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CASE 821F TIER 4 WHEEL LOADER Service Repair Manual .pdf



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821F
921F
Tier 4
Wheel Loader

SERVICE MANUAL

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

1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

1001-2

TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
4
5
6

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

Grade 8 Bolts, Nuts, and Studs

PoundInches

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

PoundInches

Newton
metres

Size

PoundFeet

Newton
metres

1/4 inch

108 to 132

12 to 15

7/16 inch

70 to 84

95 to 114

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

3/8 inch

420 to 504

48 to 57

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

Newton
metres

3/4 inch

380 to 456

515 to 618

Size

PoundFeet

7/8 inch

600 to 720

814 to 976

7/16 inch

54 to 64

73 to 87

1.0 inch

900 to 1080

1220 to 1465

1/2 inch

80 to 96

109 to 130

1-1/8 inch

1280 to 1440

1736 to 1953

9/16 inch

110 to 132

149 to 179

1-1/4 inch

1820 to 2000

2468 to 2712

5/8 inch

150 to 180

203 to 244

1-3/8 inch

2380 to 2720

3227 to 3688

3/4 inch

270 to 324

366 to 439

1-1/2 inch

3160 to 3560

4285 to 4827

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

Size

NOTE: Use thick nuts with Grade 8 bolts.

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 8.8 Bolts, Nuts, and Studs
8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs
10.9

Size

PoundInches

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

PoundFeet

Newton
metres

Newton
metres

M4

24 to 36

3 to 4

Size

M5

60 to 72

7 to 8

M10

54 to 64

73 to 87

M6

96 to 108

11 to 12

M12

93 to 112

125 to 150

M8

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton
metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

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

Grade 12.9 Bolts, Nuts, and Studs
12.9

Usually the torque values specified for grade 10.9
fasteners can be used satisfactorily on grade 12.9
fasteners.

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD
Hose ID

Thread
Size

PoundInches

Newton
metres

Tube OD
Hose ID

Thread
Size

PoundInches

Newton
metres

1/4 inch
6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch
6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch
7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch
7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch
9.5 mm

9/16-18

120 to 300

14 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

180 to 504

20 to 57

1/2 inch
12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch
15.9 mm

7/8-14

300 to 696

34 to 79
Tube OD
Hose ID

Thread
Size

PoundFeet

Newton
metres

Tube OD
Hose ID

Thread
Size

PoundFeet

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

40 to 80

54 to 108

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

60 to 100

81 to 135

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

75 to 117

102 to 158

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

125 to 165

169 to 223

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

210 to 250

285 to 338

1-1/2 inch
38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts
PoundInches

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

PoundFeet

Newton
metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Boss End
Fitting or Lock Nut

O-ring Face Seal End
Nom.
SAE
Dash
Size

Tube OD

Thread
Size

PoundInches

Newton
metres

Thread
Size

PoundInches

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

PoundFeet

Newton
metres

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

-10

Nom.
SAE
Dash
Size

5/8 inch
15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread
Size

PoundFeet

Newton
metres

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

FLUIDS AND LUBRICANTS

1002

Section
1002

1002-2

TABLE OF CONTENTS
821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
4
5
6
6
6
6
7
9
10
12

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®

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.

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.
S e e t h e c h a r t b e l ow fo r
recommended viscosity at
ambient air temperature
ranges.

RH99K130

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

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.

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.

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.

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%

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 (
3 2 .5 % ) w i th a s l i g h t a m m o n i a o d o r u s e d 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 transpor table 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, storage 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 adjusting 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, imper vious 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.

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 storage.
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

Pe r s o n a l
Equipment

Protective

SCR

Selective
Reduction

Catalytic

ULSD

Ultra Low Sulfur Diesel

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 i s r e c o m m e n d e d t h a t D E F /A d B l u e ® f i l l i n g
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.

1002-10

MAINTENANCE SCHEDULE

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

*

Check Engine Oil Level

10

13

Check Engine Coolant Level

50

3

Check Transmission Oil Level

50

Check Hydraulic Oil Level

50

Every 10 Hours 1

Every 50 Hours 4

First 100 Hours

Every 500
Hours

*
*

Grease Bucket Mounting Fittings

50

7

Grease machine and attachments

50

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

28

Clean in-line DEF supply filter

8

Lubricate The Steering Cylinder Pivots - Rod And
Closed End (4 Fittings)

100

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

11

Check Cab Air Filter

14

Check Tire Pressure & Wheel Torque

12

Check Drive Belt

XX

Trans Clutch Calibration (See Section 6002)

14

Check Axle Oil Level

500

15

Check Battery Electrolyte Level

500

16

Change Engine Oil and Filter

XX

Check ROPS

18

Drain Fuel Tank Condensation & Water Separator

19

Replace Fuel Filter

100
100

250
4

250
250

250

1000

500
500
500
500

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

*

5&6

Every 100 Hours 9

Every 250
Hours

SERVICE POINTS

CHECK

ITEM
NUMBER

SERVICE
INTERVAL

Initial Service

FREQUENCY IN HOURS

1002-11

Every 1000
Hours

Every 1500
Hours

Every 2000
Hours

Every 3000
Hours
Every 6000
Hours

20

Replace Hydraulic Oil filter

1000

21

Grease Articulation Fittings

24

Change crankcase filter

23

Replace Drive Belt

11

Replace Cab Air Filter

26

Change Transmission Oil and Filter

XX

Check Injector Calibration

XX

Check Valve Adjustment (Engine Manual)

1000

XX

Trans Clutch Calibration (See Section 6002)

1000

21

Change Front & Rear Axle Oil

1500

26

Change Transmission Oil and Filter

1500

28

Clean in-line DEF filter

29

Change Hydraulic Oil

2000

30

Change Coolant

2000

31

Replace Engine Air Cleaner

32

Lubricate cab and door

XX

Valve Clearance (Engine Manual)

XX

Replace DEF supply module filter

XX

Engine Injectors (Engine Manual)

6000

XX

Fuel Pump (Engine Manual)

6000

1000
1000

1000

1000
1000
1000

2000
2000
2000
3000

6000

1002-12

MAINTENANCE POINTS

84397762

See your Operators manual for maintenance of
safety related items and for detailed information of
the ser vice items on this char t. 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.

METRIC CONVERSION CHART

1003

Section
1003

1003-2

TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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)

1003-4

U.S. to Metric
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.

* = exact

Section
2000

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3
10
18
18
20

2000-3

ENGINE
Removal

STEP 5

STEP 1

BD02N160

Park machine on a level surface and lower bucket to
ground. Put articulation lock in LOCKED position.

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 2

STEP 6

BD03A040

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
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.

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 batte r y cove rs and disconn ec t
batteries from the machine.

2000-4

STEP 7

STEP 10

1

2

BD03A231

BD06F109

Double up a nylon lifting strap (1) and slide through
the exhaust stack (2) on the hood.

Tag and disconnect hood wiring harness connector
from rear chassis wiring harness connector.

STEP 8

STEP 11

2

1
BD03A230

BD03A227

Place a solid steel bar through the strap, raise the
hood and release tension on the lifting motor.

STEP 9
2

BD03A226

BD03A228

Remove the pin from the top of the lifting motor.

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.

2000-5

STEP 12

STEP 15

BD03A232

BD06F110

Carefully raise and remove hood from loader. Lower
hood onto suitable platform and disconnect lifting
equipment.

Loosen clamps on turbocharger and air cleaner,
remove the intake hose.

STEP 16
STEP 13

BD06F110
BD03A224

Tag and disconnect engine wiring harness connector
from air filter restriction switch.

Loosen the clamp on the turbocharger for the after
cooler inlet hose.

STEP 17
STEP 14

BD03A115
BD03A225

Loosen clamp on air cleaner intake hose and remove
the crankcase ventilation hose.

Loosen the clamp on the after cooler and remove the
after cooler inlet hose from the machine.

2000-6

STEP 18

STEP 21

BD06F111

BD06F112

Loosen the clamp on the intake manifold for the after
cooler output hose.

Remove the air cleaner and muffler from the bracket.

STEP 22

STEP 19

BD06F113
BD03A118

Loosen the clamp on the after cooler and remove the
after cooler outlet hose from the machine.

STEP 20

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.
BD06F110

Loosen the exhaust clamp from the turbocharger.

2000-7

STEP 23

STEP 26

BD06F115

BD06F118

Remove the drive belt from the engine.

Tag and disconnect the wiring from the alternator.

STEP 24

STEP 27

BD06F116

BD06F119

Loosen clamps and remove lower cooler hose from
the engine.

Remove bolt securing wiring harness clamp to
engine.

STEP 25

STEP 28
1

1
2

2

BD06F117

BD06F120

If loader is equipped with air conditioning, identify,
tag, and disconnect the engine wiring harness
connectors from air compressor clutch connector (1).
Remove the thre e m oun tin g b olts (2) for the
compressor and set the compressor on the left
battery cover.

Remove bolt securing wiring harness clamp (1) to the
engine. Remove ground wires (2) from the engine.

2000-8

STEP 29

STEP 32

1
3

2

BD06F121

Tag and remove the wires from the starter solenoid
(3), remove the ground cable (2), and ground strap
(1) from the starter.

BD06F111

Tag and remove the grid heater cable.

STEP 33

NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.

STEP 30

BD03A142

Disconnect the wiring harness from the EDC 7
controller.
NOTE: Lifting up on the lever will release the
connector from the controller.
BD06F146

Disconnect the engine coolant vent hose and root to
the rear of the engine.

STEP 34

STEP 31
3
2
1

BD06F123

Remove the fuel line from the top of the EDC 7
controller, plug the line and cap the fitting.
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.

2000-9

STEP 35

STEP 38

1

2

BD06F127

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.

Remove the lower cover for the drive shaft.

STEP 39

STEP 36

BD03A172

BD06F125

Remove bolt and clamp.

Remove the drive shaft bolts from the flywheel. Move
the drive shaft clear of the flywheel.

STEP 40

STEP 37

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
h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n
disconnected and are clear of the engine. Remove
engine from machine.

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.

2000-10

Installation

1
2

1

3

2
3

4
5
6

1

4

2

5

3

6
7

7
8

4
5
6
7
BS03B035

1. ENGINE MOUNT BOLT
2. WASHER

3. INSOLATOR UPPER
4. INSOLATOR LOWER

STEP 42

5. WASHER
6. WASHER

7. NUT
8. REMOTE OIL DRAIN HOSE

STEP 47

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.
BD03A172

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.

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).

2000-11

STEP 48

STEP 51

1

2

BD06F127

Install the lower cover for the drive shaft.

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 49

STEP 52

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.

BD06F123

Remove cap from fitting and plug from the hose,
connect fuel line to EDC 7.

STEP 53

STEP 50

BD03A142

Connect wiring harness to EDC 7 controller.
BD06F125

Install bolt and clamp for fuel return hose.

NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector
into position.

2000-12

STEP 54

STEP 57

1
2

3

BD06F111

BD06F121

Connect grid heater cable to grid heater. Remove
and discard tag.

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 55
STEP 58
3

1
2
2

1

BD06F122

Install the heater hose (2) to the rear of the engine,
mount the clamps (3), install the radiator hose (1).

STEP 56

BD06F120

Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.

STEP 59

BD06F146

Connect the engine coolant vent hose.

BD06F119

Install bolt securing wiring harness clamp to engine.

2000-13

STEP 60

STEP 63

BD06F118

Connect the wiring to the alternator. Remove and
discard tags.

BD06F115

Install the drive belt.

STEP 64
STEP 61
1
2

BD06F113
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

BD06F114

Install the cover mounting brackets to the machine
frame. Install the belt cover, install the four mounting
bolts for the belt cover.

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).

2000-14

STEP 65

STEP 68

BD06F112

BD06F111

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.

Tighten the clamp on the intake manifold for the after
cooler output hose.

STEP 69

STEP 66

BD03A115

BD06F110

Install and tighten the exhaust clamp on the
turbocharger, tighten the muffler mounting bolts.

Place the after cooler inlet hose on the machine.
Tighten the clamp on the after cooler.

STEP 70

STEP 67

BD06F110

BD03A118

Place the after cooler outlet hose on the machine.
Tighten the clamp on the after cooler.

Tighten the clamp on the turbocharger for the after
cooler inlet hose.

2000-15

STEP 71

STEP 74

BD06F110

Install the intake hose and tighten the clamps on
turbocharger and air cleaner.

STEP 72

BD03A232

Carefully raise and place hood over loader.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.

STEP 75

2

1

BD03A225

Install the crankcase ventilation hose and tighten the
clamp on air cleaner intake hose.

BD03A227

STEP 73

2

BD03A226

BD03A224

Connect engine wiring harness connector to air filter
restriction switch. Remove and discard tag.

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.

2000-16

STEP 76

STEP 78

2

1
BD03A228

BD03A221

Install the pin from the top of the lifting motor, lower
and remove lifting equipment.

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).

STEP 77

Hood Adjustment Table
Y
X
(MM) (MM)

BD06F109

Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and
discard tag.

Y
X
(MM) (MM)

Y
X
(MM) (MM)

Y
X
(MM) (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

2000-17

STEP 79

STEP 85

BD02N160

BD06F108

Check and make sure that drain caps are tight.

Lower the hood with the hood lift motor.

STEP 80

STEP 86

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).

Put articulation lock in OPERATING position.

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
an d wat er. Wh en the coo lan t is at o pe ra ting
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.

2000-18

RADIATOR
Removal

STEP 5

STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.

STEP 2

BD06F128

Remove bolt and washer securing LH fender.
Remove LH fender.

STEP 6
BD03A040

Put articulation lock in LOCKED position.

STEP 3
Put master disconnect switch in OFF position.

STEP 4

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
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.

BD03A109

Release catch and tilt air conditioning condenser
core up to gain access to upper radiator hose.

2000-19

STEP 8

STEP 11

1
2

2

BD03A108

BD03A106

Loosen the upper radiator hose clamps, remove the
hose.

Remove screws and install lifting eyes (1). Attach
suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.

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.

2000-20

Installation

STEP 15

STEP 12
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.

STEP 13

1
BD06F129

2

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).

2

STEP 16
BD03A106

Install four lock washers and bolts (2) to secure
ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g
equipment from lifting eyes. Remove lifting eyes and
install screws (1).

STEP 14

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

BD03A113

Connect connector to coolant level sender, connect
overflow hose to radiator.

BD06F130

When installing fender make sure it is behind the
fender mounting bolt.

2000-21

STEP 18

STEP 21

BD06F131

Align the whole in the fender on the bolt.

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).

STEP 19

NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.

STEP 22

BD06F132

Align the slots in the fender with the tabs on the body
of the machine.

STEP 20
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.
DSC00105.TIF

Push the fender towards the front of the machine and
secure it using washer and bolt.

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
an d wate r. Wh en the coo lan t is at o pe ra ting
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.

STALL TEST

2002

Section
2002

2002-2

TABLE OF CONTENTS
821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
921F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3
4
4
5
7
7
7
8
9
9
9
9
9
10
10

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.

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.


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