean in-line DEF filter Every 2000 Hours 29 Change Hydraulic Oil 2000 30 Change Coolant 2000 31 Replace Engine Air Cleaner 2000 32 Lubricate cab and door 2000 XX Valve Clearance (Engine Manual) 2000 Every 3000 Hours XX Replace DEF supply module filter 3000 Every 6000 Hours XX Engine Injectors (Engine Manual) 6000 XX Fuel Pump (Engine Manual) 6000 6000
  19. 19. 1002-12 MAINTENANCE POINTS 84397762 See your Operators manual for maintenance 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.
  20. 20. Section 1003 1003 METRIC CONVERSION CHART
  21. 21. 1003-2 TABLE OF CONTENTS CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
  22. 22. 1003-3 CONVERSION FACTORS Metric to U.S. MULTIPLY BY TO OBTAIN Area: sq. meter hectare 10.763 91 2.471 05 square foot acre Force: newton newton 3.596 942 0.224 809 ounce force pound force Length: millimeter meter kilometer 0.039 370 3.280 840 0.621 371 inch foot mile Mass: kilogram 2.204 622 pound Mass/Area: kilogram/hectare 0.000 466 ton/acre Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr. Mass/Volume: kg/cubic meter 1.685 555 lb/cubic 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 0.264 172 0.219 969 cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial) Volume/Time: litre/min. litre/min. 0.264 172 0.219 969 gallon/min. (US liquid) gallon/min. (Imperial)
  23. 23. 1003-4 U.S. to Metric * = exact MULTIPLY BY TO OBTAIN Area: square foot acre 0.092 903 0.404 686 square meter hectare Force: ounce force pound force 0.278 014 4.448 222 newton newton Length: inch foot mile 25.4 * 0.304 8 * 1.609 344 * millimeter meter kilometer Mass: pound ounce 0.453 592 28.35 kilogram gram Mass/Area: ton/acre 2241 702 kilogram/hectare Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr Mass/Volume: lb/cubic yd. 0.593 276 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) gallons (Imperial) 16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092 cubic centimeter cubic meter cubic meter milliliter litre litre litre litre Volume/Time: gallon/min. 3.785 412 litre/min.
  24. 24. Section 2000 2000 ENGINE AND RADIATOR REMOVAL AND INSTALLATION
  25. 25. 2000-2 TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
  26. 26. 2000-3 ENGINE Removal STEP 1 BD03A040 Park machine on a level surface and lower bucket to ground. Put articulation lock in LOCKED position. STEP 2 Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position. STEP 3 Slowly loosen the filler cap for hydraulic reservoir to release air pressure in hydraulic 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 30 liter (32 U.S. quart) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap. STEP 6 BD02N160 Put a 15.1 liter (16 U.S. quart) container below engine oil drain. Remove cap and drain oil into container. Install cap after oil has drained. NOTE: After draining oil disconnect drain hose from frame for removal with engine.
  27. 27. 2000-4 STEP 7 BD03A231 Double up a nylon lifting strap (1) and slide through the exhaust stack (2) on the hood. STEP 8 BD03A230 Place a solid steel bar through the strap, raise the hood and release tension on the 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 1 2 2
  28. 28. 2000-5 STEP 12 BD03A232 Carefully raise and remove hood from loader. Lower hood onto suitable platform and disconnect lifting equipment. STEP 13 BD03A224 Tag and disconnect engine wiring harness connector from 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 the machine.
  29. 29. 2000-6 STEP 18 BD06F111 Loosen the clamp on the intake manifold for the after cooler output hose. STEP 19 BD03A118 Loosen the clamp on the after cooler and remove the 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.
  30. 30. 2000-7 STEP 23 BD06F115 Remove the drive belt from the engine. STEP 24 BD06F116 Loosen clamps and remove lower cooler hose from the engine. STEP 25 BD06F117 If loader is equipped with air conditioning, identify, tag, and disconnect the 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 wires (2) from the engine. 1 2 1 2
  31. 31. 2000-8 STEP 29 BD06F121 Tag and remove the wires from the starter solenoid (3), remove the ground cable (2), and ground strap (1) from the starter. NOTE: Move the starter cables away from the engine, move the wiring harness away from the engine. STEP 30 BD06F146 Disconnect the engine coolant vent hose and root to the rear of 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. STEP 34 BD06F123 Remove the fuel line from the top of the EDC 7 controller, plug the line and cap the fitting. 3 1 2 2 1 3
  32. 32. 2000-9 STEP 35 BD06F124 Tag and disconnect the fuel filter heater wires (1), disconnect the fuel line (2) from the fuel filter head, plug the line and cap the fitting. STEP 36 BD06F125 Remove bolt and clamp. STEP 37 BD06F126 Connect and turn on vacuum pump to hydraulic reservoir. Tag and remove the hydraulic lines from the brake system pump, plug the lines and cap the fittings. STEP 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 engine. STEP 41 Slowly raise engine from rear chassis. Be sure all harness connections and hoses have been disconnected and are clear of the engine. Remove engine from machine. 1 2
  33. 33. 2000-10 Installation BS03B035 STEP 42 If engine rubber isolators require replacement, remove and discard isolators (3 and 4). Install new rubber isolator (4), then rubber isolator (3). STEP 43 Slowly raise engine and move into position over rear chassis. Be sure all harness connections and hoses are out of the way then lower engine. Put washer (5) between front rubber isolator (4) and chassis. Install washer (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 to engine coupling. Tighten the six bolts to a torque of 53 to 62 Nm (39 to 46 lb-ft). 1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT 2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE 1 4 3 2 7 6 5 4 3 2 1 1 7 8 7 6 5 2 3 4 5 6
  34. 34. 2000-11 STEP 48 BD06F127 Install the lower cover for the drive shaft. STEP 49 BD06F126 Connect and turn on vacuum pump to the hydraulic reservoir. Remove caps from fittings and plugs from hoses. Connect hoses to brake pump following tags installed during removal. Remove and discard tags. Turn off and disconnect 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: Start the connector on the EDC 7 with lever straight out from EDC 7. Use lever to pull connector into position. 1 2
  35. 35. 2000-12 STEP 54 BD06F111 Connect grid heater cable to grid heater. Remove and discard tag. STEP 55 BD06F122 Install the heater hose (2) to the rear of the engine, mount the clamps (3), install the radiator hose (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 2
  36. 36. 2000-13 STEP 60 BD06F118 Connect the wiring to the alternator. Remove and discard tags. STEP 61 BD06F117 If loader is equipped with air conditioning, mount the compressor using the three mounting bolts (2), connect the engine 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 the belt cover. 1 2
  37. 37. 2000-14 STEP 65 BD06F112 Place the muffler and air cleaner on the bracket. Install mounting bolts in air cleaner and tighten, install the mounting bolts in the muffler and leave loose at this time. STEP 66 BD06F110 Install and tighten the exhaust clamp 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 the turbocharger for the after cooler inlet hose.
  38. 38. 2000-15 STEP 71 BD06F110 Install the intake hose and tighten the clamps on turbocharger and air cleaner. STEP 72 BD03A225 Install the crankcase ventilation hose and tighten the clamp on air cleaner intake hose. STEP 73 BD03A224 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 to cooler housing. 1 2 2
  39. 39. 2000-16 STEP 76 BD03A228 Install the pin from the top of the lifting motor, lower and remove lifting equipment. STEP 77 BD06F109 Connect hood wiring harness connector to rear chassis wiring harness connector. Remove and discard tag. STEP 78 BD03A221 NOTE: If hood strut is not adjusted properly the hood will be damaged. When a hood is removed and replaced an initial adjustment on the strut is necessary. Adjust between the top of the lift motor adjusting jam nut (1) to the top of the threads (2) to 20 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 8 67 3 8 17 28 12 48 8 68 3 9 17 29 12 49 8 69 3 10 17 30 12 50 7 70 3 11 16 31 12 51 7 71 2 12 16 32 12 52 7 72 2 13 16 33 11 53 7 73 2 14 16 34 11 54 6 74 2 15 16 35 11 55 6 75 2 16 15 36 11 56 6 76 1 17 15 37 10 57 6 77 1 18 15 38 10 58 6 78 1 19 15 39 10 59 5 79 1 20 14 40 10 60 5 80 0 2 1
  40. 40. 2000-17 STEP 79 BD02N160 Check and make sure that drain caps are tight. STEP 80 Install a new oil filter on engine. Fill engine with 13.25 liters (14 U.S. quarts) of Case AKCELA Engine Oil (SAE 15W-40). STEP 81 If hydraulic reservoir was drained, fill reservoir of the 821F with 90.8 liters (24.0 U.S. gallons) of Case AKCELA Hy-Tran Ultra® fluid. Fill the reservoir of the 921F with 110 liters (29.0 U.S. gallons) of Case AKCELA Hy-Tran Ultra® fluid. STEP 82 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liters (32 U.S. quarts). Install the radiator cap. Fill the coolant reservoir up to the FULL mark 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 the reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. STEP 85 BD06F108 Lower the hood with the hood lift motor. STEP 86 Put articulation lock in OPERATING position.
  41. 41. 2000-18 RADIATOR Removal STEP 1 Park loader on level surface and lower bucket to ground. Apply parking brake and shut down engine. STEP 2 BD03A040 Put articulation lock in LOCKED position. STEP 3 Put master disconnect switch in OFF position. STEP 4 BD03A120 Have another person raise and hold the side panel up into the raised position. Remove 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 30.0 liter (32.0 U.S. quart) container below radiator drain. Remove radiator cap then remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap. STEP 7 BD03A109 Release catch and tilt air conditioning condenser core up to gain access to upper radiator hose.
  42. 42. 2000-19 STEP 8 BD03A108 Loosen the upper radiator hose clamps, remove the hose. STEP 9 BD06F129 Loose and remove the 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 22
  43. 43. 2000-20 Installation STEP 12 Move radiator into position above cooling frame. Carefully lower radiator while guiding it into position in cooling frame. STEP 13 BD03A106 Install four lock washers and bolts (2) to secure radiator to cooling frame. Disconnect lifting equipment from lifting eyes. Remove lifting eyes and install screws (1). STEP 14 BD03A113 Connect connector to coolant level sender, connect overflow hose to radiator. STEP 15 BD06F129 At bottom of radiator, install bottom radiator hose. Position and tighten two hose clamps to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). STEP 16 BD03A108 At top of cooling system frame, install hose. Position hose clamps and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). STEP 17 BD06F130 When installing fender make sure it is behind the fender mounting bolt. 1 22
  44. 44. 2000-21 STEP 18 BD06F131 Align the whole in the fender on the bolt. STEP 19 BD06F132 Align the slots in the fender with the tabs on the body of the machine. STEP 20 DSC00105.TIF Push the fender towards the front of the machine and secure it using washer and bolt. STEP 21 BD03A120 Have another person raise and hold the side panel up into position. Apply Loctite 242 to the threads, install the two mounting screws for the side panel and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5 pound-inches). NOTE: Photo is of the oil cooler side of the machine, the procedure is the same. STEP 22 BD02N160 Check that coolant drain cap is tight. STEP 23 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liters (32.0 U.S. quarts). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.
  45. 45. 2000-22 STEP 24 Put master disconnect switch in ON position. STEP 25 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 the reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. STEP 26 Put articulation lock in OPERATING position.
  46. 46. Section 2002 2002 STALL TEST
  47. 47. 2002-2 TABLE OF CONTENTS 821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 921F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
  48. 48. 2002-3 821F SPECIFICATIONS Engine with 4 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm C. Converter Stall ............................................................................................................................1883 to 1963 rpm D. Hydraulic Stall .............................................................................................................................1883 to 1963 rpm E. Converter & Hydraulic Stall .........................................................................................................1497 to 1577 rpm Temperature of the torque converter oil.......................................................................82° to 104° C (180° to 220° F) Temperature of the hydraulic oil.......................................................................................54° to 57°C (129° to 134°F) Engine with 5 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm C. Converter Stall ............................................................................................................................1860 to 1900 rpm D. Hydraulic Stall .............................................................................................................................1923 to 2003 rpm E. Converter & Hydraulic Stall .........................................................................................................1524 to 1604 rpm Temperature of the torque converter oil.......................................................................82° to 104° C (180° to 220° F) Temperature of the hydraulic oil.......................................................................................54° to 57°C (129° to 134°F) NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd gear. STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.
  49. 49. 2002-4 921F SPECIFICATIONS Engine with 4 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm C. Converter Stall ............................................................................................................................1900 to 1940 rpm D. Hydraulic Stall .............................................................................................................................1860 to 1940 rpm E. Converter & Hydraulic Stall.........................................................................................................1525 to 1605 rpm Temperature of the torque converter oil.......................................................................82° to 104° C (180° to 220° F) Temperature of the hydraulic oil.......................................................................................54° to 57°C (129° to 134°F) Engine with 5 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2135 to 2185 rpm C. Converter Stall ............................................................................................................................1945 to 1985 rpm D. Hydraulic Stall .............................................................................................................................2017 to 2097 rpm E. Converter & Hydraulic Stall.........................................................................................................1531 to 1611 rpm Temperature of the torque converter oil.......................................................................82° to 104° C (180° to 220° F) Temperature of the hydraulic oil.......................................................................................54° to 57°C (129° to 134°F) NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd gear. STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.
  50. 50. 2002-5 INSTRUMENT CLUSTER DISPLAYS 1. With the engine running, press the up or down key and scroll through the information screens and trip screens. The following sequence is using the down key only. NOTE: Pressing the escape key will return the LCD back to the normal driving screen. BD06F188 2. From the driving screen push the down arrow, as shown. BD06F183 3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, and fuel level. BD06F027 4. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, engine oil temperature in either Fahrenheit or Celsius, as well as oil pressure. BD06F184 5. Push the down button again for the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil.
  51. 51. 2002-6 BD06F169 6. Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour. BD06F170 7. By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.
  52. 52. 2002-7 PROCEDURE TO HEAT THE OIL Torque Converter 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored. 4. Place the declutch switch in the OFF position. 5. Place the automatic switch in the manual mode position. Push down and hold the brake pedal for the remainder of this procedure. 6. Release the parking brake. 7. Move the transmission control lever to Forward and turn the transmission control lever to 3rd gear. 8. Increase the engine speed to full throttle and run the engine at this speed for 30 seconds. 9. Decrease the engine speed to low idle and move the transmission control lever to the Neutral position for 15 seconds. 10. Repeat steps 7, 8, and 9 until the temperature of the torque converter oil is 82° to 104°C (180° to 220°F). Hydraulic System 1. Apply the parking brake. 2. Start the engine and run at full throttle. 3. To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on. 4. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height. 5. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).
  53. 53. 2002-8 POWER MODE SELECTION 1. After the oil temperatures have been raised to operating temperatures the power mode must be set to “Auto”. BD06H038 2. Press and hold the confirmation “enter” button for two seconds to arrive at the above service screen. 3. Use down arrow to scroll through the menu’s. 4. High light Power Mode and press the enter key. 5. Power Mode Menu A. Max - Maximum power possible B. Standard - Standard operation C. Auto - Will cycle between Max and Standard D. Eco - Limited power for economy 6. High light Auto mode and press the enter key. 7. Press the escape key to return to the normal driving screen.
  54. 54. 2002-9 PERFORMING STALL TESTS Test No. 1 - Torque Converter and Hydraulic Stall Together 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. Run engine at low idle. Push the clutch cutout switch to OFF. Put the transmission in manual mode. Push down and hold the brake pedal for the remainder of this procedure. 5. Turn the transmission control lever to third gear. 6. Increase the engine speed to full throttle. 7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. NOTE: The stall speed must be read while the lift arms are in motion. 8. Check the engine speed. 9. Release the bucket control lever. 10. Decrease the engine speed to low idle. 11. Lower the bucket to the ground, place the transmission in neutral and apply the parking brake. 12. Stop the engine. Understanding the Results of Test No. 1 1. If the engine speed was as specified, the engine, torque converter, transmission and hydraulic system are probably good. 2. If the engine speed was not as specified, do Test No. 2 and 3. Test No. 2 - Torque Converter Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. Run the engine at low idle. 5. Push down and hold the brake pedal for the remainder of this test. 6. Turn the transmission control lever to third gear. 7. Increase the engine speed to full throttle. 8. Check the engine speed. 9. Decrease the engine speed to low idle. 10. Place the transmission in neutral and apply the parking brake. 11. Stop the engine. Understanding the Results of Test No. 2 1. If the engine speed was as specified, the engine, torque converter and transmission are probably good. 2. If the engine speed was more than specified, the problem can be in the torque converter or the transmission. See Section 6002 for troubleshooting information. 3. If the engine speed was less than specified, do Test No. 3.
  55. 55. 2002-10 Test No. 3 - Hydraulic Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Increase the engine speed to full throttle. 4. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. NOTE: The stall speed must be read while the lift arms are in motion. 5. Check the engine speed. 6. Release the bucket control lever. 7. Decrease the engine speed to low idle. 8. Lower the bucket to the ground. 9. Stop the engine. Understanding the Results of Test No. 3 1. If the engine speed was as specified, the engine and hydraulic system are good. 2. If the engine speed was more or less than specified the main relieef setting may be too low or too high. See Section 8002 for troubleshooting information. 3. If the engine speed was less than specified in all tests, the engine is probably the cause.
  56. 56. Section 2003 2003 AFTER COOLER
  57. 57. 2003-2 TABLE OF CONTENTS TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
  58. 58. 2003-3 TROUBLESHOOTING AFTER COOLER STEP 1 Park machine on level ground, lower the bucket. Put transmission in neutral, apply the parking brake. Turn off engine. STEP 2 Raise hood. Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port. STEP 3 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. If the pressure difference is greater than 60 mbar (0.87 psi), inspect cooler components for damaged or missing parts. STEP 4 BD03A116 Inspect the turbocharger flex hose for leaks or holes and insure that the clamps are tight. STEP 5 BD03A115 Inspect the after cooler inlet flex hose for leaks or holes and insure that the clamps are tight. BD03A118 Inspect the after cooler outlet flex hose for leaks or holes and insure that the clamps are tight. STEP 6 BD03A119 Inspect the intake manifold flex hose for leaks or holes and insure that the clamps are tight. STEP 7 BD03A109 Visually inspect top of after cooler for damage or leaks NOTE: If the leak source has not been located, remove and test the after cooler.
  59. 59. 2003-4 AFTERCOOLER REMOVAL Removal STEP 1 BD03A116 Loosen clamps and remove turbocharger outlet components. STEP 2 BD03A115 Loosen clamps and remove air cooler inlet hose. STEP 3 BD03A119 Loosen clamps and remove Intake hose. STEP 4 BD03A118 Loosen clamps and remove air cooler outlet hose. STEP 5 BD03112 Raise air conditioning/air cooler cover. Support cover with appropriate lifting device. Remove cover support latch. STEP 6 BD03A111 Remove three cover mounting bolts and lift cover off.
  60. 60. 2003-5 STEP 7 BD03A109 Unlatch air conditioning condenser clamp. STEP 8 BD03A107 Rotate air conditioning condenser up and remove the two retaining bolts, one on each side. Move the air conditioning condenser back away from the air cooler STEP 9 BD03A117 Remove the two bolts at the rear of the after cooler mounting frame. STEP 10 BD03A113 Remove two bolts, one from each side of the after cooler mounting frame. STEP 11 Lift air cooler and frame from machine with appropriate lifting devise. STEP 12 BD03A111 Remove four bolts that mount air cooler in the air cooler frame. Remove air cooler from frame.
  61. 61. 2003-6 Leak Test BS03B028 Check the core for leaks by closing off the outlet tube and attaching regulated air pressure 550kPa (80psi) to the inlet tube. Submerge the cooler in water and watch for air leakage. NOTE: If leakage is detected replace the after cooler. Installation STEP 1 BD03A111 Install after cooler in its frame. Install four mounting bolts. Support after cooler with appropriate lifting device. Install the after cooler and frame in the machine. STEP 2 BD03A113 Install two side mounting bolts STEP 3 BD03A117 Install two bolts at the rear of the after cooler mounting frame.
  62. 62. 2003-7 STEP 4 BD03A107 Position air conditioner condenser and install mounting bolts. Rotate the condenser down and latch. STEP 5 BD03112 Support cover with appropriate lifting device. Raise air conditioning/air cooler cover over machine. Install cover support latch. STEP 6 BD03A111 Install three cover mounting bolts. STEP 7 BD03A116 Install air cooler inlet hose. Tighten clamps at turbocharger outlet. STEP 8 BD03A115 Tighten clamps at air cooler inlet. STEP 9 BD03A119 Install air cooler outlet hose and tighten clamps at engine intake.
  63. 63. 2003-8 STEP 10 BD03A118 Tighten clamps at air cooler outlet. STEP 11 Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port. STEP 12 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. confirm that the pressure difference is less than 60 mBar (0.87 psi).
  64. 64. Section 2010 2010 ENGINE INTAKE AIR FILTRATION
  65. 65. 2010-2 TABLE OF CONTENTS Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
  66. 66. 2010-3 AIR FILTRATION Pre-cleaner Disassembly & Reassembly STEP 1 721F-8469.PNG Access pre-cleaner located on top of engine compartment hood. STEP 2 IMG_1683.AI.TIF Loosen wing nut. STEP 3 IMG_1682.AI.TIF Disassemble and remove precleaner from machine. STEP 4 IMG_1680.AI.TIF Empty debris and clean wipe precleaner with a damp clean cloth. Reassemble/install unit on machine.
  67. 67. 2010-4 Primary/Secondary Fillter Element Disassembly STEP 1 721F-8469.PNG Raise engine compartment hood using controls located behind access cover (1). Air filter housing/element (2) is located in main engine compartment on left hand side of engine. STEP 2 IMG_0099.PNG Turn master electric switch “off”. STEP 3 IMG_0115.PNGD Release all clips securing air filter element housing cover. STEP 4 IMG_0142.PNG Remove cover from air filter element housing. STEP 5 IMG_0143A.PNG Remove primary filter element by lifting up on handle 1 2
  68. 68. 2010-5 STEP 6 IMG_0144A.PNG Remove secondary filter element from right side of housing. Remove debris from inside filter element housing before installing new filter elements. NOTE: Do not clean the seconday filter element. It must be replaced if damaged or clogged. Primary/Secondary Element Reassembly STEP 1 IMG_0144A.PNG Install new secondary filter element by inserting it into positioning slot. NOTE: Make sure filter element is firmly seated into housing. STEP 2 IMG_0143A.PNG Install new primary filter element by sliding it down into housing. NOTE: Make sure primary and secondary filter elements form an effective seal. STEP 3 IMG_0142.PNG Install housing cover. STEP 4 721F-8508.PNG Lock clips to secure filter housing cover. NOTE: If cover does not fit properly, recheck filter element installation. Cover will be difficult to install if filter elements are not properly installed.
  69. 69. 2010-6 STEP 5 IMG_0099.PNG Turn master electric power switch “on”. Clear any fault codes. Start machine and confirm problem has been corrected.
  70. 70. Section 2020 2020 SCR SYSTEM SENSORS
  71. 71. 2020-2 TABLE OF CONTENTS SCR System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 NOx Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
  72. 72. 2020-3 SCR SYSTEM SENSORS Upstream Exhaust Temperature Sensor Removal NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.” STEP 1 721F-8469.PNG Raise the hood using controls located behind the access cover. STEP 2 IMG_0099.PNG Turn master electric switch to the “off” position. STEP 3 IMG_0912.TIF Locate exhaust temperature sensor (1) on exhaust system before the catalyst (2). STEP 4 IMG_1507.TIF Loosen hex nut on sensor. 2 1
  73. 73. 2020-4 STEP 5 IMG_1510.JPG Remove temperature sensor from exhaust system. STEP 6 IMG_1514.TIF Remove wire ties securing wire harness to support brackets. Unplug sensor from machine wiring harness and remove it. Upstream Exhaust Temperature Sensor Reinstall NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.” STEP 1 IMG_1510.TIF Install temperature sensor into exhaust pipe. STEP 2 IMG_1507.TIF Secure sensor into exhaust pipe. Sensor torque 40 to 50 Nm (30 to 36 lb ft.). Reconnect sensor to wire harness and secure harness to support brackets using new wire ties.
  74. 74. 2020-5 STEP 3 IMG_0099.PNG Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected. Downstream Exhaust Temperature Sensor Removal NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.” STEP 1 721F-8469.PNG Raise the hood using controls located behind the access panel. STEP 2 IMG_0099.PNG Turn master electric switch to the “off” position. STEP 3 IMG_1465.TIF Locate the exhaust temperature sensor (1) on exhaust system after catalyst (2). STEP 4 GRAPHIC_ID Loosen hex nut and remove sensor from exhaust system. 1 2
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