CASE 1021G Tier 2 Wheel Loader Service Repair Manual

SERVICE MANUAL 1021G 1121G

Wheel Loader

1/2

Part number 48083742

1021G 1121G Tier 2 Wheel Loader

SERVICE MANUAL

Part number 48083742 English July 2018

© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.

SERVICE MANUAL 1021G ZBAR - EH, NEW CAB TIER2 1121G ZBAR - EH, NEW CAB TIER2

48083742_EN 31/07/2018 EN

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

Transmission.............................................................................. 21 [21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

Four-Wheel Drive (4WD) system .................................................. 23 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 48083742_EN 31/07/2018

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

Frames and ballasting ................................................................. 39 [39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

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[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.5 [55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

Front loader and bucket............................................................... 82 [82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 [82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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INTRODUCTION

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INTRODUCTION

Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Personal safety Carefully read this Manual before proceeding with maintenance, repairs, refuelling or other machine operations.

Repairs have to be carried out only by authorized and instructed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy hammers.

Non-authorized persons are not allowed to repair or carry out maintenance on this machine. Do not carry out any work on the equipment without prior authorization.

Ask your employer about the safety instructions in force and safety equipment.

TULI12WEX2004AA

1

TULI12WEX2005AA

2

Nobody should be allowed in the cab during machine maintenance unless he is a qualified operator helping with the maintenance work.

If it is necessary to move the equipment to carry out repairs or maintenance, do not lift or lower the equipment from any other position than the operator’s seat.

Never carry out any operation on the machine when the engine is running, except when specifically indicated.

Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc.

All repair and maintenance operations should be carried out with the greatest care and attention.

Service stairs and platforms used in a workshop or in the field should be built in compliance with the safety rules in force.

Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

DANGER Unexpected movement!

Make sure parking brake is applied. Secure machine with wheel chocks.

Failure to comply will result in death or serious injury.

D0013A

Before performing any work on the machine, attach a maintenance in progress tag. This tag can be applied on the left-hand control lever, safety lever or cab door.

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INTRODUCTION

Emergency Be prepared for emergencies. Always keep a fire extinguisher and first aid kit readily available. Ensure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.

SMIL12WEX0174AA

3

TULI12WEX2008AA

4

TULI12WEX2009AA

5

Equipment Wear close fitting clothing and safety equipment appropriate for the job: • Safety helmet • Safety shoes • Heavy gloves • Reflective clothing • Wet weather clothing If working conditions require, the following personal safety equipment should be on hand: • Respirators (or dust proof masks) • Ear plugs or acoustic ears protections • Goggles with lateral shield or masks for eye protection Do not wear rings, wristwatches, jewelry, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught into moving parts.

Engine - Radiator Never leave the engine running in enclosed spaces without proper ventilation which is able to evacuate toxic exhaust gases- Keep the exhaust manifold and tube free from combustible materials.

Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage.

Never attempt to check or adjust the belts when the engine is running.

Never lubricate the machine with the engine running.

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INTRODUCTION

Pay attention to rotating components and do not allow anyone to approach these areas to avoid becoming entangled.

Hands, clothing or tools getting caught in the fan blades or engine belts, can cause amputations, violent hemorrages and generate conditions of grave danger. For this reason avoid touching or approaching all rotating or moving parts.

A surging spray of the coolant from the radiator can cause serious burns and scalds.

Before checking the coolant level, shut-off the engine and allow machine to cool down the radiator and hoses.

Slowly unscrew the cap to release any residual pressure.

TULI12WEX2010AA

6

TULI12WEX2011AA

7

TULI12WEX2012AA

8

If it is necessary to remove the cap while engine is hot, wear safety clothes and equipment, then loosen the cap slowly to relieve the pressure gradually.

When checking the fuel, oil and coolant levels, use lights and lamps explicitly designated as explosion proof. If these types of lamps are not used, fires or explosions may occur.

Hydraulic systems Jets of fluids under pressure can penetrate the skin causing serious injuries.

Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Relieve the residual pressure by moving the hydraulic control levers several times.

Tighten all connections before applying pressure.

To protect the eyes wear a facial shield or safety goggles.

Protect your hands and body from possible jets of fluids under pressure.

Swallowing hydraulic oil is a severe health hazard.

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INTRODUCTION

When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Any fluid penetrating the skin must be removed within a few hours to avoid serious infections.

Flammable splashes may originate because of heating near lines with fluids under pressure, resulting in serious burns. Do not weld or use torches near lines containing fluids or other flammable materials.

TULI12WEX2013AA

Lines under pressure can accidentally be pierced when the heat expands beyond the area immediately heated.

Arrange for temporary fire resistant shields to protect hoses or other components during welding or torch use.

Have any visible leakage repaired immediately.

Discharged oil pollutes the environment. Soak up any oil that has spilled with a proper binding agent. Sweep up binding agent and dispose of it separately from other waste.

Never search for leakages with fingers; instead, use a piece of cardboard and always wear goggles.

Never repair a damaged line; always replace it. Replace hydraulic hoses immediately on detecting any damaged or moist areas.

Always store hydraulic oil in the original containers.

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9

INTRODUCTION

Product identification

LEIL16WHL2581FA

1.

2.

3.

4.

5.

Cab door and hand holds Steps Bucket (Z-bar version) Timed disconnect switch and battery jump post Bucket cylinder

6.

7.

8.

9.

1

Roll Over Protection System (ROPS) cab Loader lift arms Battery access Hand rails

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INTRODUCTION

LEIL16WHL2582FA

1.

2.

3.

4.

Hand rails Pre-cleaner Cab air filter access Bucket cylinder

5.

6.

7.

8.

2

Battery access Bucket (Z-bar version) Windshield washer reservoir Steps

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SERVICE MANUAL Engine 1021G ZBAR - EH, NEW CAB TIER2 1121G ZBAR - EH, NEW CAB TIER2

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Engine - Engine and crankcase

Engine - General specification 1021G ZBAR - EH, NEW CAB TIER2

ANZ --- APAC --- LA --- MEA

Engine with 4 Speed Transmission A. Low idle Alternate low idle Alternate accelerated idle Working idle (setting from factory) B. Maximum No Load RPM C. Converter Stall D. Hydraulic Stall E. Converter & Hydraulic Stall Temperature of the torque converter oil Temperature of the hydraulic oil

870-930 RPM 670-730 RPM 1270-1330 RPM 1020-1080 RPM 2162-2212 RPM 1973-2123 RPM 1885-2195 RPM 1487-1797 RPM 82 – 104 °C (180 – 219 °F) 54 – 57 °C (129 – 135 °F)

NOTE: hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode.

Engine - General specification 1121G ZBAR - EH, NEW CAB TIER2

Engine with 4 Speed Transmission A. Low idle Alternate low idle Alternate accelerated idle Working idle (setting from factory) B. Maximum No Load RPM C. Converter Stall D. Hydraulic Stall E. Converter & Hydraulic Stall Temperature of the torque converter oil Temperature of the hydraulic oil

ANZ --- APAC --- LA --- MEA

870-930 RPM 670-730 RPM 1270-1330 RPM 1020-1080 RPM 2162-2212 RPM 1973-2123 RPM 1885-2195 RPM 1487-1797 RPM 82 – 104 °C (180 – 219 °F) 54 – 57 °C (129 – 135 °F)

NOTE: hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode.

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Engine - Engine and crankcase

Engine - Remove Prior operation: Engine hood - Remove (90.105) 1. Park the machine on a level surface and lower the bucket to the ground. Put the articulation lock (1) in LOCKED position.

LEIL15WHL1782AA

1

LEIL16WHL1125AA

2

LEIL15WHL0564AA

3

2. Push the hydraulic functions lock-out switch in the normal operation position.

3. Move the loader hydraulic control handle to the raise and lower position in order to release any hydraulic pressure in the lift circuit.

4. Move the loader control handle in and out of the tilt position several times, this will relieve any pressure in the pilot accumulator.

5. Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve load travel stabilizer.

6. Actuate the brake pedal several times to discharge brake accumulators.

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Engine - Engine and crankcase

7. Slowly loosen the filler cap on the hydraulic oil tank to release air pressure.

LEIL15WHL0825AA

4

LEIL15WHL0663AA

5

LEIL16WHL1528AB

6

8. Locate the timed disconnect switch in the battery box.

Put the timed disconnect switch in the OFF position.

9. Tag and disconnect the positive cable (battery to isolator) cable (1) and the positive cable (isolator to starter) (2) from the battery isolator.

Disconnect the connector (3) from the timed disconnect switch.

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Engine - Engine and crankcase

10. Loosen and remove the bolts that hold the battery cover in place on both the left-hand and right-hand rear of the machine.

Disconnect the battery cable from the battery.

LEIL16WHL0891AB

7

LEIL15WHL1489AA

8

LEIL15WHL0719AB

9

11. Open the access cover.

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

NOTE: see machine specifications for cooling system volume.

12. Open the access cover.

Place a suitable container below the engine oil drain.

Remove the drain plug and drain the oil into the container. Reinstall drain plug.

NOTE: see machine specifications for engine oil sump volume.

RCPH11WHL104AAH

13. Loosen the clamp on the air intake hose under the air inlet engine hood.

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10

Engine - Engine and crankcase

14. Remove the mounting bolts (arrows) from engine compartment top cover (1).

15. Attach a suitable lifting device and lift strap to the engine compartment cover and exhaust stack. Carefully remove the cover (1), the exhaust stack (2) and the precleaner (3) as an assembly.

LEIL15WHL0679AB

11

LEIL17WHL0307AB

12

LEIL15WHL0682AB

13

LEIL17WHL0302AB

14

16. Disconnect the radiator vent hose (1) from the radiator. Remove the P-clamps that secure the hose to the left-hand muffler support bracket.

Tag and disconnect the ENG_H connector.

17. Remove the hydraulic oil lines (1) and related fittings.

18. Remove the two bolts, washers and nuts (2) to unfix the exhaust pipe support bracket (1) from the hydraulic tank.

Remove the clamp saddle (5), U-bolt (6), washers and nuts to separate the exhaust system pipe (4) from the bracket (1).

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Engine - Engine and crankcase

19. Loosen the clamp (2) to disconnect the exhaust system pipe (1) from the engine.

LEIL17WHL0301AB

15

LEIL17WHL0300AB

16

LEIL17WHL0304AB

17

LEIL17WHL0259AB

18

20. Remove the two bolts, washers and nuts (3) to unfix from the muffler the bracket (1) that supports the check valve (2). Loosen the clamp (4) to disconnect the aspirator engine hose from the muffler.

21. Attach a suitable lift equipment to the left-hand and right-hand support brackets (1), (4).

Remove the hardware to unfix the left-hand and righthand support brackets (1), (4) from the hydraulic tank and engine wall.

Move the exhaust system assembly (left-hand and right-hand support brackets (1), (4), muffler supports (2), muffler (3)) out of the machine.

NOTE: be sure all wire harness connections and hoses are out of the way during removal.

22. Loosen the V-band clamp (1) to disconnect the air intercooler inlet elbow (2). Discard the O-ring.

Loosen the clamps (3) to disconnect the air intercooler inlet tube (4).

NOTE: for clarity, the engine wall is not shown in the figure.

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Engine - Engine and crankcase

23. Loosen the clamps (3) to disconnect the air intake tube (4).

NOTE: for clarity, the engine wall is not shown in the figure.

LEIL17WHL0260AB

19

LEIL17WHL0261AB

20

LEIL17WHL0262AB

21

LEIL15WHL0819AB

22

24. Loosen the clamps (2) to disconnect the upper radiator tube (1).

NOTE: for clarity, the engine wall is not shown in the figure.

25. Remove the V-band clamp (1) to disconnect the air intake elbow (2) from the turbocharger. Discard the O-ring.

26. Remove the oil dipstick P-clamp (2). Pull the oil dipstick tube (1) through the wall.

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Engine - Engine and crankcase

27. Tag and disconnect the cable (grid heater power relay to heater) (1) and cable (ground heater) (2).

LEIL17WHL0303AB

23

LEIL17WHL0297AB

24

LEIL17WHL0296AB

25

LEIL17WHL0299AB

26

28. Tag and disconnect the WSH connector (1) from the fuel pre-filter. Remove the bolt, washer and nut (2) to unfix the P-clamp securing the wire to the support bracket.

Tag and disconnect the WIF connector from the fuel pre-filter.

29. Remove the bolt, washer and nut to unfix the P-clamp securing the pressure hoses of the air conditioning compressor to the support bracket.

30. Disconnect the fuel hose (tank to pre-filter) (2) and fuel hose (pre-filter to engine) (1).

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Engine - Engine and crankcase

31. Remove the bolts, washers and nuts (2), (3) to unfix fuel pre-filter (1) from the support bracket.

NOTE: pay attention to the GRD_WIF wire release at the location (2); tag the wire.

LEIL17WHL0298AB

27

LEIL15WHL0669AB

28

LEIL15WHL0670AB

29

LEIL15WHL1138AB

30

32. Loosen the clamp (2) on the crankcase vent hose (1).

33. Remove the bolt (3) with related washers and nut to separate the two clamps (4) from the hose support bracket (5).

34. Loosen the clamp (6) on the crankcase vent hose (1).

35. Cut the straps (7).

36. Remove the crankcase vent hose (1).

37. Loosen the P-clamps (2) on the engine to crankcase vent filter hose (1).

38. Remove the engine to the crankcase vent filter hose (1).

39. Remove the drain hose filter (3) from the crankcase vent filter.

40. Loosen the bolts (2) to remove the crankcase vent filter (1) from the machine.

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Engine - Engine and crankcase

41. Loosen the four nuts (2) and related washers (3) that hold the support bracket (1) of the crankcase vent filter to the rear chassis.

NOTE: one of these four nuts (2) is used to secure a P-clamp that hold the wiring harness to the support bracket (1).

LEIL15WHL1140AB

31

LEIL17WHL0270AB

32

LEIL17WHL0269AB

33

LEIL17WHL0268AB

34

42. Remove the two washers and nuts (5) to unfix the air intake bracket (1) from the hydraulic tank.

43. Remove the saddle, U-bolt, washers and nuts (2) to separate the air intake upper hose (3) from the air intake bracket (1).

44. Loosen the clamp (4) to disconnect the air intake upper hose (3).

45. Tag and disconnect the air restriction switch (7) from the air cleaner. Cut the strap.

46. Loosen the clamps (6) to disconnect the air intake hose (3) from the plenum and engine turbocharger.

47. Loosen the clamp (5) to disconnect the air intake plenum (2) from the elbow.

48. Loosen the clamp (4) to disconnect the air intake elbow (1) from the air filter housing.

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Engine - Engine and crankcase

49. Remove the bolts, washers and nuts (1) to unfix the air cleaner bracket (2) from the engine wall.

50. Remove the four nuts and washers (3) to unfix the air cleaner bracket (2) from the rear chassis. Move the air cleaner (4) with the air cleaner bracket (2) out of the machine.

LEIL17WHL0267AB

35

LEIL17WHL0305AB

36

LEIL17WHL0264AB

37

LEIL17WHL0256AB

38

51. Disconnect the engine heater cable from the engine.

52. Cut the cable ties (9).

53. Remove the bolt, washers, nut and two P-clamps (8) from the bracket (4).

54. Remove the bolt, washers, nut and P-clamp (7) from the bracket (4).

55. Remove the clamp (6) to disconnect the engine vent hose (5) from the engine.

56. Disconnect the fill hose (2) from the 90° elbow (1).

Disconnect the 90° elbow (1) from the engine. Discard the O-ring.

57. Remove the brackets (3) and (4) from the engine block.

58. Loosen the clamps (7) to disconnect the heater return tube (2) and heater supply tube (3).

Remove the bolt, washer, nut (1) and two P-clamps (4) to separate the tubes from the engine.

Remove the bolt, washer (5) and two P-clamps (4) to separate the tubes from the bracket (6).

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Engine - Engine and crankcase

59. Remove the bolt, washer (6) and two P-clamps (4) to separate the heater supply and return tubes (3), (2) from the bracket (5).

Remove the bolts and washers (7), (8) to unfix the bracket (5) from the engine.

Disconnect the heater supply tube (3) from the engine.

Disconnect the heater return tube (2) from the zinc lower radiator tube (1).

LEIL17WHL0255AB

39

LEIL17WHL0253AB

40

LEIL15WHL1055AB

41

LEIL17WHL0266AB

42

60. Loosen the clamp (1) to disconnect the zinc lower radiator tube (2) from the elbow radiator hose.

Remove the two bolts and washers (arrows) to disconnect the zinc lower radiator tube (2) from the engine.

Discard the O-ring.

61. Attach a lifting equipment to the engine wall (2). Remove the engine wall hold-down bolts (1) to unfix the engine wall from the rear chassis. Lift and remove the engine wall.

NOTE: prior to remove the engine wall to be sure that all the P-clamp installed on the wall are be removed.

62. Remove the drive belt on the engine.

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Engine - Engine and crankcase

63. Tag and disconnect the ALT_B and ALT_5 connectors (4), (5).

Remove the bolts, washers and nut (2), (3) to disconnect the alternator (1) from the engine.

LEIL17WHL0265AB

43

LEIL17WHL0263AB

44

LEIL17WHL0306AB

45

LEIL15WHL1085AA

46

64. Cut the cable strap (5). Tag and disconnect the ACT_10 connector from air compressor clutch connector (4).

Recovery the refrigerant as indicated in Air conditioning - Service instruction (50.200).

Disconnect the low-pressure line (3) from the suction port (compressor to condenser hose) and the highpressure line (2) from the discharge port (cab to compressor hose) of the air-conditioning compressor. Immediately install protective caps on the open ports and lines.

Remove the mounting bolts (6) to disconnect the air conditioning compressor (1).

65. Remove the P-clamps that secure the wires to the engine block.

Tag and disconnect the GND_ENG1, GND_ENG3, GND_ENG4 terminals and GND_CENG1, GND_CENG2 terminals.

66. Disconnect the electrical connector to the engine control unit.

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Engine - Engine and crankcase

67. Tag and disconnect the ST wire (1) from the engine starter.

LEIL15WHL1299AB

47

LEIL16WHL1527AB

48

LEIL15WHL1331BB

49

68. Tag and disconnect the negative cable (starter to ground) (1), the negative cable (battery to starter) (2) from the engine starter.

Tag and disconnect the positive cable (battery isolator to starter) (3) and CPWR, XM1C connectors (4), (5) from the engine starter.

69. Remove the three nuts (1) from the engine starter.

Remove the engine starter.

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Engine - Engine and crankcase

70. Disconnect the hydraulic fittings (2) and (3) from the hydraulic oil supply tube (1).

LEIL17WHL0258AB

50

LEIL17WHL0257AB

51

LEIL15WHL1086AB

52

LEIL15WHL1207AB

53

71. Loosen the two clamps to disconnect the hydraulic oil return tube (2) from the lower hose (1).

72. Connect a suitable lifting equipment to the engine lifting brackets (1).

Take up all slack in lifting equipment.

73. Loosen and remove the bolts (1) that fasten the center drive shaft (2) to the transmission.

NOTICE: the bolts (1) that fasten the center drive shaft (2) to the transmission must be replaced when removed.

NOTE: steps 74 and 75 are related only to CASE CONSTRUCTION 1021G.

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Engine - Engine and crankcase

74. Remove the bolts (1) and related washers.

Remove the converter housing cover plate (2) and remove the flex plate bolts.

LEIL15WHL1330AB

54

LEIL15WHL1019AB

55

LEIL15WHL1502AB

56

LEIL15WHL1020AB

57

75. Remove the twelve flex plate bolts (1).

NOTE: steps 76 and 77 are related only to CASE CONSTRUCTION 1121G. 76. Remove the cover (1). Remove the plug (2) to gain access to the flywheel.

77. Turn the flywheel (clockwise as seen from the engine front) until one of the torque converter bolts is visible through the hole, and remove the bolt. Continue turning the flywheel (clockwise) in 30° increments to expose each bolt, until all the twelve bolts are removed.

78. Remove the twelve bell housing bolts (1).

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Engine - Engine and crankcase

79. Loosen the oil drain hose (15) and the O-ring (14) from the elbow (13).

80. Separate the engine mounting brackets (8) from the engine.

Remove the engine bracket upper bolts (11) and the related washers (12).

Remove the engine bracket upper bolts (9) and the related washers (10).

Separate the engine mounting brackets (8) from the engine mounting plate (7). Remove the bolt (1), the washers (2), rubber lower isolator (3), the rubber upper isolator (4) the washer (5) and the nut (6).

LEIL15WHL1326BB

58

LEIL15WHL1082AA

59

81. Slowly raise the engine from the rear chassis. Be sure that all the wire harness connections and the hoses have been disconnected and are clear of the engine.

Guide the oil drain hose from the frame as the engine is lifted. Remove the engine from machine.

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Engine - Engine and crankcase

Engine - Install 1. Attach a suitable lifting equipment to the engine lifting brackets (1).

LEIL15WHL1142AB

1

LEIL15WHL1326BB

2

LEIL15WHL1020AB

3

2. Install the two engine mounting brackets (8) to the engine.

Tighten the engine bracket upper bolts (11) and related washers (12) to a torque of 170 – 231 N·m (125.4 – 170.4 lb ft).

Tighten the engine bracket lower bolts (9) and related washers (10) to a torque of 69.6 – 79.6 N·m (51.3 – 58.7 lb ft).

3. Inspect the engine mounts. If the engine rubber isolators require replacement, remove and discard the isolators (3) and (4). Place the engine over the rear chassis.

Install the bolts (1), washers (2), rubber lower isolators (3), engine mounting plate (7), rubber upper isolators (4), washers (5) and nuts (6) to fix the engine to the rear chassis. Tighten the bolts (1) to a torque of 397 – 447 N·m (292.8 – 329.7 lb ft).

Install new rubber lower isolator (2) and new upper isolator (4).

4. Tighten the oil drain hose (15) with a new O-ring (14) to the elbow (13).

5. Install the twelve bell housing bolts (1). Tighten the bell housing bolts (1) to a torque of 54 – 60 N·m (40 – 44 lb ft).

NOTE: steps 6 and 7 are related only to CASE CONSTRUCTION 1021G. 48083742_EN 31/07/2018

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Engine - Engine and crankcase

6. Install the twelve flex plate bolts (1). Tighten the flex plate bolts (1) to a torque of 33 – 41 N·m (24 – 30 lb ft).

LEIL15WHL1019AB

4

LEIL15WHL1330AB

5

LEIL15WHL1502AB

6

LEIL15WHL1207AB

7

7. Apply DOW 732 RTV SILICONE CLEAR to the converter housing cover plate (1).

Install the converter housing cover plate (2).

NOTE: step 8 is related only to CASE CONSTRUCTION 1121G. 8. Turn the flywheel (clockwise as seen from the engine front) until one of the torque converter bolts location is visible through the hole, and install the bolt. Continue turning the flywheel (clockwise) in 30 ° increments to expose each bolt location, until all the twelve bolts are installed.

Install the plug (2). Install the cover (1).

9. Hold the center drive shaft (2) in position and install the bolts (1) that fasten the center drive shaft (2) to the transmission.

Tighten the bolts to a torque of 136 – 149 N·m (100 – 110 lb ft).

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Engine - Engine and crankcase

10. Use two clamps to connect the hydraulic oil return tube (2) to the lower hose (1) and secure them.

LEIL17WHL0257AB

8

LEIL17WHL0258AB

9

11. Connect the hydraulic fittings (2) and (3) to the hydraulic oil return tube (1).

12. Position the engine starter on the machine.

Install the three flange nuts (1) to secure the engine starter to the engine. Tighten the flange nuts to 40 – 48 N·m (30 – 35 lb ft).

LEIL15WHL1331BB

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10

Engine - Engine and crankcase

13. Install the negative cable (starter to ground) (1), the negative cable (battery to starter) (2) on the engine starter. Tighten the related nut.

Use existing hardware to mount the positive cable (battery isolator to starter) (3) and CPWR, XM1C connectors (4), (5) to the engine starter. Torque to 22.5 – 29.4 N·m (16.6 – 21.7 lb ft).

LEIL16WHL1527AB

11

LEIL15WHL1299AB

12

LEIL15WHL1085AA

13

LEIL17WHL0306AB

14

14. Install and tighten the ST wire (1) to the engine starter.

15. Connect the electrical connector to the engine control unit.

16. Secure the wires to the engine block with clamps.

Connect the GND_ENG1, GND_ENG3, GND_ENG4 terminals and GND_CENG1, GND_CENG2 terminals.

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