CASE 621F 721F TIER 4 WHEEL LOADER Service Repair Manual Instant Download

621F 721F Tier 4 Wheel Loader from PIN NBF213602 and above SERVICE MANUAL Part number 84605841 1st edition English Printed in U.S.A. Copyright 2012 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A. 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

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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 1

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 2

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) 84605841 14/05/2012 3

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) 1 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 2. 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 4

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) 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 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) 84605841 14/05/2012 5

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) 1 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 2. Tighten wheel bolts to a final torque of 640 - 720 N m (472 - 531 lb ft). in sequence shown in figure 84605841 14/05/2012 6

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 147.6 l (39.0 US gal) 90.8 l (24.0 US gal) 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 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. 84605841 14/05/2012 7

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) 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 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. 84605841 14/05/2012 8

INTRODUCTION Engine Oil Viscosity/Temperature Range 1 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 2 RCPH10WHL453BAH 84605841 14/05/2012 9

INTRODUCTION Hydraulic/Brake System Temperature Range 3 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 pro- tection, 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 10

INTRODUCTION Hydraulic Fluid CASE AKCELA HY-TRAN ULTRA HYDRAULIC TRANSMISSION OIL is specifically designed for high pressure applica- tions and for Case hydraulic systems. Your Case Dealer can provide hydraulic fluid to fulfill different climate/temper- ature 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 yourengine. Thisoilinsurescorrectlubricationofyouren- gine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temper- atures. 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 ad- ditive in the sump. Oil change intervals shown in this man- ualarebasedontestscarriedoututilizingCaselubricants. 4 RCPH10WHL012AAD 84605841 14/05/2012 11

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 ma- chine. 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 machine s warranty. NOTE: B7 is the highest biodiesel (7% blend) that should be used in this machine. 84605841 14/05/2012 12

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 per- mits 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 contam- ination, 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 13

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 7 Capacities 7 Capacities 7 Capacities 7 Capacities 7 8 Capacities Capacities 8 Capacities 8 Capacities 8 Capacities 8 11 Capacities Capacities 11 Capacities 11 11 Capacities Capacities 11 Capacities 84605841 14/05/2012 14

SERVICE MANUAL Engine 621F 721F 84605841 14/05/2012 10

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 10

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 PAGE 10.001 / 22 10.001 / 22 10.001 / 23 10.001 / 23 10.001 / 23 10.001 / 33 10.001 / 33 10.001 / 34 10.001 / 34 10.001 / 35 10.001 / 50 Engine - Remove Engine - Remove Engine - Remove Engine - Remove Engine - Remove Engine - Install Engine - Install Engine - Install Engine - Install Engine - Install Engine - 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 10.400 / 16 10.500 / 20 10.500 / 20 10.500 / 20 10.500 / 21 10.500 / 21 10.500 / 21 10.500 / 22 10.500 / 22 10.500 / 24 10.500 / 24 10.500 / 25 10.500 / 25 10.500 / 26 10.500 / 27 10.500 / 27 10.500 / 29 10.500 / 29 10.500 / 31 84605841 14/05/2012 10

84605841 14/05/2012 10

Engine - 10 Engine and crankcase - 001 621F 721F 84605841 14/05/2012 10.001 / 1

Contents Engine - 10 Engine and crankcase - 001 SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 84605841 14/05/2012 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 PAGE 10.001 / 22 10.001 / 22 10.001 / 23 10.001 / 23 10.001 / 23 10.001 / 33 10.001 / 33 10.001 / 34 10.001 / 34 10.001 / 35 10.001 / 50 Engine - Remove Engine - Remove Engine - Remove Engine - Remove Engine - Remove Engine - Install Engine - Install Engine - Install Engine - Install Engine - Install Engine - Install 84605841 14/05/2012 10.001 / 3

Engine - Engine and crankcase Engine - Remove NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen- erate 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. Parkmachineonalevelsurfaceandlowerthebucket to the ground. Put articulation lock in LOCKED posi- tion and stop the engine. 1 RCPH10WHL063BAL 2. Actuate the brake pedal several times to discharge brake accumulators. 2 RCPH10WHL435AAH 3. 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. 3 RCPH10WHL119BAL 84605841 14/05/2012 10.001 / 4

Engine - Engine and crankcase 4. 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. 4 RCPH10WHL099BAL 5. Locate the master and hood raise switch by the bat- tery box. Then raise the hood and put the master disconnect switch in the OFF position. 5 RCPH10WHL106AAH 6. 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. 6 RAPH12WEL0597AA 7. Place a suitable container below radiator drain, re- move 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 vol- ume. 7 RCPH10WHL054BAL 84605841 14/05/2012 10.001 / 5

Engine - Engine and crankcase 8. 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 vol- ume. 8 RCPH10WHL054BAL 9. After oil drains, disconnect drain hose from frame by removing jam nut (1). Then pull hose from frame in preparation for engine removal. (2) 9 RAPH12WEL0598AA 10. Double up a nylon lifting strap (1) and slide through the exhaust stack (2) on the hood. 10 RAPH12WEL0599AA 84605841 14/05/2012 10.001 / 6

Engine - Engine and crankcase 11. 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. 11 RAPH12WEL0600AA 12. Tag and disconnect the camera wire harness (if ma- chine is equipped with a camera.) 12 RAPH12WEL0601AA 13. 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.) 13 RAPH12WEL0602AA 84605841 14/05/2012 10.001 / 7

Engine - Engine and crankcase 14. Remove mount bolt (1) and backup alarm wiring har- ness clamp from cooler housing. Then tag and re- move hood ground wire (2) from cooler housing. 14 RAPH12WEL0603AA 15. Tag and disconnect hood wiring harness connector from rear chassis wiring harness connector. 15 RAPH12WEL0604AA 16. 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. 16 RAPH12WEL0605AA 84605841 14/05/2012 10.001 / 8

Engine - Engine and crankcase 17. Remove the pin from the bottom of the lifting motor cylinder where it attaches to the loader frame. 17 RAPH12WEL0606AA 18. Put the master disconnect switch in the ON position. Then, retract the lifting motor cylinder (2), replace pin and disconnect wiring harness (1). 18 RAPH12WEL0062AA 19. 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. 19 RAPH12WEL0608AA 84605841 14/05/2012 10.001 / 9

Engine - Engine and crankcase 20. Have another person balance the hood and remove the hood hinge mounting bolts (arrows) from the cooler frame. 20 RAPH12WEL0605AA 21. 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. 21 RAPH12WEL0609AA 22. Tag and disconnect engine wiring harness connector from air filter restriction switch. 22 RAPH12WEL0610AA 84605841 14/05/2012 10.001 / 10

Engine - Engine and crankcase 23. Tag and disconnect engine wiring harness connector from air inlet humidity sensor. 23 RAPH12WEL0611AA 24. Loosen clamp (1) on the crankcase ventilation hose (2) and disconnect hose. 24 RAPH12WEL0612AA 25. Loosen clamps on turbocharger and air filter hous- ing. Then remove the intake air hose. Cover tur- bocharger inlet to prevent debris entry. 25 RAPH12WEL0613AA 84605841 14/05/2012 10.001 / 11

Engine - Engine and crankcase 26. Loosen the clamp on the turbocharger for the after cooler inlet elbow. 26 RAPH12WEL0614AA 27. Loosen the clamp on the hose at the after cooler inlet and remove the tube. 27 RAPH12WEL0615AA 28. Loosen clamp on the air inlet hose at the air filter housing. 28 RAPH12WEL0616AA 84605841 14/05/2012 10.001 / 12

Engine - Engine and crankcase 29. Remove bolts from the cooler box (1) and the cen- ter support bracket (2) securing the air inlet hose bracket. Then remove air inlet hose and bracket. 29 RAPH12WEL0617AA 30. Remove four the bolts securing the air filter housing to the mounting support bracket. Then remove air filter housing. 30 RAPH12WEL0618AA 31. 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. 31 RAPH12WEL0619AA 84605841 14/05/2012 10.001 / 13

Engine - Engine and crankcase 32. Remove the drive belt from the engine. 32 RAPH12WEL0620AA 33. If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness con- nectors 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. 33 RAPH12WEL0621AA 34. Tag and disconnect the wiring from the alternator. 34 RAPH12WEL0622AA 84605841 14/05/2012 10.001 / 14

Engine - Engine and crankcase 35. Remove SCR coolant return line. 35 RAPH12WEL0623AA 36. 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. 36 RAPH12WEL0624AA 37. Remove bolts securing wiring harness clamps to en- gine. 37 RAPH12WEL0625AA 84605841 14/05/2012 10.001 / 15

Engine - Engine and crankcase 38. Remove ground wires from the engine. NOTE: Move the wiring harness away from the engine. 38 RAPH12WEL0625AA 39. If the machine is so equipped, unplug the engine block heater and set it aside. 39 RAPH12WEL0626AA 40. Loosen the exhaust clamp from the turbocharger. 40 RAPH12WEL0627AA 84605841 14/05/2012 10.001 / 16

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Engine - Engine and crankcase 41. Disconnect the engine coolant vent hose from the engine. 41 RAPH12WEL0628AA 42. Loosen clamps and remove lower coolant hose from the engine. 42 RAPH12WEL0629AA 43. Remove the radiator hose from the engine. 43 RAPH12WEL0630AA 84605841 14/05/2012 10.001 / 17

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