Case 1221F, Service Manual

Page 1: ...pyright 2013 CNH America LLC All Rights Reserved Case is a registered trademark of CNH America LLC Racine Wisconsin 53404 U S A Part number 47544213 1st edition English August 2013 SERVICE MANUAL 1221F Tier 4 Wheel Loader ...

Page 2: ...rves not only to give an understanding of the structure but also serves as reference material for troubleshooting Operational checks and troubleshooting This group explains the system operational checks and troubleshooting charts correlating problem to remedy Tests and adjustments This group explains checks to be amide before and after performing repairs as well as adjustments to be made at comple...

Page 3: ...any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 3 3 Section number 3 Power train system Consecutive page number for each section Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example 1 2 3 Symbol Item Remarks Special safet...

Page 4: ...he left to convert it to 55 mm Carry out the same procedure as above to convert 55 mm to 2 165 inches The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1mm 0 03937 in ͽ 0 1 2 3 4 5 6 7 8 9 0 0 039 0 079 0 118 0 157 0 197 0 236 0...

Page 5: ...0 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 1...

Page 6: ... 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8 359 8 579 40 8 799 ...

Page 7: ... 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2 1070 5 1077 7 150 ...

Page 8: ...1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2333 2347 2361 2375 23...

Page 9: ...5 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 8 27 80 6 16 7 62 143 6 3...

Page 10: ...embly and Assembly 3 82 SECTION 4 BRAKE SYSTEM Group 1 Structure and Function 4 1 Group 2 Operational Checks and Troubleshooting 4 30 Group 3 Tests and Adjustments 4 37 Group 4 Disassembly and assembly 4 39 SECTION 5 STEERING SYSTEM Group 1 Structure and Function 5 1 Group 2 Operational Checks and Troubleshooting 5 18 Group 3 Tests and Adjustments 5 26 Group 4 Disassembly and Assembly 5 34 SECTION...

Page 11: ...ELECTRICAL SYSTEM Group 1 Component Location 7 1 Group 2 Electrical Circuit 7 3 Group 3 Monitoring System 7 21 Group 4 Electrical Component Specification 7 64 Group 5 Connectors 7 71 Group 6 Troubleshooting 7 92 ...

Page 12: ...SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 13 Group 3 Operational Checkout Record Sheet 1 26 ...

Page 13: ......

Page 14: ...hem contain substances that may be harmful to your health Modern oils contain additives Do not burn contaminated fuels and or waste oils in ordinary heating systems Avoid spillage when draining off used engine coolant mixtures engine gearbox and hydraulic oils brake fluids etc Do not mix drained brake fluids or fuels with lubricants Store them safely until they can be disposed of in a proper way t...

Page 15: ...e DO NOT remove this manual or the safety manual from the machine See your dealer for additional manuals Also see the manual information on the Title pages first and second pages in front of the Table of Contents of this manual The safety information given in this manual does not re place safety codes insurance needs federal state or lo cal laws Make sure that your machine has the correct equipmen...

Page 16: ...Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling 1 3 ...

Page 17: ... clear of moving parts Loose clothing jewelry watches long hair and other loose or hanging items can become entangled in moving parts Wear protective equipment when appropriate DO NOT attempt to remove material from any part of the machine while it is being operated or components are in motion Ensure all guards and shields are in good condition and properly installed before operating the machine N...

Page 18: ...he machine Do not attempt to clean lubricate clear obstructions or make adjustments to the machine while it is in motion or while the engine is running Always ensure the working area is clear of tools parts other persons and pets before you start operating the machine Unsupported hydraulic cylinders can lose pressure and drop the equipment causing a crushing hazard DO NOT leave equipment in a rais...

Page 19: ...curely Should the fuel cap be lost replace it only with the manufacturer s approved cap Use of a non approved cap without proper venting may result in pressurization of the tank Use the correct fuel for the operating season Never use gasoline for cleaning purposes Wheels and Tires Ensure the tires are correctly inflated DO NOT exceed recommended load or pressure Follow instructions in the Operator...

Page 20: ...ng to the manufacturer s instructions At least once each day and at the end of the day remove all trash and debris from the machine Ensure no debris is near hot components such as engine transmission exhaust battery etc More frequent cleaning of your machine may be necessary depending on the operating environment and conditions At least once each day remove debris accumulation around moving compon...

Page 21: ... motion The operator presence system should never be disconnected or bypassed If the system is inoperable the system must be repaired Seat Belts Seat belts must be worn at all times Seat belt inspection and maintenance Keep the seat belts in good condition Keep sharp edges and items than can cause damage away from the belts Periodically check belts buckles retractors tethers slack take up system a...

Page 22: ...o the atmosphere Do not attempt to service or repair the system Service repair or recharging must be performed only by a trained service technician Personal Protective Equipment PPE Wear Personal Protective Equipment PPE such as hard hat eye protection heavy gloves hearing protection pro tective clothing etc Certain protective equipment should be replaced and renewed upon age and wear Old hard hat...

Page 23: ...re you do not make contact with the ground and the machine at the same time Do not permit anyone to touch the machine until power has been shut off to the power lines Electrical Storm Safety Do not operate machine during an electrical storm If you are on the ground during an electrical storm stay away from machinery and equipment Seek shelter in a permanent and protected structure If an electrical...

Page 24: ...attachment or furthermost contact point to view operation danger area Carry loads in the recommended positions for maximum stability Never lift loads in excess of capacity Know tipping weights Know and understand the job site traffic flow patterns and obey signal personnel road signs and flaggers Know and understand that job site conditions may change on an hourly basis It is the operator s respon...

Page 25: ...e any repairs as necessary Check for any loose bolts Torque as required Do not modify the machine or attachments Such modifications can damage and or affect the integrity of the attach ment and can effect safety and function of the attachment and or machine Check all controls in a clear area and make certain the machine is operating correctly 1 12 ...

Page 26: ...Tire Head light Hydraulic tank Radiator Main control valve Battery Counterweight Step Bucket cylinder Bucket link Bell crank Cab Air cleaner DPF assy Engine Boom Front axle Steering cylinder Transmission Rear axle Fuel tank Boom cylinder Main pump 1221F ...

Page 27: ... 8 0 Dump clearance at 45 G 3300 10 10 Dump reach full lift H 1430 4 8 Width over tires I 3220 10 7 Dump angle J degree 47 Roll back angle carry position K 48 Cycle time Lift with load sec 6 1 Dump with load 1 4 Lower empty 4 1 Maximum travel speed km hr mph 36 0 22 4 Braking distance m ft in 12 39 4 Minimum turning radius center of outside tire 6 43 21 1 Gradeability degree 30 Breakout force kg l...

Page 28: ...mp clearance at 45 G 3670 12 0 Dump reach full lift H 1480 4 10 Width over tires I 3220 10 7 Dump angle J degree 47 Roll back angle carry position K 49 Cycle time Lift with load sec 6 1 Dump with load 1 4 Lower empty 4 1 Maximum travel speed km hr mph 36 0 22 4 Braking distance m ft in 12 39 4 Minimum turning radius center of outside tire 6 43 21 1 Gradeability degree 30 Breakout force kg lb 23130...

Page 29: ...arance at 45 G 3145 10 4 Dump reach full lift H 1560 5 1 Width over tires I 3220 10 7 Dump angle J degree 47 Roll back angle carry position K 48 Cycle time Lift with load sec 6 1 Dump with load 1 4 Lower empty 4 1 Maximum travel speed km hr mph 36 0 22 4 Braking distance m ft in 12 39 4 Minimum turning radius center of outside tire 6 43 21 1 Gradeability degree 30 Breakout force kg lb 25280 55730 ...

Page 30: ...learance at 45 G 3520 11 7 Dump reach full lift H 1600 5 3 Width over tires I 3220 10 7 Dump angle J degree 47 Roll back angle carry position K 49 Cycle time Lift with load sec 6 1 Dump with load 1 4 Lower empty 4 1 Maximum travel speed km hr mph 36 0 22 4 Braking distance m ft in 12 39 4 Minimum turning radius center of outside tire 6 43 21 1 Gradeability degree 30 Breakout force kg lb 24630 5430...

Page 31: ...ntial 1814 4000 Rear axle include differential 1820 4010 Tire 29 5 25 22PR L3 430 948 Hydraulic tank assembly 280 617 Fuel tank assembly 485 1070 Main pump 45 99 Steering pump 45 99 Fan brake pump assembly 12 26 Main control valve 2 3 spool 88 104 194 229 Flow amplifier 29 64 Boom assembly 1221F 2050 4520 1221F XR 2260 4980 Bell crank assembly 282 620 Bucket link 60 132 5 4 m3 bucket with bolt on ...

Page 32: ...n chamber type Direct injection type Cylinder bore stroke 130Ý150 mm 5 12 Ý5 91 Piston displacement 11900 cc 726 cu in Compression ratio 16 6 Rated gross horse power 360 ps at 2000 rpm Maximum gross torque at 1400 rpm 173 kgfÂm 1250 lbfÂft Engine oil quantity 43 11 4 U S gal Wet weight 1269 kg 2797 lb High idling speed 2130 Ü 50 rpm Low idling speed 800 Ü 25 rpm Rated fuel consumption 162 g ps hr ...

Page 33: ...ef valve pressure dump 310 kgf cm2 4410 psi Item Specification Type Pressure reducing type Operating Minimum 5 kgf cm2 71 psi Maximum 30 kgf cm2 427 psi Single operation angle degree 17 Item Specification Steering pump Main pump Type Variable piston pump Capacity 110 cc rev 100 cc rev Maximum operating pressure 280 kgf cm2 3980 psi Rated oil quantity 220 min 58 1 U S gpm 200 min 52 8 U S gpm Rated...

Page 34: ...e with lock up clutch Transmission Full automatic power shift Converter stall ratio 2 51 1 Gear shift Forward fifth gear reverse third gear Control Electrical single lever type kick down system Automatic kick down from 2nd to 1st gear FNR switch on joystick lever option Pump rated f ow 135再 min 35 7 U S gpm at 2000 rpm Travel speed Forward 1 2 3 4 5 6 1 11 8 18 3 26 6 41 0 km hr Reverse 1 2 3 6 1 ...

Page 35: ...0Ý1 5 6 9 Ü 1 4 49 9 Ü 10 1 13 Brake valve mounting bolt M8Ý1 25 2 5 Ü 0 5 18 1 Ü 3 6 14 Cut off valve mounting bolt M10Ý1 5 6 9 Ü 1 4 50 Ü 10 1 15 Remote control block for EH RCV M8Ý1 25 2 5 Ü 0 5 18 1 Ü 3 6 16 Stop valve M10Ý1 5 6 9 Ü 1 4 50 Ü 10 1 17 Safety valve M10Ý1 5 6 9 Ü 1 4 50 Ü 10 1 18 Hydraulic oil tank mounting bolt M20Ý2 5 57 9 Ü 8 7 419 Ü 62 9 19 Power train system Transmission bolt...

Page 36: ...2Ý2 5 48 3 63 3 350 457 65 8 98 0 476 709 M24Ý3 0 62 5 84 5 452 611 85 0 115 615 832 M30Ý3 0 124 168 898 1214 169 229 1223 1655 M36Ý4 0 174 236 1261 1703 250 310 1808 2242 Bolt size 8T 10T kgÂm lbÂft kgÂm lbÂft M 8Ý1 0 2 17 3 37 15 7 24 3 3 04 4 44 22 0 32 0 M10Ý1 25 4 46 6 66 32 3 48 2 5 93 8 93 42 9 64 6 M12Ý1 25 7 78 11 58 76 3 83 7 10 6 16 0 76 6 115 M14Ý1 5 13 3 18 1 96 2 130 17 9 24 1 130 17...

Page 37: ...7 9 5 68 7 3 4 36 18 130 1 41 21 152 1 1 4 50 35 253 Thread size Width across flat mm kgfÂm lbfÂft 9 16 18 19 4 28 9 11 16 16 22 5 36 2 13 16 16 27 9 5 68 7 1 3 16 12 36 18 130 1 7 16 12 41 21 152 1 11 16 12 50 35 253 Thread size Width across flat mm kgfÂm lbfÂft 1 4 19 4 28 9 3 8 22 5 36 2 1 2 27 9 5 68 7 3 4 36 18 130 1 41 21 152 1 1 4 50 35 253 ...

Page 38: ...reeze and water 50 50 67 17 7 SAE 30 SAE 10W SAE 10W 30 SAE 15W 40 ø Refer to below list ISO VG 32 ISO VG 46 ISO VG 68 ASTM D975 NO 1 ASTM D975 NO 2 NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type SAE 10W 30 SAE 15W 40 Recommended oil list BP TERRAC SUPER TRANSMISSION 10W 30 CASTROL AGRI TRANS PLUS 10W 30 MOBILFLUID 426 SHELL DONAX TD 10W 30 TOTAL DYNATRANS MPV 侏 侏1 余SAE 余API 余ISO 余NLGI 余A...

Page 39: ...Cluster turn signals and warning indicator check 侕 侕 2 Transmission axle and engine neutral start switch and reverse warning alarm switch checks  Transmission control lever and neutral 侕 侕  Neutral start and reverse warning 侕 侕  Alarm circuit checks 侕 侕 3 Monitor indicator and gauge checks engine running  Monitor display and alternator output checks 侕 侕  Monitor bypass circuit and seat belt i...

Page 40: ... 侕 Â1st 2nd 3rd and 4th speed clutch pack drag check 侕 侕 ÂTransmission pressure pump flow and leakage check 侕 侕 ÂTransmission shift modulation check 侕 侕 ÂTorque converter check 侕 侕 ÂEngine power check 侕 侕 6 Hydraulic system checks ÂHydraulic system warm up procedure 侕 侕 ÂHydraulic pump performance check 侕 侕 ÂPilot control valve boom float check 侕 侕 ÂBoom down solenoid valve check 侕 侕 ÂControl valv...

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