Case 721f tier 4 wheel loader service repair manual by 1631278

621F 721F Tier 4 Wheel Loader from PIN NBF213602 and above

SERVICE MANUAL

Part number 84605841 1st edition English May 2012

Contents INTRODUCTION Engine....................................................................................... 10 Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202 Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304 Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.310 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414 Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500 Engine generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.AAA

Transmission.............................................................................. 21 Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113 Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135 Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155

Four-Wheel Drive (4WD) system .................................................. 23 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.314

Front axle system ....................................................................... 25 Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.100 Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.102 Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

Rear axle system........................................................................ 27 Powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.100 Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.106 Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120

Brakes and controls .................................................................... 33 Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202

Hydraulic systems....................................................................... 35 84605841 14/05/2012

Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000 Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106 Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357 Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359 Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.525 Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.701

Steering..................................................................................... 41 Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.910

Wheels ...................................................................................... 44 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.511

Cab climate control ..................................................................... 50 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200

Electrical systems ....................................................................... 55 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000 Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.011 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015 Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.030 Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.031 Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.036 Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.047 Heating, Ventilation, and Air-Conditioning (HVAC) control system . . . . . . . . . . . . . . . . . . . . . . . 55.050 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls . . . . . . . . . . . . . . . . . . . . . . . . . 55.051 Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100 Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201 Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.302 External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404 84605841 14/05/2012

External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.405 Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408 Loader arm and bucket control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.415 Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512 Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.514 Wiper/Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.518 Cab brake controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.519 Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.524 Selective Catalytic Reduction (SCR) electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.988 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

Platform, cab, bodywork, and decals ............................................. 90 Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150

84605841 14/05/2012

INTRODUCTION

84605841 14/05/2012

Contents INTRODUCTION Torque – 621F Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 621F WE, 621F NA

Torque – 721F Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 721F WE, 721F NA

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 621F WE, 621F NA, 721F WE, 721F NA

Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

84605841 14/05/2012

INTRODUCTION

Torque – 621F Torque Specifications 621F WE, 621F NA

Axle Wheel mounting nuts Front axle mounting bolts Rear axle trunnion pin bolts

640 - 720 N·m (472 - 531 lb ft) 651 - 678 N·m (480 - 500 lb ft) 325 - 353 N·m (240 - 260 lb ft)

Chassis Cab mounts Exhaust stack to hood Counterweight mounting bolts Articulation pivot pin bolts Articulation mount pin retainer bolts Seat mounting bolts Steering wheel retaining nut Hydraulic oil filter mounting bolts Steering cylinder base end pin retaining bolt Steering cylinder rod end pin retaining bolt Horn mounting bolt Hood - rear grill bolts Hood hinge bolts Steps - lower entry strap bolts

773 - 854 N·m (570 - 630 lb ft) 36 - 44 N·m (27 - 32 lb ft) 955 - 1075 N·m (704 - 793 lb ft) 224 - 278 N·m (165 - 205 lb ft) 69 N·m (51 lb ft) 73 - 87 N·m (54 - 64 lb ft) 50 N·m (37 lb ft) 23 - 27 N·m (17 - 20 lb ft) 290 - 375 N·m (214 - 277 lb ft) Bolts must turn freely 53 - 62 N·m (39 - 46 lb ft) 9 - 11 N·m (7 - 8 lb ft) 65 - 79 N·m (48 - 58 lb ft) 27 - 31 N·m (20 - 23 lb ft)

Cooling Fan to fan hub Fan hub to motor shaft (no impact tools) Radiator hose clamps Hydraulic tank cover nuts Hydraulic tank sight gauge

40 - 48 N·m (30 - 35 lb ft) 67 - 74 N·m (49 - 55 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 14 - 18 N·m (10 - 13 lb ft) 2.7 - 5.5 N·m (2.0 - 4.1 lb ft)

Diesel Exhaust Fluid (DEF) System Heater valve bolts Dosing module bolts DEF control module/pump assembly mounting bolts

17 - 19 N·m (13 - 14 lb ft) 7 - 8 N·m (58 - 68 lb in) 20 - 28 N·m (15 - 21 lb ft)

Driveshafts Coupling to flywheel Driveshaft to coupling Front driveshaft yoke nut Carrier bearing mounting bolts 550R U-joints 410R U-joints Dust cover mounting bolts

53 - 62 N·m (39 - 46 lb ft) 53 - 62 N·m (39 - 46 lb ft) 339 - 373 N·m (250 - 275 lb ft) 99 - 128 N·m (73 - 94 lb ft) 75 - 81 N·m (55 - 60 lb ft) 61 - 81 N·m (45 - 60 lb ft) 20 - 27 N·m (15 - 20 lb ft)

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INTRODUCTION

Engine Engine mounting brackets Engine rubber isolator mounts (Qty 4) Brake pump to engine mounting Brake pump gear nut (no impact tools) Turbo to turbo exhaust elbow clamp Muffler to turbo elbow exhaust clamp Front muffler bracket to engine block Muffler brackets to muffler Charge Air Cooler (CAC) hose clamps (Qty 8) Air cleaner to turbo hose clamp Alternator pulley (no impact tools) Starter mounting nuts

118 - 133 N·m (87 - 98 lb ft) 244 - 298 N·m (180 - 220 lb ft) 57 - 65 N·m (42 - 48 lb ft) 70 - 79 N·m (52 - 58 lb ft) 5 N·m (4 lb ft) 20 - 25 N·m (15 - 18 lb ft) 118 - 133 N·m (87 - 98 lb ft) 114 - 128 N·m (84 - 94 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 60 - 70 N·m (44 - 52 lb ft) 40 - 50 N·m (30 - 37 lb ft)

Loader XT loader linkage bolts XT guide link nuts Loader link pin keeper

650 - 732 N·m (479 - 540 lb ft) 240 - 305 N·m (177 - 225 lb ft) 325 - 373 N·m (240 - 275 lb ft)

Transmission Transmission rubber isolator mounts (Qty 3) Transmission upper mounting bracket bolts Transmission lower mounting bracket bolts (Qty 2) Hydraulic pump to transmission mounting Cooler clamps Hydraulic pump suction hose clamp flange Steering priority manifold to pump Transmission fill tube bolts Transmission sight gauge bolts

890 - 1000 N·m (656 - 738 lb ft) 251 - 319 N·m (185 - 235 lb ft) 481 - 590 N·m (355 - 435 lb ft) 335 - 375 N·m (247 - 277 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 73 - 90 N·m (54 - 66 lb ft) 37 - 48 N·m (27 - 35 lb ft) 17 - 33 N·m (13 - 24 lb ft) 2.7 - 5.5 N·m (2 - 4 lb ft)

Wheels Wheel nuts

Initial torque: 298 N·m (220 lb ft) Final torque: 640 - 720 N·m (472 - 531 lb ft)

RCPH10WHL320AAH

Do the following initial and final torque procedures: 1.

Tighten wheel nuts to an initial torque of 298 N·m (220 lb ft) in sequence shown in figure

Tighten wheel nuts to a final torque of 640 - 720 N·m (472 - 531 lb ft). in sequence shown in figure

84605841 14/05/2012

INTRODUCTION

Torque – 721F Torque Specifications 721F WE, 721F NA

Axle Wheel mounting bolts Front axle mounting bolts Rear axle trunnion pin bolts

640 - 720 N·m (472 - 531 lb ft) 765 - 855 N·m (564 - 631 lb ft) 651 - 678 N·m (480 - 500 lb ft)

Cooling Fan to fan hub Fan hub to motor shaft (no impact tools) Radiator hose clamps Hydraulic tank cover nuts Hydraulic tank sight gauge

40 - 48 N·m (30 - 35 lb ft) 67 - 74 N·m (49 - 55 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 14 - 18 N·m (10 - 13 lb ft) 2.7 - 5.5 N·m (2.0 - 4.1 lb ft)

Diesel Exhaust Fluid (DEF) System Heater valve bolts Dosing module bolts DEF control module/pump assembly mounting bolts

17 - 19 N·m (13 - 14 lb ft) 7 - 8 N·m (58 - 68 lb in) 20 - 28 N·m (15 - 21 lb ft)

Driveshafts Coupling to flywheel Driveshaft to coupling Front driveshaft yoke nut Carrier bearing mounting bolts 550R U-joints Dust cover mounting bolts Flex plate to flywheel bolts Carrier bearing bolt Drive line mounting bolts

53 - 62 N·m (39 - 46 lb ft) 53 - 62 N·m (39 - 46 lb ft) 339 - 373 N·m (250 - 275 lb ft) 99 - 128 N·m (73 - 94 lb ft) 75 - 81 N·m (55 - 60 lb ft) 20 - 27 N·m (15 - 20 lb ft) 33 - 41 N·m (24 - 30 lb ft) 150 - 164 N·m (111 - 121 lb ft) 136 - 149 N·m (100 - 110 lb ft)

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INTRODUCTION

Engine Engine mounting brackets Engine rubber isolator mounts (Qty 4) Brake pump to engine mounting Brake pump gear nut (no impact tools) Turbo to turbo exhaust elbow clamp Muffler to turbo elbow exhaust clamp Muffler bracket to muffler Charge Air Cooler (CAC) hose clamps (Qty 8) Air cleaner to turbo hose clamp Alternator pulley (no impact tools) Starter mounting nuts

118 - 133 N·m (87 - 98 lb ft) 244 - 298 N·m (180 - 220 lb ft) 57 - 65 N·m (42 - 48 lb ft) 70 - 79 N·m (52 - 58 lb ft) 5 N·m (4 lb ft) 20 - 25 N·m (15 - 18 lb ft) 114 - 128 N·m (84 - 94 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 60 - 70 N·m (44 - 52 lb ft) 40 - 50 N·m (30 - 37 lb ft)

Loader XT loader linkage bolts XT guide link nuts Loader link pin keeper

650 - 732 N·m (479 - 540 lb ft) 240 - 305 N·m (177 - 225 lb ft) 325 - 373 N·m (240 - 275 lb ft)

Transmission Transmission rubber isolator mounts (Qty 3) Transmission upper mounting bracket bolts Transmission lower mounting bracket bolts (Qty 2) Cooler clamps Hydraulic pump suction hose clamp flange Steering priority manifold to pump Transmission fill tube bolts Transmission sight gauge bolts

890 - 1000 N·m (656 - 738 lb ft) 251 - 319 N·m (185 - 235 lb ft) 481 - 590 N·m (355 - 435 lb ft) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) 73 - 90 N·m (54 - 66 lb ft) 37 - 48 N·m (27 - 35 lb ft) 17 - 33 N·m (13 - 24 lb ft) 2.7 - 5.5 N·m (2 - 4 lb ft)

Wheels Wheel bolts

Initial torque: 298 N·m (220 lb ft) Final torque: 640 - 720 N·m (472 - 531 lb ft)

RCPH10WHL320AAH

Do the following initial and final torque procedures: 1.

Tighten wheel bolts to an initial torque of 298 N·m (220 lb ft) in sequence shown in figure

Tighten wheel bolts to a final torque of 640 - 720 N·m (472 - 531 lb ft). in sequence shown in figure

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INTRODUCTION

Capacities 621F WE, 621F NA, 721F WE, 721F NA

621F Capacities and Specifications Engine Type of oil Capacity (with filter change) Total system capacity Cooling System System capacity Hydraulic System Type of fluid

CASE AKCELA ENGINE OIL 15W-40 13.25 l (14.0 US qt) 15.1 l (16 US qt) 26.8 l (28.4 US qt) CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL

Total system capacity Reservoir capacity Fuel System System capacity Transmission Type of oil Service capacity (with filter change) Axles Type of oil Standard front axle Standard rear axle Optional front axle Optional rear axle Diesel Exhaust Fluid (DEF) Total capacity Grease Fittings As required

147.6 l (39.0 US gal) 90.8 l (24.0 US gal) 246 l (65.0 US gal) CASE AKCELA NEXPLORE™ FLUID 26.7 l (28.2 US qt) CASE AKCELA NEXPLORE™ FLUID 22 l (23.2 US qt) 22 l (23.2 US qt) 35 l (37.0 US qt) 35 l (37.0 US qt) 41.3 l (10.9 US gal) CASE AKCELA MOLY GREASE

NOTE: Machines are shipped from the factory with break-in oil.

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INTRODUCTION

721F Capacities and Specifications Engine Type of oil Capacity (with filter change) Total system capacity Cooling System System capacity Hydraulic System Type of fluid

CASE AKCELA ENGINE OIL 15W-40 13.25 l (14.0 US qt) 15.1 l (16 US qt) 28.4 l (30.0 US qt) CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL

177.8 l (47.0 US gal) 90.8 l (24.0 US gal) 253 l (66.8 US gal) CASE AKCELA NEXPLORE™ FLUID 34 l (35.9 US qt) CASE AKCELA NEXPLORE™ FLUID 35 l (37.0 US qt) 23 l (24.3 US qt) 35 l (37.0 US qt) 35 l (37.0 US qt) 41.3 l (10.9 US gal) CASE AKCELA MOLY GREASE

NOTE: Machines are shipped from the factory with break-in oil.

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INTRODUCTION

Engine Oil Viscosity/Temperature Range

RCPH11WHL023FAH

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

Transmission Oil Viscosity/Temperature Range

RCPH10WHL453BAH

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INTRODUCTION

Hydraulic/Brake System Temperature Range

RCPH10WHL006EAL

Coolant Solution Only use ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent leakage. Do not use non-approved anti-rust additives. NOTICE: Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the ambient temperature is over -36 °C (-32.8 °F) use a blend of 50 % ethylene-glycol based anti-freeze. For areas where the temperature is below -36 °C (-32.8 °F)- it is advisable to use a blend of 40 % water and 60 % anti-freeze.

Fuel •

Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

•

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

•

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

•

For very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier for appropriate fuel supply.

•

If the temperature falls below the fuel cloud point (point at which wax begins to form, the wax crystals will cause power loss or will prevent the engine from starting.

•

In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.

Fuel Storage Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

84605841 14/05/2012

INTRODUCTION

Hydraulic Fluid CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL is specifically designed for high pressure applications and for Case hydraulic systems. Your Case Dealer can provide hydraulic fluid to fulfill different climate/temperature conditions. Refer to the charts at the beginning of this section.

Transmission Component Oil Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for your climate/temperature conditions such as CASE AKCELA NEXPLORE™ FLUID. See charts at the beginning of this section.

Grease The type of grease to use depends on ambient temperature such as: CASE AKCELA MOLY GREASE.

Environment Before servicing machine and disposing oil, fluids, and lubricants, follow all environmental regulations. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental recycling center or your dealer for correct disposal information.

Engine Oil CASE AKCELA ENGINE OIL 15W-40 is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures. If CASE AKCELA ENGINE OIL 15W-40 cannot be obtained, use only oil of the API SERVICE CI-4 category. NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out utilizing Case lubricants.

84605841 14/05/2012

RCPH10WHL012AAD

INTRODUCTION

Consumables - Biodiesel Fuel Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters. NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. NOTICE: Verify with your local dealer which blends are approved for your engine. Use of biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to engine and fuel system. Use of non-approved biodiesel fuels may void warranty coverage.

Biodiesel Fuel Usage Conditions Biodiesel fuels must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuels must be pre-blended by the supplier. Mixing biodiesel fuels on site can result in an incorrect mixture which can damage engine and fuel system. Engine performance is effected by the use of biodiesel fuels. There may be up to 12 percent reduction in power or torque depending on the blend used. NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance. The reduced power must be accepted if using any biodiesel fuel blends. NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions. Using biodiesel fuels may require changing engine oil, engine oil filters, and fuel filter elements more frequently. Biodiesel fuels can remove rust and other particles that adhere to the inside of the fuel tank. These particles are trapped by vehicle filters and may cause shortened filter life or filter blockages. Blockages are more common in cold weather conditions. Consult your dealer for information on cold weather operation and proper maintenance intervals when using any biodiesel fuel blend. Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel. Frequently inspect hoses and other engine components when using biodiesel fuel. DO NOT allow water to collect in the fuel or storage tanks. Biodiesel fuel attracts moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

Biodiesel Storage NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months. If long periods of storage are required, run the machine for 20 hours using regular diesel fuel to flush the biodiesel fuel from the engine fuel system. NOTICE: Biodiesel fuels must not be stored in on-site storage tanks for more than 3 months. Any spillage of biodiesel fuels must be cleaned up immediately before it can cause damage to the environment or the paint finish of the machine. Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage. Failure to follow the requirements and conditions of biodiesel fuel usage will void your machineâ&#x20AC;&#x2122;s warranty. NOTE: B7 is the highest biodiesel (7% blend) that should be used in this machine.

84605841 14/05/2012

INTRODUCTION

Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. (A) When you drain the oil or disconnect any line. (B) When you disassemble a component. (C) From normal wear of the hydraulic components. (D) From damaged or worn seals. (E) From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems. (A) Cylinder rod seals leak. (B) Control valve spools do not return to neutral. (C) Movement of control valve spools is difficult. (D) Hydraulic oil becomes too hot. (E) Pump gears, housing, and other parts wear rapidly. (F) Relief valves or check valves held open by dirt. (G) Quick failure of components that have been repaired. (H) Cycle times are slow; machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. There are two types of contamination, microscopic and visible. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems: (A) Cylinder rod seal leak. (B) Control valve spools do not return to NEUTRAL. (C) The hydraulic system has a high operating temperature. Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: (A) Particles of metal or dirt in the oil. (B) Air in the oil. (C) The oil is dark and thick. (D)The oil has an odor of burned oil. (E) Water in the oil. If you find contamination, use a Portable Filter to clean the hydraulic system.

84605841 14/05/2012

CONSUMABLES INDEX IU

Consumable CASE Akcela Engine oil 15W-40 CASE Akcela HY-TRAN® Ultra™ hydraulic transmission oil CASE Akcela NEXPLORE™ fluid CASE Akcela NEXPLORE™ fluid CASE Akcela Moly grease CASE Akcela Engine oil 15W-40 CASE Akcela HY-TRAN® Ultra™ hydraulic transmission oil CASE Akcela NEXPLORE™ fluid CASE Akcela NEXPLORE™ fluid CASE Akcela Moly grease CASE Akcela HY-TRAN® Ultra™ hydraulic transmission oil CASE Akcela NEXPLORE™ fluid CASE Akcela Moly grease CASE Akcela Engine oil 15W-40 CASE Akcela Engine oil 15W-40

PAGE

Capacities

Capacities Capacities

7 8

Capacities

Capacities Capacities

8 11

Capacities

Capacities Capacities

11 11

Capacities

84605841 14/05/2012

SERVICE MANUAL Engine

621F 721F

84605841 14/05/2012

Contents Engine - 10

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 621F , 721F

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202 621F , 721F

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304 621F , 721F

Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.310 621F , 721F

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 621F , 721F

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414 621F , 721F

Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500 621F NA, 621F WE, 721F NA, 721F WE

Engine generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.AAA 621F , 721F

84605841 14/05/2012

CONSUMABLES INDEX IU

Consumable DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® CASE Akcela Engine oil 15W-40 Loctite® 242 DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue®

Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine

Remove Remove Remove Remove Remove Install Install Install Install Install Install

Radiator - Install Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Coolant control valve - Remove Coolant control valve - Remove Coolant control valve - Install

84605841 14/05/2012

PAGE 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001

/ / / / / / / / / / /

22 22 23 23 23 33 33 34 34 35 50

10.400 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500 10.500

/ / / / / / / / / / / / / / / / / / /

16 20 20 20 21 21 21 22 22 24 24 25 25 26 27 27 29 29 31

84605841 14/05/2012

Engine - 10 Engine and crankcase - 001

621F 721F

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10.001 / 1

Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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10.001 / 2

CONSUMABLES INDEX IU

Consumable DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® CASE Akcela Engine oil 15W-40

Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine

Remove Remove Remove Remove Remove Install Install Install Install Install Install

PAGE 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001 10.001

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10.001 / 3

/ / / / / / / / / / /

22 22 23 23 23 33 33 34 34 35 50

Engine - Engine and crankcase

Engine - Remove NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that generate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot be avoided, remove the sensors using extreme caution prior to performing any service procedure. 1.

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

RCPH10WHL063BAL

RCPH10WHL435AAH

RCPH10WHL119BAL

Actuate the brake pedal several times to discharge brake accumulators.

Put key switch in ON position. Pilot control switch must be in the ON position and then move loader control lever(s) back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

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Engine - Engine and crankcase

Raise grill located above the cooler box just behind the cab. Then slowly loosen the hydraulic reservoir filler cap to release pressure in the reservoir.

RCPH10WHL099BAL

RCPH10WHL106AAH

RAPH12WEL0597AA

RCPH10WHL054BAL

Locate the master and hood raise switch by the battery box. Then raise the hood and put the master disconnect switch in the OFF position.

Raise both side panels (1). Then remove the thumb screws (2) and inner fender panels (3).

NOTE: Left side of the machine is shown. The operation is similar for the right side.

Place a suitable container below radiator drain, remove radiator cap and coolant drain plug (arrow) to drain engine coolant. Then reinstall drain plug and radiator cap after coolant has drained.

NOTE: See machine specifications for cooling system volume.

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Engine - Engine and crankcase

Place a suitable container below engine oil drain. Remove drain plug and drain oil into container. Then reinstall drain plug.

NOTE: See machine specifications for engine oil sump volume.

10.

RCPH10WHL054BAL

RAPH12WEL0598AA

After oil drains, disconnect drain hose from frame by removing jam nut (1). Then pull hose from frame in preparation for engine removal. (2)

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

RAPH12WEL0599AA

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Engine - Engine and crankcase

11.

12.

13.

Place a bar or pipe through the strap loop inside the hood and attach the strap to a suitable lifting device. Then raise the hood with the strap to release tension on the lifting motor.

RAPH12WEL0600AA

RAPH12WEL0601AA

RAPH12WEL0602AA

Tag and disconnect the camera wire harness (if machine is equipped with a camera.)

Cut wire ties and remove camera wire harness from hood. Then place it off to the side in a safe location. (If machine is equipped with a camera.)

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Engine - Engine and crankcase

14.

15.

16.

Remove mount bolt (1) and backup alarm wiring harness clamp from cooler housing. Then tag and remove hood ground wire (2) from cooler housing.

RAPH12WEL0603AA

RAPH12WEL0604AA

RAPH12WEL0605AA

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

Have another person balance the hood and LOOSEN the hood hinge mounting bolts (arrows) from the cooler frame.

NOTE: Do not remove the hood hinge mounting bolts at this time.

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Engine - Engine and crankcase

17.

18.

19.

Remove the pin from the bottom of the lifting motor cylinder where it attaches to the loader frame.

RAPH12WEL0606AA

RAPH12WEL0062AA

RAPH12WEL0608AA

Put the master disconnect switch in the ON position. Then, retract the lifting motor cylinder (2), replace pin and disconnect wiring harness (1).

Put master disconnect switch (1) in OFF position. Remove the battery cover and disconnect ground lead from the batteries (2). You may replace battery cover if desired to give you a place to stand.

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Engine - Engine and crankcase

20.

21.

Have another person balance the hood and remove the hood hinge mounting bolts (arrows) from the cooler frame.

RAPH12WEL0605AA

RAPH12WEL0609AA

RAPH12WEL0610AA

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

NOTE: Radiator overflow hose may interfere with left hand hood hinge movement and hood removal.

22.

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

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Engine - Engine and crankcase

23.

24.

25.

Tag and disconnect engine wiring harness connector from air inlet humidity sensor.

RAPH12WEL0611AA

RAPH12WEL0612AA

RAPH12WEL0613AA

Loosen clamp (1) on the crankcase ventilation hose (2) and disconnect hose.

Loosen clamps on turbocharger and air filter housing. Then remove the intake air hose. Cover turbocharger inlet to prevent debris entry.

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Engine - Engine and crankcase

26.

27.

28.

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

RAPH12WEL0614AA

RAPH12WEL0615AA

RAPH12WEL0616AA

Loosen the clamp on the hose at the after cooler inlet and remove the tube.

Loosen clamp on the air inlet hose at the air filter housing.

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Engine - Engine and crankcase

29.

30.

31.

Remove bolts from the cooler box (1) and the center support bracket (2) securing the air inlet hose bracket. Then remove air inlet hose and bracket.

RAPH12WEL0617AA

RAPH12WEL0618AA

RAPH12WEL0619AA

Remove four the bolts securing the air filter housing to the mounting support bracket. Then remove air filter housing.

Remove the four mounting bolts from the belt cover. Then remove the cover.

NOTE: After removing the belt cover, remove the cover mounting bracket from the left rear side of machine frame.

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Engine - Engine and crankcase

32.

33.

34.

Remove the drive belt from the engine.

RAPH12WEL0620AA

RAPH12WEL0621AA

RAPH12WEL0622AA

If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness connectors from air compressor clutch connector (1) and high pressure switch (2). Then remove the three mounting bolts (3) for the compressor and carefully set it on the left battery cover.

Tag and disconnect the wiring from the alternator.

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Engine - Engine and crankcase

35.

36.

Remove SCR coolant return line.

RAPH12WEL0623AA

RAPH12WEL0624AA

RAPH12WEL0625AA

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

NOTE: Move the starter cables away from the engine.

37.

Remove bolts securing wiring harness clamps to engine.

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Engine - Engine and crankcase

38.

Remove ground wires from the engine.

NOTE: Move the wiring harness away from the engine.

39.

40.

RAPH12WEL0625AA

RAPH12WEL0626AA

RAPH12WEL0627AA

If the machine is so equipped, unplug the engine block heater and set it aside.

Loosen the exhaust clamp from the turbocharger.

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Engine - Engine and crankcase

41.

42.

43.

Disconnect the engine coolant vent hose from the engine.

RAPH12WEL0628AA

RAPH12WEL0629AA

RAPH12WEL0630AA

Loosen clamps and remove lower coolant hose from the engine.

Remove the radiator hose from the engine.

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Engine - Engine and crankcase

44.

45.

46.

Remove the return radiator hose (1) and the engine coolant vent hose (2) from the top of the radiator.

RAPH12WEL0631AA

RAPH12WEL0632AA

RAPH12WEL0633AA

Remove hood wire harness clamp from the fan shroud.

Remove engine coolant overflow bottle.

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Engine - Engine and crankcase

47.

48.

49.

Remove engine coolant overflow bottle support bracket.

RAPH12WEL0634AA

RAPH12WEL0635AA

RAPH12WEL0636AA

Remove cooling fan screen.

Remove heater hose (1) and the SCR heater supply line (2) from the engine.

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Engine - Engine and crankcase

50.

51.

52.

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

RAPH12WEL0637AA

RAPH12WEL0638AA

RAPH12WEL0639AA

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

Tag and disconnect the fuel filter heater wire (1) and water sensor (2). Then drain fuel filter and disconnect inlet (3) and outlet (4) fuel lines from the fuel filter head. Plug the lines and cap the fittings.

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Engine - Engine and crankcase

53.

54.

Remove ground wire and fuel filter head attachment bolt (1). Then remove fuel line support clamp (2).

RAPH12WEL0640AA

RAPH12WEL0063AA

RAPH12WEL0064AA

Tag and disconnect the post SCR catalyst EGT sensor from machine wire harness (1) and the post SCR catalyst NOx sensor (2). Then tag and remove the grid heater cable (3).

NOTE: Hold the rear nut with a second wrench to prevent grid heater damage.

55.

Remove wire harness support clamp.

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Engine - Engine and crankcase

56.

57.

58.

Tag and disconnect Pre-SCR catalyst EGT sensor (1). Then remove tie wrap, wire harness bolts and wire harness support clamp (2).

RAPH12WEL0065AA

RAPH12WEL0066AA

RAPH12WEL0067AA

Tag and disconnect wire harness from DEF/ ADBLUE® Dosing Module.

Tag and disconnect wire harness from DEF/ ADBLUE® Control Module (1) and the coolant flow control valve (2).

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Engine - Engine and crankcase

59.

60.

61.

Tag and disconnect wire harness from primary fuel filter.

RAPH12WEL0068AA

RAPH12WEL0069AA

RAPH12WEL0070AA

Remove DEF/ADBLUE® storage tank cover located on the Right Hand side of the machine.

Tag and disconnect wire harness and DEF/ADBLUE® supply and return lines from the DEF/ADBLUE® storage tank. Cap the supply lines.

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Engine - Engine and crankcase

62.

63.

64.

Remove hood lift cylinder support bracket.

RAPH12WEL0071AA

RAPH12WEL0072AA

RAPH12WEL0073AA

Attach suitable lifting straps to the SCR Catalyst support structure.

Remove bolts securing the SCR Catalyst support structure at the front and rear of the structure. The mounting points are positioned on the left and right side in the front of the engine compartment, and in the center at the rear of the engine compartment.

NOTE: The right front mount is shown.

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Engine - Engine and crankcase

65.

66.

Using suitable lifting device, carefully lift SCR catalyst support structure (with SCR system components attached) from the machine.

RAPH12WEL0075AA

RAPH12WEL0076AA

RAPH12WEL0077AA

Disconnect the wiring harness from the EDC 7 controller.

NOTE: Lifting up on the lever will release the connector from the controller.

67.

Remove the fuel line from the top of the primary fuel filter, plug the line and cap the fitting.

NOTE: Make note on how fuel lines are routed.

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Engine - Engine and crankcase

68.

Remove the fuel line support clamp.

NOTE: Make note on how fuel lines are routed.

69.

70.

RAPH12WEL0078AA

RAPH12WEL0079AA

RAPH12WEL0080AA

Remove the upper and lower covers for the drive shaft.

Remove the drive shaft bolts (1) from the flywheel. Move the drive shaft clear of the flywheel.

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Engine - Engine and crankcase

71.

Connect and turn on vacuum pump to hydraulic reservoir. Tag and remove the hydraulic lines from the brake system pump (arrow), plug the lines and cap the fittings.

72.

Connect suitable lifting equipment to engine lifting brackets. Take up all slack in lifting equipment. Remove the engine mounting bolts.

73.

Slowly raise engine from rear chassis. Be sure all wire harness connections and hoses have been disconnected and are clear of the engine. Guide the oil drain hose from the frame as the engine is lifted. Remove engine from machine.

Next operation: Engine - Install (10.001)

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RAPH12WEL0081AA

RAPH12WEL0082AA

Engine - Engine and crankcase

Engine - Install WARNING Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape. Failure to comply could result in death or serious injury. W0296A

Prior operation: Engine - Remove (10.001) NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that generate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot be avoided, remove the sensors using extreme caution prior to performing any service procedure.

RAIL12WEL0130FA

1. 2. 3. 4. 1.

Engine mount bolt Washer Isolator upper Isolator lower

5. 6. 7. 8.

Washers Washer Nut Remote oil drain hose

Inspect engine mounts. If engine rubber isolators require replacement, remove and discard isolators (3) and (4). Install new rubber isolator (4), then rubber isolator (3).

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Engine - Engine and crankcase

Attach suitable lifting device to the engine and slowly move it into position over the rear chassis. Be sure all harness connections and hoses are out of the way or positioned correctly for reconnecting, before lowering engine.

RAPH12WEL0082AA

RAPH12WEL0080AA

RAPH12WEL0082AA

Tighten engine mounting bolts to a torque of 244 298 NÂˇm (180 - 220 lb ft).

Disconnect lifting equipment from engine lifting brackets.

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Engine - Engine and crankcase

Connect vacuum pump to the hydraulic reservoir and turn it on. 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.

RAPH12WEL0081AA

RAPH12WEL0598AA

RAPH12WEL0080AA

Connect engine oil drain hose (1) to frame bracket (2).

At front of engine, position drive shaft on engine coupling. Install bolts to secure drive shaft to engine coupling. Tighten the bolts to a torque of 53 - 62 NÂˇm (39 - 46 lb ft).

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Engine - Engine and crankcase

Install the upper and lower drive shaft dust covers. Torque to 20 - 27 NÂˇm (15 - 20 lb ft).

NOTE: Attach p-clamp, securing coolant line.

10.

RAPH12WEL0079AA

RAPH12WEL0078AA

Install bolt and clamp for fuel return hose.

Remove cap from fitting and plug from the hose. Then connect fuel line to the top of the primary fuel filter.

RAPH12WEL0077AA

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Engine - Engine and crankcase

11.

Connect wiring harness to EDC 7 controller.

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

12.

RAPH12WEL0076AA

RAPH12WEL0075AA

RAPH12WEL0073AA

Connect a suitable lifting device to the SCR catalyst support structure and carefully lift it (with SCR system components attached) and position it over the rear chassis of the machine. Lower support structure into position on the machine.

NOTE: Be sure all wire harness connections and hoses are out of the way or positioned correctly for reconnecting.

13.

Install bolts securing the SCR Catalyst support structure at the front (right hand side pictured) and rear mounting points. Torque bolts to 125 - 150 NÂˇm (92 - 111 lb ft).

NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that generate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot be avoided, remove the sensors using extreme caution prior to performing any service procedure.

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Engine - Engine and crankcase

14.

15.

16.

Remove lifting straps from the SCR Catalyst support structure.

RAPH12WEL0072AA

RAPH12WEL0071AA

RAPH12WEL0070AA

Install hood lift cylinder support bracket. Torque bolts to 310 - 380 N·m (229 - 280 lb ft).

Remove caps and plugs from lines and tag from wire harness. Connect wire harness and DEF/ADBLUE® supply and return lines to the DEF/ADBLUE® storage tank.

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Engine - Engine and crankcase

17.

18.

19.

Install DEF/ADBLUEÂŽ storage tank cover.

RAPH12WEL0069AA

RAPH12WEL0068AA

RAPH12WEL0067AA

Connect wire harness to the primary fuel filter.

Connect the wire harness to the DEF/ADBLUEÂŽ Control Module (1) and the coolant flow control valve (2).

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

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Engine - Engine and crankcase

20.

21.

22.

Connect the wire harness to the DEF/ADBLUEÂ® Dosing Module.

RAPH12WEL0066AA

RAPH12WEL0065AA

RAPH12WEL0064AA

Connect the Pre-SCR catalyst EGT sensor (1). Then secure with a tie wrap (2), and wire harness clamps (3). Install wire harness support clamp.

Attach wire harness support clamp.

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Engine - Engine and crankcase

23.

Connect the post SCR catalyst EGT sensor (1) and the post SCR catalyst NOx sensor (2) to the machine wire harness. Then connect the grid heater cable (3)

NOTE: Hold the rear nut with a second wrench to prevent grid heater damage.

24.

25.

RAPH12WEL0063AA

RAPH12WEL0640AA

RAPH12WEL0639AA

Connect the ground wire and attach fuel filter head mounting bolt (1). Install fuel line support clamp (2).

Connect the fuel filter heater wire (1) and water sensor (2). Then remove the plugs and caps and connect the fuel inlet line (3) and fuel outlet line (4) to the fuel filter head.

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Engine - Engine and crankcase

26.

27.

28.

Connect the after cooler outlet hose to the after cooler and secure the clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

RAPH12WEL0638AA

RAPH12WEL0637AA

RAPH12WEL0636AA

Connect the after cooler outlet hose to the intake manifold and secure clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

Connect the heater hose (1) and the SCR heater supply line (2) to the engine and secure clamps. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

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Engine - Engine and crankcase

29.

30.

31.

Install cooling fan screen.

RAPH12WEL0635AA

RAPH12WEL0634AA

RAPH12WEL0633AA

Install engine coolant overflow bottle support bracket.

Install engine coolant overflow bottle.

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Engine - Engine and crankcase

32.

33.

34.

Install hood wire harness clamp on the fan shroud.

RAPH12WEL0632AA

RAPH12WEL0631AA

RAPH12WEL0630AA

Connect the radiator hose (1) and the engine coolant vent hose (2) to the top of the radiator. Torque clamp to 10.1 - 11.3 NÂˇm (7.4 - 8.3 lb ft).

Connect the radiator hose to the engine. Torque clamp to 10.1 - 11.3 NÂˇm (7.4 - 8.3 lb ft).

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Engine - Engine and crankcase

35.

36.

37.

Connect lower coolant hose to the engine and tighten clamps. Torque clamp to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

RAPH12WEL0629AA

RAPH12WEL0628AA

RAPH12WEL0627AA

Connect the engine coolant vent hose to the engine and secure clamp. Torque clamp to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

Connect exhaust hose to the turbocharger and secure clamp. Torque clamp to 5 N·m (4 lb ft).

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Engine - Engine and crankcase

38.

39.

40.

Connect engine block heater if machine is so equipped.

RAPH12WEL0626AA

RAPH12WEL0625AA

Connect ground wires to the engine.

Install bolts securing wiring harness clamps to the engine.

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Engine - Engine and crankcase

41.

42.

43.

Connect the wires to the starter solenoid (1), connect the ground cable (2) and ground strap (3) to the starter.

RAPH12WEL0624AA

RAPH12WEL0623AA

RAPH12WEL0622AA

Connect SCR coolant return line and secure clamp. Torque to 10.1 - 11.3 NÂˇm (7.4 - 8.3 lb ft).

Connect the wiring harness to the alternator.

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Engine - Engine and crankcase

44.

45.

46.

If loader is equipped with air conditioning, secure compressor to support bracket with mounting bolts (1). Then connect the engine wiring harness to the high pressure switch (2) and air compressor clutch connector (3).

RAPH12WEL0621AA

RAPH12WEL0620AA

RAPH12WEL0619AA

Install the drive belt.

Secure belt cover mounting bracket to the machine frame. Then Install the belt cover.

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Engine - Engine and crankcase

47.

48.

49.

Position air filter housing on mounting support bracket and secure it with four bolts.

RAPH12WEL0618AA

RAPH12WEL0617AA

RAPH12WEL0616AA

Position the air inlet hose, then install the center support bracket (2) attached to the air inlet hose and secure it to the cooler box (1).

Connect air inlet hose on the air filter housing and secure clamp. Torque to 10.1 - 11.3 NÂˇm (7.4 - 8.3 lb ft).

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Engine - Engine and crankcase

50.

51.

52.

Connect hose on the after cooler inlet and secure clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

RAPH12WEL0615AA

RAPH12WEL0614AA

RAPH12WEL0613AA

Connect the after cooler inlet hose to the turbocharger and secure clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

Connect the intake air hose to the turbocharger and air filter housing. Secure clamps and torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

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Engine - Engine and crankcase

53.

54.

55.

Connect the crankcase ventilation hose (2). Secure with clamp (1) and torque to 10.1 - 11.3 NÂˇm (7.4 8.3 lb ft).

RAPH12WEL0612AA

RAPH12WEL0611AA

RAPH12WEL0610AA

Connect wiring harness to air inlet humidity sensor, then remove tag.

Connect engine wiring harness to air filter restriction switch and remove tag.

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Engine - Engine and crankcase

56.

Connect suitable lifting device to the hood. Carefully raise the hood over the machine and lower it into position.

NOTE: Radiator overflow hose may interfere with left hand hood hinge movement and hood removal.

57.

58.

RAPH12WEL0609AA

RAPH12WEL0605AA

RAPH12WEL0608AA

Have another person balance the hood and install the hood hinge mounting bolts to the cooler frame. Torque bolts to 65 - 79 NÂˇm (48 - 58 lb ft).

Remove the battery cover and reconnect the ground lead to batteries (2). Put the master disconnect switch (1) in ON position.

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Engine - Engine and crankcase

59.

60.

61.

Connect the hood lifting cylinder motor to the machine wiring harness (1). Extend the cylinder (2) and remove pin from the bottom of the cylinder. Switch the master disconnect switch to the OFF position.

RAPH12WEL0062AA

RAPH12WEL0606AA

RAPH12WEL0599AA

Attach lifting motor cylinder to the loader frame and reinstall the pin at the bottom of the lifting motor cylinder.

Remove lifting device from the hood.

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Engine - Engine and crankcase

62.

63.

64.

Reconnect hood wiring harness to rear chassis wiring harness connector. Remove tags.

RAPH12WEL0604AA

RAPH12WEL0603AA

RAPH12WEL0601AA

Attach backup alarm wiring harness clamp (1) and hood ground wire (2) to the cooler housing. Then remove marking tags.

Reconnect the camera wire harness (if machine is equipped with a camera). Remove marking tags.

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Engine - Engine and crankcase

65.

66.

67.

68.

Reattach camera wire harness to hood (if machine is equipped with a camera).

RAPH12WEL0602AA

RCPH10WHL054BAL

RCPH10WHL106AAH

Be sure engine oil drain cap is secured. Refill engine with CASE AKCELA ENGINE OIL 15W-40.

Be sure engine coolant drain cap is secure. Refill cooling system with a 50 % ethylene-glycol and 50 % water coolant solution. Install radiator cap.

Switch the master disconnect switch to the ON position.

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Engine - Engine and crankcase

69.

Start the engine and run it at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol and water. Check machine for fluid leaks. When coolant is at operating temperature, recheck the coolant level at the reservoir.

NOTE: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn cap to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. 70.

Install the left and right side inner fender panels (2), then lower left and right hand side panels (1). Close the hood.

NOTE: Left side of the machine is shown. This operation is repeated for the right side.

RAPH12WEL0597AA

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Index Engine - 10 Engine and crankcase - 001 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Air cleaners and lines - 202

621F 721F

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Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air cleaner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Air cleaners and lines

Air cleaner - Remove 1.

Access pre-cleaner located on top of engine compartment hood.

RCPH11WHL663BAU

RCPH11WHL720BAU

RCPH11WHL719BAU

Remove wing nut.

Remove pre-cleaner assembly from machine.

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Engine - Air cleaners and lines

Empty debris and wipe pre-cleaner with a damp clean cloth. Reassemble and install assembly on the machine.

RCPH11WHL718BAU

RCPH11WHL663BAU

RCPH11WHL653BAU

Primary/secondary filter element disassembly 5.

Raise engine compartment hood using controls located behind access cover (1). Air filter housing/element (2) is located in main engine compartment on operator’s left hand side of engine.

Turn master electric switch “off”.

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Engine - Air cleaners and lines

10.

Release all clips securing air filter element housing cover.

RCPH11WHL746BAU

RCPH11WHL747BAU

RCPH11WHL748BAU

Remove cover from air filter element housing.

Remove the primary filter element. To do this, push filter element down to loosen the filter seal. Then pull up on the handle to lift the filter element out of the housing.

Remove secondary filter element from the right side of the filter element housing. Remove debris from inside the housing before installing new filter elements.

NOTE: Do not clean the secondary filter element. It must be replaced if damaged or clogged.

RCPH11WHL749BAU

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Engine - Air cleaners and lines

Air cleaner - Install (10.202)

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Engine - Air cleaners and lines

Air cleaner - Install Prior operation: Air cleaner - Remove (10.202) 1.

Install new secondary filter element.

NOTE: Make sure filter element is positioned correctly in slot and firmly seated into housing.

RCPH11WHL749BAU

RCPH11WHL748BAU

RCPH11WHL747BAU

Install new primary filter element by sliding it down into housing. With the handle, pull filter element rearward to make the seal engage in the housing.

NOTE: Make sure primary and secondary filter elements form an effective seal.

Install housing cover.

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Engine - Air cleaners and lines

Lock clips to secure filter housing cover.

NOTE: If cover does not fit properly, recheck filter element installation. Cover will be difficult to install if filter elements are not properly installed.

RCPH11WHL745BAU

RCPH11WHL653BAU

Turn master electric power switch â&#x20AC;&#x153;onâ&#x20AC;?. Clear any fault codes. Start machine and confirm issue has been corrected.

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Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Engine lubrication system - 304

621F 721F

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Contents Engine - 10 Engine lubrication system - 304

SERVICE Blowby re-circulation system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Engine lubrication system

Blowby re-circulation system - Remove 1.

Locate the blowby recirculation system filter under the hood on the engine in back of the cooling fan. It can be accessed from the right side of the machine.

RCPH11WHL685BAU

RCPH11WHL663BAU

RCPH11WHL653BAU

Raise the hood using the controls located behind the access cover. Then remove the inner fender panel.

Turn the master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

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Engine - Engine lubrication system

Remove the screws on the filter housing cover plate. It may be necessary to use an off-set screwdriver.

RAPH12WEL0089AA

RAPH12WEL0090AA

RCPH10WHL467AAH

Remove the filter housing cover plate.

Remove the filters from the filter housing and replace them.

Next operation: Blowby re-circulation system - Install (10.304)

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Engine - Engine lubrication system

Blowby re-circulation system - Install Prior operation: Blowby re-circulation system - Remove (10.304) 1.

Install the new filter elements into the filter housing. Take care to fit the filter elements correctly.

RCPH10WHL467AAH

RAPH12WEL0090AA

RAPH12WEL0089AA

Install the filter housing cover plate.

Secure the filter housing cover plate with screws. It may be necessary to use an off-set screwdriver.

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Engine - Engine lubrication system

Turn the master electric switch to the â&#x20AC;&#x153;onâ&#x20AC;? position.

RCPH11WHL653BAU

RCPH11WHL663BAU

Install the inner fender panel. Then lower the hood using the controls located behind the access cover.

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Index Engine - 10 Engine lubrication system - 304 Blowby re-circulation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blowby re-circulation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Aftercooler - 310

621F 721F

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Contents Engine - 10 Aftercooler - 310

SERVICE Aftercooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DIAGNOSTIC Aftercooler Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Engine - Aftercooler

Aftercooler - Remove WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Raise hood using controls located behind the access cover.

RCPH11WHL652BAU

RCPH11WHL653BAU

After hood is raised, turn master electric switch to the off position.

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Engine - Aftercooler

On the underside of hood, remove bolts (1) from exhaust stack, then remove plate (2).

Remove exhaust stack (3).

RAPH12WEL0194AA

RAPH12WEL0170AA

RAPH12WEL0193AA

Double up a nylon lifting strap. From the topside, slide looped strap through the hood exhaust opening.

Place a solid steel bar through the strap loop (see arrow) and tighten. Attach the other end of the strap to a suitable lifting device and remove any slack in the line.

NOTE: Note the position of the lifting bar strap. It is offset to even out the weight distribution of the hood.

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Engine - Aftercooler

Remove cotter pin and pin from the lift cylinder. Turn electrical master switch back on and run lift cylinder up. Once cylinder is retracted, return the electrical master switch back to the OFF position.

RAPH12WEL0191AA

RAPH12WEL0169AA

RAPH12WEL0207AA

Remove the hood bracket bolts and move hood away from back plate, allowing enough clearance to reach air cooler unit front bolts.

Turbocharger tube removal 9.

Loosen top left side clamp of the air cooler outlet hose.

NOTE: Loosen only the clamp closest to the air cooler.

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Engine - Aftercooler

10.

Loosen the clamp at the elbow-turbocharger connection end. Remove tube and plug turbocharger.

RAPH12WEL0206AA

Intake port tube removal 11.

12.

Loosen top right side clamps of the air cooler intake hose. Slide hose back far enough to clear air cooler tube.

RAPH12WEL0200AA

RAPH12WEL0202AA

Loosen end clamp on intake port side of the engine. Remove tube with hose.

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Engine - Aftercooler

Screen cover removal 13.

Unlatch the rubber T-handle from the screen cover.

NOTE: Screen cover may be different from what is shown.

14.

RAPH12WEL0190AA

RAPH12WEL0189AA

Lift screen cover part way. Pull cotter pin and washer from screen tab and locking bar prop.

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Engine - Aftercooler

15.

Open screen cover completely and remove the bolts. Lift and remove cover.

NOTE: Always use proper lifting devices.

RAPH12WEL0181AA

air cooler unit removal NOTE: For Commodity King, include instruction 16. For Standard 721F omit instruction 16 and go to instruction 17.

Commodity king only 16.

Lift side panels. Unbolt and remove left and right beam seals, then lower side panels.

NOTE: Left side shown.

RAPH12WEL0222AA

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Engine - Aftercooler

17.

18.

19.

With a sharp cutting tool, make a slice in the gasket (arrowed) near the shoulder bolt.

RAPH12WEL0177AA

RAPH12WEL0221AA

RAPH12WEL0146AA

Remove shoulder bolt, washers and nut (1) from air conditioner condenser unit (2).

Lift air conditioner condenser up and angle toward the back of the cab. Support in place if needed.

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Engine - Aftercooler

20.

21.

22.

Lift up side panels. Remove the left and right side bolt of air cooler unit.

RAPH12WEL0169AA

RAPH12WEL0174AA

RAPH12WEL0172AA

Remove front bolts of air cooler unit.

Remove air cooler unit out of cooler package framework.

Next operation: Aftercooler - Testing (10.310)

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Engine - Aftercooler

Aftercooler - Install WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Aftercooler - Remove (10.310) Aftercooler - Testing (10.310) 1.

Attach frame to air cooler assembly. Bolt in place with four bolts and washers.

RAPH12WEL0172AA

RAPH12WEL0174AA

RAPH12WEL0169AA

Using proper lifting equipment, lift and position completed air cooler unit into the cooler package framework with the tubes situated within the front plate cutâ&#x20AC;&#x201C;out, facing the engine (1). Insert two bolts (2) and partially set.

NOTE: Do not tighten bolts at this time.

Raise side panel and insert bolt into each side of the air cooler unit. Run bolt PART way.

Once air cooler unit is semiâ&#x20AC;&#x201C;secured, tighten sides and front bolts, then lower side panels.

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Engine - Aftercooler

Slide air conditioner condenser unit back in place.

RAPH12WEL0145AA

RAPH12WEL0221AA

RAPH12WEL0179AA

Using a shoulder bolt, three washers and a nut (1), secure air conditioner condenser unit (2) in place.

Flip latch closed on air conditioner condenser unit.

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Engine - Aftercooler

Line up screen cover and run center bolt PART way (1). Insert outer bolts (2) then securely tighten all three bolts.

NOTE: Screen cover may be different than shown. NOTE: For Commodity King, continue instructions. Standard 721F go to instruction 12.

RAPH12WEL0181AA

RAPH12WEL0222AA

Commodity king only 9.

Lift side panel. Attach hood beam seal with weather stripping shield facing up.

NOTE: Left side panel shown.

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Engine - Aftercooler

10.

Slide beam seal onto hood hinge stud and tighten in place with washer and nut.

RAPH12WEL0184AA

11.

Insert two bolts on opposite end of beam seal and frame. Tighten in place with washers and nuts.

NOTE: Repeat procedure on right side.

RAPH12WEL0185AA

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Engine - Aftercooler

Screen cover installed 12.

13.

Raise screen cover locking bar prop on left side.

RAPH12WEL0187AA

RAPH12WEL0188AA

Partially lower screen cover, lining up screen tab with locking bar prop.

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Engine - Aftercooler

14.

15.

Place washer on the outside of hinge followed with a cotter pin to secure in place.

RAPH12WEL0189AA

RAPH12WEL0190AA

Close screen cover, locking in place with the rubber Tâ&#x20AC;&#x201C;handle.

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Engine - Aftercooler

Hood installed 16.

Line up hood hinge bolt holes to frame. Partially set bolts to hold in place. Once hood lines up evenly, tighten all bolts and torque to 65 - 79 NÂˇm (48 - 58 lb ft).

17.

Turn electrical master switch on and electrically lower lift cylinder, lining up holes. Insert pin through both holes.

18.

Return electrical master switch to the off position.

19.

RAPH12WEL0169AA

RAPH12WEL0191AA

RAPH12WEL0192AA

Insert cotter pin through rear of cylinder pin, securing lift cylinder in place.

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Engine - Aftercooler

20.

21.

Remove hood lifting device.

RAPH12WEL0193AA

RAPH12WEL0195AA

Replace exhaust stack. Insert stack studs through the pre-drilled holes on the top of the hood.

NOTE: Exhaust stack opening faces toward the rear.

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Engine - Aftercooler

22.

On underside of hood, place reinforce plate (1) over stack studs (2), securing in place with washers and nuts. Torque to 36 - 44 NÂˇm (27 - 32 lb ft).

RAPH12WEL0194AA

RAPH12WEL0207AA

RAPH12WEL0204AA

Turbocharger tube installation 23.

Remove plug from turbocharger. Place the upper end of the hose onto the air cooler tube. DO NOT CLAMP at this time.

NOTE: Note direction of clamps.

24.

On the opposite end, make sure that Oâ&#x20AC;&#x201C;ring is in elbow fitting.

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Engine - Aftercooler

25.

26.

27.

Align O–ring end of tube to turbocharger.

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Clamp in place. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).

Return to top air cooler tube connection and torque clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) in place.

NOTE: Note direction of clamps.

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Engine - Aftercooler

Intake port tube installation 28.

29.

30.

Lightly lubricate inside of hose (1). Slide hose over top end of tube (2).

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RAPH12WEL0200AA

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Slide hose back far enough to clear right side air cooler tube.

Align opposite end of tube to the intake port manifold side of the engine. Make sure there is clearance between hood and exhaust stack on both sides of tube.

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Engine - Aftercooler

31.

32.

Slide clamps in place and tighten. Torque to 10.1 11.3 N·m (7.4 - 8.3 lb ft).

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RAPH12WEL0201AA

RCPH11WHL653BAU

Line up top tube and slide hose over air cooler tube until hose fits flush against the frame. Slide clamps in place and tighten Torque to 10.1 - 11.3 N·m (7.4 8.3 lb ft).

NOTE: Note the direction of clamps.

33.

Turn power on (1), activate hood cylinder (2) and close hood.

Next operation: Aftercooler - Pressure test (10.310)

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Engine - Aftercooler

Aftercooler - Pressure test CAUTION Eye injury hazard! Use caution when removing the cap due to possible air pressure. Failure to comply could result in minor or moderate injury. C0056A

CAUTION Eye injury hazard! Always wear eye or full face protection when performing this procedure. Failure to comply could result in minor or moderate injury. C0081A

Park machine on a level surface and lower the bucket to the ground. Put transmission in neutral, apply the parking brake, then turn off engine.

RCPH10WHL350FAH

RAPH12WEL0205AA

RAPH12WEL0202AA

Raise hood. Remove the turbocharger outlet tube. Plug tube and turbocharger.

NOTE: Plug is dealer fabricated.

Remove inlet hose (1) from manifold (2). Plug inlet hose and with pressurized air, pressurize the system between 15 - 20 psi.

NOTE: Always wear eye or full face protection when performing this procedure. Failure to comply could result in minor or moderate injury. NOTE: Pressurized plug is dealer fabricated.

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Engine - Aftercooler

For air leaks or lack of pressure, inspect cooler components for damage or missing parts.

RAPH12WEL0181AA

RAPH12WEL0207AA

RAPH12WEL0201AA

Inspect the turbocharger top air cooler outlet flex hose for leaks or holes and ensure that the clamps are tight.

Inspect the manifold top air cooler inlet flex hose for leaks or holes and ensure that the clamps are tight.

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Engine - Aftercooler

Visually inspect top of air cooler for damage or leaks.

NOTE: If the leak source has not been located, remove and test the air cooler using Aftercooler - Testing (10.310).

RCPH10WHL139AAH

RAPH12WEL0202AA

RAPH12WEL0204AA

Pressure test reassemble 8.

Unplug and remove pressurized air system from manifold. Realign tube on manifold. Make sure there is clearance between the hood and exhaust stack on both sides of the tube. Tighten clamp and torque to 10.1 - 11.3 NÂˇm (7.4 - 8.3 lb ft).

Remove plug from turbocharger tube. Remove plug from turbocharger. Make sure gasket remained inside turbocharger tube.

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Engine - Aftercooler

10.

11.

12.

Align tube ends and secure in place with clamp. Torque to 10.1 - 11.3 NÂ·m (7.4 - 8.3 lb ft).

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RCPH11WHL653BAU

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Lower hood.

Close screen and T-handle secure in place (if available). Put transmission in park and turn off.

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Engine - Aftercooler

Aftercooler - Testing Test Point NÂ° 1 Condition Check the core for leaks by closing off the outlet tube and attaching regulated air pressure 550 kPa ( 80 psi) to the inlet tube. Submerge the cooler in water and watch for air leakage. Check

Expected Result Other Result (Possible Cause) Action Result Action If leakage is detected replace the after cooler.

bs03b028

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Index Engine - 10 Aftercooler - 310 Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Aftercooler - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Aftercooler - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Engine - 10 Engine cooling system - 400

621F 721F

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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CONSUMABLES INDEX IU

Consumable LoctiteÂ® 242

Radiator - Install

PAGE 10.400 / 16

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Engine - Engine cooling system

Radiator - Remove 1.

Park loader on level surface and lower bucket to ground. Apply parking brake and shut down engine. Then place articulation lock in locked position.

RCPH10WHL063BAL

RCPH11WHL653BAU

RAIL12WEL0099AA

Put master disconnect switch in OFF position.

Raise the center cooler box cover (1). Have another person lift and hold the cooler box side panel (2) up into the raised position.

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Engine - Engine cooling system

Remove the mounting screws for the side panel, and remove the panel.

RAIL12WEL0097AA

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RAIL12WEL0100AA

Remove the thumb screw and washer (1) securing left hand inner fender panel (2) and remove fender.

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Engine - Engine cooling system

Remove radiator cap.

NOTE: Machine pictured includes the heavy duty/high debris cooling option. Your machine may differ slightly in appearance.

RAIL12WEL0103AA

RCPH10WHL054BAL

RAIL12WEL0101AA

Place a suitable container below radiator drain. Then remove drain cap and drain coolant into container. Install and secure both caps after coolant has drained.

Release catch and tilt air conditioning condenser core up.

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Engine - Engine cooling system

10.

Loosen the upper radiator hose clamp and remove the hose from radiator.

RAIL12WEL0102AA

RAIL12WEL0103AA

RAIL12WEL0104AA

Disconnect overflow hose from radiator.

NOTE: Machine pictured includes the heavy duty/high debris cooling option. Your machine may differ slightly in appearance.

11.

Remove cooler box support brace bolts (1). Then remove cooler box support brace (2).

NOTE: This step only required for machines equipped with the heavy duty/high debris cooling option. NOTE: Machine pictured includes the heavy duty/high debris cooling option. Your machine may differ slightly in appearance.

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Engine - Engine cooling system

12.

13.

14.

Remove coolant overflow bottle.

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RAIL12WEL0107AA

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Remove coolant overflow bottle support bracket.

Remove cooling fan screen shroud.

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