Case 821E, Service Manual

Page 1: ...SERVICE MANUAL WHEEL LOADER 821E TIER 3 84299244 Replaces 87364100 Revised December 2009 Issued September 2006 ...

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Page 7: ... August 2006 CASE LLC 700 State Street Racine WI 53404 U S A Bur 5 3090 SECTION INDEX GENERAL Standard Torque Specifications 1001 Fluids and Lubricants 1002 Metric Conversion Chart 1003 Section Title Section Number Find manuals at http best manuals com search s CASE 84299244 ...

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Page 9: ...H America LLC All rights reserved Printed in U S A Issued April 2003 Revised July 2005 CASE LLC 700 State Street Racine WI 53404 U S A Bur 8 71603 GENERAL TORQUE SPECIFICATIONS Find manuals at http best manuals com search s CASE 84299244 ...

Page 10: ...LE OF CONTENTS TORQUE SPECIFICATIONS DECIMAL HARDWARE 3 TORQUE SPECIFICATIONS METRIC HARDWARE 4 TORQUE SPECIFICATIONS STEEL HYDRAULIC FITTINGS 5 TORQUE SPECIFICATIONS STEEL HYDRAULIC FITTINGS 6 Find manuals at http best manuals com search s CASE 84299244 ...

Page 11: ... 5 8 inch 150 to 180 203 to 244 3 4 inch 270 to 324 366 to 439 7 8 inch 400 to 480 542 to 651 1 0 inch 580 to 696 787 to 944 1 1 8 inch 800 to 880 1085 to 1193 1 1 4 inch 1120 to 1240 1519 to 1681 1 3 8 inch 1460 to 1680 1980 to 2278 1 1 2 inch 1940 to 2200 2631 to 2983 Grade 8 Bolts Nuts and Studs Size Pound Inches Newton metres 1 4 inch 144 to 180 16 to 20 5 16 inch 288 to 348 33 to 39 3 8 inch ...

Page 12: ...hes Newton metres M4 24 to 36 3 to 4 M5 60 to 72 7 to 8 M6 96 to 108 11 to 12 M8 228 to 276 26 to 31 M10 456 to 540 52 to 61 Size Pound Feet Newton metres M12 66 to 79 90 to 107 M14 106 to 127 144 to 172 M16 160 to 200 217 to 271 M20 320 to 380 434 to 515 M24 500 to 600 675 to 815 M30 920 to 1100 1250 to 1500 M36 1600 to 1950 2175 to 2600 8 8 Grade 10 9 Bolts Nuts and Studs Size Pound Inches Newto...

Page 13: ... 7 8 12 210 to 250 285 to 338 Split Flange Mounting Bolts Size Pound Inches Newton metres 5 16 18 180 to 240 20 to 27 3 8 16 240 to 300 27 to 34 7 16 14 420 to 540 47 to 61 Size Pound Feet Newton metres 1 2 13 55 to 65 74 to 88 5 8 11 140 to 150 190 to 203 Straight Threads with O ring Tube OD Hose ID Thread Size Pound Inches Newton metres 1 4 inch 6 4 mm 7 16 20 144 to 228 16 to 26 5 16 inch 7 9 m...

Page 14: ...16 16 384 to 480 43 to 54 3 4 16 540 to 600 61 to 68 Thread Size Pound Feet Newton metres 10 5 8 inch 15 9 mm 1 14 552 to 672 62 to 76 7 8 14 60 to 65 81 to 88 Nom SAE Dash Size Tube OD Thread Size Pound Feet Newton metres 1 1 16 12 85 to 90 115 to 122 1 3 16 12 95 to 100 129 to 136 12 3 4 inch 19 0 mm 1 3 16 12 65 to 80 90 to 110 1 5 16 12 115 to 125 156 to 169 14 7 8 inch 22 2 mm 1 3 16 12 65 to...

Page 15: ...Section 1002 1002 Copyright 2006 CNH Ameica LLC All rights reserved Printed in U S A Issued August 2006 CNH America LLC 700 State Street Racine WI 53404 U S A Bur 5 3100 FLUIDS AND LUBRICANTS ...

Page 16: ...F CONTENTS CAPACITIES AND LUBRICANTS 3 ENGINE OIL RECOMMENDATIONS 4 TRANSMISSION TEMPERATURE CHART 5 DIESEL FUEL SYSTEM 5 Fuel Storage 5 Specifications for Acceptable No 2 Diesel Fuel 5 MAINTENANCE SCHEDULE 6 Model 821E 6 MAINTENANCE POINTS 7 Model 821E 7 ...

Page 17: ...c Reservoir Refill Capacity 90 liters 23 8 U S Gallons Total System Capacity 176 liters 46 5 U S Gallons Type of Oil Case AKCELA Hy Tran Ultra Transmission Refill Capacity with Filter Change 39 7 litres 10 5 U S Gallons Type of Oil Case AKCELA No 1 15W 40 Axles Capacity Front 37 4 litres 39 5 U S Quarts Rear 23 7 litres 25 U S Quarts Type of Lubricant Case AKCELA Transaxle Fluid NOTE DO NOT use an...

Page 18: ...tions If Case AKCELA No 1 Multi Viscosity Oil is not available use only oil meeting API engine oil service category CH 4 preferred or CG 4 See the char t below for recommended viscosity at ambient air temperature ranges NOTE Do not put performance additives or other oil additive products in the engine crankcase The oil change intervals given in this manual are according to tests with Case AKCELA l...

Page 19: ...Diesel Fuel or Specification D975 81 of the American Society for Testing and Materials Fuel Storage If you keep fuel in storage for a period of time you can get foreign material or water in the fuel storage tank Many engine problems are caused by water in the fuel Keep the fuel storage tank outside and keep the fuel as cool as possible Remove water from the storage container at regular periods of ...

Page 20: ...Pivots 10 Z bar 100 11 Lubricate Loader Lift Cylinder Pivots 18 XT 100 Every 250 Hours 12 23 Check Cab Air Filter 250 13 Check Radiator Coolant Level 250 14 Check Tire Pressure Wheel Torque 4 250 22 Check Drive Belt 250 XX Trans Clutch Calibration See Section 6002 250 1000 Every 500 Hours 15 Check Axle Oil Level 500 16 Check Battery Electrolyte Level 500 17 Change Engine Oil and Filter 500 17 Chan...

Page 21: ...tems and for detailed information of the service items on this chart Operators and service manuals are available for this machine from your dealer If you operate the machine in severe conditions lubricate and service the machine more frequently 1 29 17 12 23 10 11 5 11 5 22 16 2 13 4 8 10 26 18 14 21 15 19 25 24 8 21 15 6 17 6 9 8 20 3 18 17 28 27 ...

Page 22: ...1002 8 Bur 5 3100 Issued 8 06 Printed in U S A NOTES ...

Page 23: ...Section 1003 1003 Copyright 2003 CNH Ameica LLC All rights reserved Printed in U S A Issued April 2003 CNH America LLC 700 State Street Racine WI 53404 U S A Bur 7 52590 METRIC CONVERSION CHART ...

Page 24: ...1003 2 Bur 7 52590 Issued 4 03 Printed in U S A TABLE OF CONTENTS CONVERSION FACTORS 3 Metric to U S 3 U S to Metric 4 ...

Page 25: ...meter 1 685 555 lb cubic yd Power kilowatt 1 341 02 horsepower Pressure kilopascal bar 0 145 038 14 50385 lb sq inch lb sq inch Temperature degree C 1 8 x C 32 degree F Torque newton meter newton meter 8 850 748 0 737 562 lb inch lb foot Velocity kilometer hr 0 621 371 miles hr Volume cubic centimeter cubic meter cubic meter milliliter litre litre litre litre 0 061 024 35 314 66 1 307 950 0 033 81...

Page 26: ...me lb cubic yd 0 593 276 kg cubic meter Power horsepower 0 745 700 kilowatt Pressure lbs sq in lbs sq in lbs sq in 6 894 757 0 069 0 070 303 kilopascal bar kg sq cm Temperature degree F 1 8 F 32 degree C Torque pound inch pound foot 0 112 985 1 355 818 newton meter newton meter Velocity miles hr 1 609 344 kilometer hr Volume cubic inch cubic foot cubic yard ounce US fluid quart US liquid quart Imp...

Page 27: ...ssued August 2006 CASE LLC 700 State Street Racine WI 53404 U S A Bur 5 3110 SECTION INDEX ENGINES Engine and Radiator Removal and Installation 2000 Stall Tests 2002 After Cooler 2003 FOR ENGINE REPAIR SEE THE ENGINE SERVICE MANUAL 87519803 Section Title Section Number ...

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Page 29: ...n 2000 2000 Copyright 2006 CNH Ameica LLC All rights reserved Printed in U S A Issued August 2006 CNH America LLC 700 State Street Racine WI 53404 U S A Bur 5 2700 ENGINE AND RADIATOR REMOVAL AND INSTALLATION ...

Page 30: ...2000 2 Bur 5 2700 Issued 8 06 Printed in U S A TABLE OF CONTENTS Engine 3 Removal 3 Installation 10 Radiator 18 Removal 18 Installation 20 ...

Page 31: ... air pressure in hydraulic reservoir STEP 4 BD06F108 The master and hood raise switch are located in the right batter box Raise the hood with the hood lift motor Put master disconnect switch in OFF position Remove both battery covers and disconnect batteries from the machine STEP 5 BD02N160 Put a 37 liter 10 gallon container below radiator drain Remove radiator cap Remove cap and drain coolant int...

Page 32: ...release tension on the lifting motor STEP 9 BD03A228 Remove the pin from the top of the lifting motor STEP 10 BD06F109 Tag and disconnect hood wiring harness connector from rear chassis wiring harness connector STEP 11 BD03A227 BD03A226 Remove mount bolt 1 and backup alarm wiring harness clamp from cooler housing Have another person balance the hood and remove the hood hinge mounting bolts 2 from ...

Page 33: ...ness connector from air filter restriction switch STEP 14 BD03A225 Loosen clamp on air cleaner intake hose and remove the crankcase ventilation hose STEP 15 BD06F110 Loosen clamps on turbocharger and air cleaner remove the intake hose STEP 16 BD06F110 Loosen the clamp on the turbocharger for the after cooler inlet hose STEP 17 BD03A115 Loosen the clamp on the after cooler and remove the after cool...

Page 34: ... cooler and remove the after cooler outlet hose from the machine STEP 20 BD06F110 Loosen the exhaust clamp from the turbocharger STEP 21 BD06F112 Remove the air cleaner and muffler from the bracket STEP 22 BD06F113 BD06F114 Remove the four mounting bolts from the belt cover remove the cover NOTE After removing the belt cover remove the cover mounting brackets from the machine frame ...

Page 35: ...g and disconnect the engine wiring harness connectors from air compressor clutch connector 1 Remove the three mounting bolts 2 for the compressor and set the compressor on the left battery cover STEP 26 BD06F118 Tag and disconnect the wiring from the alternator STEP 27 BD06F119 Remove bolt securing wiring harness clamp to engine STEP 28 BD06F120 Remove bolt securing wiring harness clamp 1 to the e...

Page 36: ...root to the rear of the engine STEP 31 BD06F122 Remove the radiator hose 1 from the rear of the engine remove the heater hose from the rear of the engine 2 remove the clamp bolts and clamps 3 from the bell housing STEP 32 BD06F111 Tag and remove the grid heater cable STEP 33 BD03A142 Disconnect the wiring harness from the EDC 7 controller NOTE Lifting up on the lever will release the connector fro...

Page 37: ...d cap the fittings STEP 38 BD06F127 Remove the lower cover for the drive shaft STEP 39 BD03A172 Remove the drive shaft bolts from the flywheel Move the drive shaft clear of the flywheel STEP 40 Connect suitable lifting equipment to engine lifting brackets Take up all slack in lifting equipment Remove the engine mounting bolts and lift the engine enough to gain access to the drain hose pull the dra...

Page 38: ... 2 bolt 1 washer 6 and nut 7 in engine isolators Lower engine into position STEP 44 Tighten engine mounting bolts to a torque of 244 to 298 Nm 180 to 220 lb ft STEP 45 Disconnect lifting equipment from engine lifting brackets STEP 46 Connect engine oil drain hose to frame bracket STEP 47 BD03A172 At front of engine position drive shaft on engine coupling Install six bolts to secure drive shaft to ...

Page 39: ... off and disconnect vacuum pump from hydraulic reservoir STEP 50 BD06F125 Install bolt and clamp for fuel return hose STEP 51 BD06F124 Remove cap from fitting and plug from the hose connect fuel line 2 Connect fuel filter heater wires 1 Remove and discard tag STEP 52 BD06F123 Remove cap from fitting and plug from the hose connect fuel line to EDC 7 STEP 53 BD03A142 Connect wiring harness to EDC 7 ...

Page 40: ...all the radiator hose 1 STEP 56 BD06F146 Connect the engine coolant vent hose STEP 57 BD06F121 Install the wires to the starter solenoid 3 install the ground cable 2 and ground strap 1 to the starter Remove and discard tags STEP 58 BD06F120 Install bolt securing wiring harness 1 clamp to the engine Install ground wires 2 to the engine STEP 59 BD06F119 Install bolt securing wiring harness clamp to ...

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