Page 1

SERVICE MANUAL

WHEEL LOADER 721E TIER 3

84243980 (Replaces 87634099) CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

North American English Part Number 84243980 Printed in U.S.A. • Rac © 2009 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America

Revised December 2009 Issued September 2007


721E Wheel Loader Service Manual 84243980 (Replaces 87364099)

Table of Contents Description

Section No.

General

Form No.

Tab 1

Section Index - General

5-2670

Standard Torque Specifications

1001

8-71603

Fluids and Lubricants

1002

5-2680

Metric Conversion Chart

1003

7-52950

Engines

Tab 2

Section Index - Engines

5-2690

Engine and Radiator Removal and Installation

2000

5-2700

Stall Tests

2002

5-2710

After Cooler

2003

6-49850

For Engine Repair, See the Engine Service Manual

87519803

Fuel System

Tab 3

Section Index - Fuel System

5-2720

For Fuel System Repair, See the Engine Service Manual Electrical

Tab 4

Section Index - Electrical

5-2730

Removal and Installation of Starter and Alternator

4001

5-2740

Electrical Specifications and Troubleshooting

4002

5-2750

Batteries

4003

6-42330

Instrument Cluster

4005

5-2760

Steering

Tab 5 84298386 (Replaces 5-2770)

Section Index - Steering Removal and Installation of Steering Components

5001

5-2780

Steering Specifications, Pressure Checks, and Troubleshooting

5002

5-2790

Steering Cylinders

5005

5-2800

Center Pivot

5006

5-2810

Auxiliary Steering Motor and Pump

5008

6-42430

Joystick Steering

5009

5-17020

84243981 CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

(Replaces 5-2660)

Copyright Š 2009 CNH America LLC. All rights reserved. Printed in U.S.A. Revised December 2009 (Issued August 2006)


721E Wheel Loader Service Manual 84243980 (Replaces 87364099)

Table of Contents Description

Section No.

Power Train

Form No.

Tab 6 84251801 (Replaces 5-2820)

Section Index - Power Train Removal and Installation of Power Train Components

6001

5-2830

Transmission Specifications, Pressure Checks, and Troubleshooting

6002

5-2840

Transmission

6003

5-2850

Front Axle

6004

5-2860

Rear Axle

6004

5-2870

Rear Axle, Serial Number N8F203816 and After

6004

84243983

Drive Shafts, Center Bearing, and Universal Joints

6005

5-2880

Wheels and Tires

6006

6-47730

Transmission Control Valve

6007

6-81450

Brakes

Tab 7

Section Index - Brakes

5-2890

Removal and Installation of Brake Components

7001

5-2900

Hydraulic Brake Troubleshooting

7002

5-2910

Brake Pump

7003

5-2920

Brake Accumulators

7004

6-47761

Parking Brake

7008

5-2930

Hydraulics

Tab 8

Section Index - Hydraulics

5-2940

Removal and Installation of Hydraulic Components

8001

5-2950

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

5-2960

Cleaning the Hydraulic System

8003

7-49641

Hydraulic Pump

8004

5-2970

Loader Control Valve

8005

5-2980

Cylinders

8006

5-2990

Coupler Solenoid Locking Valve

8007

6-42600

Ride Control Accumulator

8013

5-3000

Ride Control Valve

8014

5-3010

84243981 CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

(Replaces 5-2660)

Copyright Š 2009 CNH America LLC. All rights reserved. Printed in U.S.A. Revised December 2009 (Issued August 2006)


721E Wheel Loader Service Manual 84243980 (Replaces 87364099)

Table of Contents Description

Section No.

Mounted Equipment

Form No.

Tab 9

Section Index - Mounted Equipment

5-3020

Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant

9002

5-4030

Air Conditioner System Service Removal And Installation Of Air Conditioning And Heater Components

9003

5-3030

9004

5-3040

Loader

9006

5-3050

Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF)

9007

5-3060

Cab Glass Installation

9010

6-42710

In Rear Pocket

5-3070

Electrical Schematic Foldouts and Hydraulic Schematic Foldout

84243981 CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

(Replaces 5-2660)

Copyright © 2009 CNH America LLC. All rights reserved. Printed in U.S.A. Revised December 2009 (Issued August 2006)


SECTION INDEX

GENERAL Section Title

Section Number

Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-2670

Copyright © 2006 CNH America LLC. All rights reserved. Printed in U.S.A. Issued August, 2006


1001 Section 1001 GENERAL TORQUE SPECIFICATIONS

CASE, LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 8-71603

Copyright © 2004 CNH America LLC. All rights reserved. Printed in U.S.A. Issued April, 2003 Revised July, 2005


1001-2

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

Bur 8-71603

Revised 7-05

3 4 5 6

Printed in U.S.A.


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

Bur 8-71603

NOTE: Use thick nuts with Grade 8 bolts.

Revised 7-05

Printed in U.S.A.


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

Bur 8-71603

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.

Revised 7-05

Printed in U.S.A.


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

Bur 8-71603

Revised 7-05

Printed in U.S.A.


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

Bur 8-71603

Revised 7-05

Printed in U.S.A.


1002

Section 1002 FLUIDS AND LUBRICANTS

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-2680

Copyright © 2006 CNH America LLC. All rights reserved. Printed in U.S.A. Issued August, 2006


1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 721E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 721E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2680

Issued 8-06

3 4 5 5 5 5 6 6 7 7

Printed in U.S.A.


1002-3

CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ......................................................................................... 14.2 liters (15 U.S. quarts) Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4 Engine Cooling System Capacity...................................................................................................................36.9 liters (9.75 U.S. Gallons) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 246 liters (65 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 Hydraulic System Hydraulic Reservoir Refill Capacity ........................................................................ 105.7 liters (27.9 U.S. Gallons) Total System Capacity............................................................................................ 176.0 liters (46.5 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ............................................................................25.6 litres (6.75 U.S. Gallons) Type of Oil ................................................................................................................ Case AKCELA No. 1 15W-40 Axles Capacity Front......................................................................................................................... 30.3 litres (32 U.S. Quarts) Rear ......................................................................................................................... 23.7 litres (25 U.S. Quarts) Type of Lubricant .................................................................................................... Case AKCELA Transaxle Fluid 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®

Bur 5-2680

Issued 8-06

Printed in U.S.A.


1002-4

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

BD03A102

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.

BC02N250

Bur 5-2680

Issued 8-06

Printed in U.S.A.


1002-5

TRANSMISSION TEMPERATURE CHART

BC04F193

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%

Bur 5-2680

Issued 8-06

Printed in U.S.A.


1002-6

MAINTENANCE SCHEDULE Model 721E

Variable Periodic (* )

29

Air cleaner

19

Hydraulic Filter

22

Alternator, AC, Drive Belt

13

Radiator Coolant Level

XX

Fire extinguisher

14

Tires

Every 10 Hours 1

Every 100 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours Every 6000 hours Bur 5-2680

* * * * * *

Check Engine Oil Level

10

2

Check Engine Coolant Level

50

18

Bleed Fuel Filter of Condensation

Every 50 Hours 3

First 100 Hours

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

SERVICE POINTS

CHECK

ITEM NUMBER

SERVICE INTERVAL

Initial Service

FREQUENCY IN HOURS

*

50

Check Transmission Oil Level

50

4

Check Hydraulic Oil Level

50

5&6

Grease Bucket Mounting Fittings

17

Change Engine Oil and Filters

100

18 & 26

Replace Fuel Filters

100

19

Change Hydraulic Filter

100

21

Change Oil in Axles

100

9

Grease Front Drive Shaft Support Bearing

100

8

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

100

10

Lubricate Loader Lift & Cylinder Pivots (10) Z-bar

100

11

Lubricate Loader Lift & Cylinder Pivots (18) XT

100

12 & 23

Check Cab Air Filter

250

22

Check Drive Belt

250

13

Check Radiator Coolant Level

14

Check Tire Pressure & Wheel Torque

4

250

XX

Trans Clutch Calibration (See Section 6002)

250

1000

17

Change Engine Oil and Filter

17

Change Crankcase Filter

15

Check Axle Oil Level

500

16

Check Battery Electrolyte Level

500

26

Replace Fuel Filter

18

Drain Fuel Tank Condensation & Water Separator

19

Replace Hydraulic Oil filter

20

Grease Articulation Fittings

21

Change Front & Rear Axle Oil

22

Replace Cab Air Filter

24

Change Transmission Oil and Filter

XX

Replace Drive Belt

XX

Check Injector Calibration

XX

Check Valve Adjustment (Engine Manual)

1000

XX

Trans Clutch Calibration (See Section 6002)

1000

26

Change Hydraulic Oil

2000

27

Change Coolant

2000

28

Replace Engine Air Cleaner

XX

Valve Clearance (Engine Manual)

XX

Engine Injectors (Engine Manual)

6000

XX

Fuel Pump (Engine Manual)

6000

50

250

500 500

500 500 1000 1000 1000 1000 1000 1000 1000

2000 2000 6000 Issued 8-06

Printed in U.S.A.


1002-7

MAINTENANCE POINTS Model 721E 1

29

12 23

17

11

10

5

26 18 14 21 15

19 25 24

10

8

8

21 15

6

13

2

4

16

22

11 5

17

6

9

8

20

3

18

17

28

27 BC06F531

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.

Bur 5-2680

If you operate the machine in severe conditions, lubricate and service the machine more frequently.

Issued 8-06

Printed in U.S.A.


1002-8

NOTES

Bur 5-2680

Issued 8-06

Printed in U.S.A.


1003

Section 1003 METRIC CONVERSION CHART

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 7-52590

Copyright © 2003 CNH Ameica LLC. All rights reserved. Printed in U.S.A. Issued April, 2003


1003-2

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

Bur 7-52590

Issued 4-03

Printed in U.S.A.


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)

Bur 7-52590

Issued 4-03

Printed in U.S.A.


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

Bur 7-52590

Issued 4-03

Printed in U.S.A.


SECTION INDEX

ENGINES Section Title

Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002 After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003

FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL 87519803

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-2690

Copyright © 2006 CNH America LLC. All rights reserved. Printed in U.S.A. Issued August, 2006


Section 2000

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-2700

Copyright © 2006 CNH Ameica LLC. All rights reserved. Printed in U.S.A. Issued August, 2006

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION


2000-2

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

Bur 5-2700

Issued 8-06

3 3 10 18 18 20

Printed in U.S.A.


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 37 liter (10 gallon) 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 14.2 liter (15 U.S. quarts) 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 in the right batter 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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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 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.

Remove the pin from the top of the lifting motor.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

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

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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. Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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).

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).

STEP 45 Disconnect lifting equipment from engine lifting brackets.

STEP 46 Connect engine oil drain hose to frame bracket.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

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

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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).

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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

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

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

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

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.

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

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

Issued 8-06

Printed in U.S.A.


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 14.2 liters (15 quarts) of Case AKCELA No. 1 Engine Oil (SAE 15W-40).

Put articulation lock in OPERATING position.

STEP 81 If hydraulic reservoir was drained, fill reservoir with 105.7 liters (27.9 gallons) of Case AKCELA Hy-Tran UltraÂŽ fluid.

STEP 82 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 36.9 liters (9.75 gallons). 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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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 37 liter (10 gallon) 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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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 Âą 3.0 Nm (57.5 Âą 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 36.9 liter (9.75 gallon). 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.

Bur 5-2700

Issued 8-06

Printed in U.S.A.


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.

Bur 5-2700

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.

Issued 8-06

Printed in U.S.A.


2002

Section 2002 STALL TEST

CNH America LLC. 700 State Street Racine, WI 53404 U.S.A.

Bur 5-2710

Copyright © 2006 CNH Ameica LLC. All rights reserved. Printed in U.S.A. Issued August, 2006


2002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bur 5-2710

Issued 8-06

3 3 3 3 5 5 5 6 7 7 7 7 7 8 8

Printed in U.S.A.


2002-3

SPECIFICATIONS Low idle ..............................................................................................................................................875 to 925 rpm Alternate low idle .................................................................................................................................575 to 625 rpm Cold low idle ....................................................................................................................................1175 to 1225 rpm In gear low idle when in boost or auto power modes (see note) .....................................................1050 to 1150 rpm Full throttle (no load)........................................................................................................................2090 to 2225 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: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this accelerated level until the transmission is placed back into neutral for two seconds.

Stall Speeds Torque converter..............................................................................................................................1880 to 2025 rpm Hydraulic system .............................................................................................................................1885 to 2195 rpm Torque converter and hydraulic system together.............................................................................1600 to 1900 rpm

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.

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.

BD06F183

3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, fuel level, and the voltage level.

BD06F188

2. From the driving screen push the down arrow, as shown.

Bur 5-2710

Issued 8-06

Printed in U.S.A.


2002-4

BD06F169

BD06F027

4. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Fahrenheit or Celsius, as well as oil pressure PSI.

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

BD06F184

5. Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and radiator coolant temperature.

Bur 5-2710

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.

Issued 8-06

Printed in U.S.A.


2002-5

PROCEDURE TO HEAT THE OIL Torque Converter

Hydraulic System

1. Sit in the seat.

1. Apply the parking brake.

2. Start the engine and run the engine at low idle.

2. Start the engine and run at full throttle.

3. To measure the oil temperature with the instrument cluster:

3. To measure the oil temperature with the instrument cluster:

A. Press the up or down arrow key.

A. Press the up or down arrow key.

B. Stop at the info screen with the temperatures that need to be monitored.

B. Stop at the info screen with the temperatures that need to be monitored are on.

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.

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).

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).

Bur 5-2710

Issued 8-06

Printed in U.S.A.


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