Case 921E, Service Manual

Page 1: ...rt Number 84299249 Printed in U S A Rac 2009 CNH America LLC All Rights Reserved Case is a registered trademark of CNH America 84299249 Replaces 87624950 Revised December 2009 Issued February 2007 CNH AMERICA LLC 700 STATE STREET RACINE WI 53404 U S A ...

Page 2: ... Engine Repair See Your Cummins Dealer Fuel System Tab 3 Section Index Fuel System 5 5440 For Fuel System Repair See Your Cummins Dealer Electrical Tab 4 Section Index Electrical 5 5450 Removal and Installation of Starter and Alternator 4001 5 5460 Electrical Specifications and Troubleshooting 4002 5 5470 Batteries 4003 6 42331 Instrument Cluster and Equipment Fault Codes 4005 5 5480 Steering Tab ...

Page 3: ...008 5 5650 Hydraulics Tab 8 Section Index Hydraulics 5 5660 How to Read Symbols in a Hydraulic Schematic 8000 5 5670 Removal and Installation of Hydraulic Components 8001 5 5680 Hydraulic Specifications Troubleshooting and Pressure Checks 8002 5 5690 Cleaning the Hydraulic System 8003 5 5700 Hydraulic Pump 8004 5 5710 Loader Control Valve 8005 5 5720 Cylinders 8006 5 5730 Mounted Equipment Tab 9 S...

Page 4: ...serves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 5 5800 921E Wheel Loader Service Manual 84299249 Replaces 87624950 Table of Contents Description Section No Form No Find manuals at https best manuals com ...

Page 5: ...S A Issued February 2007 CASE LLC 700 State Street Racine WI 53404 U S A Bur 5 5380 SECTION INDEX GENERAL Standard Torque Specifications 1001 Fluids and Lubricants 1002 Metric Conversion Chart 1003 Section Title Section Number Find manuals at https best manuals com ...

Page 6: ...ght 2004 CNH 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 https best manuals com ...

Page 7: ...n U S A TABLE 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 https best manuals com ...

Page 8: ...0 203 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 540 to 648 61 to 73...

Page 9: ...4 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 Newton metres M4 36 to 4...

Page 10: ...85 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 mm 1 2 20 192 to 300 ...

Page 11: ...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 12: ...Section 1002 1002 Copyright 2007 CNH Ameica LLC All rights reserved Printed in U S A Issued February 2007 CNH America LLC 700 State Street Racine WI 53404 U S A Bur 5 5390 FLUIDS AND LUBRICANTS ...

Page 13: ...inted in U S A TABLE OF CONTENTS CAPACITIES AND LUBRICANTS 3 ENGINE OIL RECOMMENDATIONS 4 DIESEL FUEL SYSTEM 5 Fuel Storage 5 Specifications for Acceptable No 2 Diesel Fuel 5 Biodiesel Information 5 MAINTENANCE SCHEDULE 6 Model 921E 6 ...

Page 14: ...ystem Capacity 242 0 liters 64 0 U S Gallons Type of Oil Case AKCELA Hy Tran Ultra Transmission Refill Capacity with Filter Change 28 4 liters 7 5 U S Gallons Total System Capacity 44 5 liters 11 8 U S Gallons Type of Oil Case AKCELA No 1 15W 40 Axles Capacity Front with out axle coolers 51 0 liters 13 5 U S Gallons Rear with out axle coolers 51 0 liters 13 5 U S Gallons Front with axle coolers 55...

Page 15: ...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 16: ...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 time Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank Specifications for Acceptable No 2 Diesel Fuel API gravity minimum 34 Flash point minimu...

Page 17: ...E OPERATORS MANUAL CHECK THE TIRE CONDITION AND AIR PRESSURE SEE OPERATORS MANUAL CLEAN THE CAB AIR FILTERS SEE OPERATORS MANUAL REPLACE FUEL FILTER SEE OPERATORS MANUAL EVERY 500 HOURS OF OPERATION CHANGE THE ENGINE OIL AND REPLACE THE ENGINE OIL FILTER SEE OPERATORS MANUAL CHECK THE BATTERY FLUID LEVEL SEE OPERATORS MANUAL DRAIN WATER AND SEDIMENT FROM THE FUEL TANK SEE OPERATORS MANUAL CHECK TH...

Page 18: ...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 19: ...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 20: ...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 21: ...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 22: ...U S A Issued February 2007 CASE LLC 700 State Street Racine WI 53404 U S A Bur 5 5400 SECTION INDEX ENGINES Engine and Radiator Removal and Installation 2000 Stall Tests 2002 After Cooler 2003 FOR ENGINE REPAIR SEE YOUR CUMMINS DEALER Section Title Section Number ...

Page 23: ... 2000 2000 Copyright 2007 CNH Ameica LLC All rights reserved Printed in U S A Issued February 2007 CNH America LLC 700 State Street Racine WI 53404 U S A Bur 5 5410 ENGINE AND RADIATOR REMOVAL AND INSTALLATION ...

Page 24: ...2000 2 Bur 5 5410 Issued 2 07 Printed in U S A TABLE OF CONTENTS Engine 3 Removal 3 Installation 13 Radiator 24 Removal 24 Installation 25 ...

Page 25: ... in the lift circuit STEP 4 Move the loader control handle in and out of the tilt position several times this will relieve any pressure in the pilot accumulator STEP 5 Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve see ride control valve remove section 8001 STEP 6 Actuate brake pedal several times to discharge brake accumulators STEP 7 Slowly ...

Page 26: ... 13 BD07B110 Attach a sling to the rear of the hood Raise and remove weight from the hood lifting motor STEP 14 BD07B111 Remove the pin from the top of the lifting motor STEP 15 BD07B112 Put punch in the hole to hold washer and bolt from turning while removing nut from inside STEP 16 BD07B113 Push bolt and washer away from hinge do not remove at this time ...

Page 27: ...fting equipment STEP 19 BD07B115 Loosen clamp and remove inlet air hood STEP 20 BD07B116 Remove hand rail bolts STEP 21 BD07B117 Loosen hand rail bolts turn the hand rail out away from the engine hood STEP 22 Repeat steps 20 and 21 for the other hand rail STEP 23 BD07B118 Remove hood mounting bolts attach sling to exhaust stack STEP 24 Carefully raise and remove hood from loader Lower hood onto su...

Page 28: ...ank cap Drain the engine oil and engine cooling system NOTE The oil cooler will not drain by draining the reservoir STEP 27 BD07B296 Located behind the rear axle on the right side of the frame disconnect the return line from the oil cooler drain the oil cooler STEP 28 If loader is equipped with air conditioning recover the freon Refer to section 9003 STEP 29 BD07B199 Release the latch on the fan s...

Page 29: ... cooler hoses STEP 32 BD07B205 Disconnect the lower radiator hose and cooling pack grounding wire STEP 33 BD07B206 Tag and disconnect the fuel cooler hoses from the fuel cooler remove brackets securing fuel hoses to cooler pack STEP 34 BD07B230 Disconnect the fuel tank vent hose STEP 35 BD07B221 Disconnect the top hose from the condenser ...

Page 30: ...ng equipment to the lifting points on cooler pack STEP 38 BD07B208 Remove the mounting bolts for the cooler pack STEP 39 Carefully raise and remove cooler pack from loader Lower cooler pack onto suitable platform and disconnect lifting equipment STEP 40 BD07B209 Loosen the hose clamps disconnect and remove the after cooler tubes from the machine STEP 41 BD07B212 Loosen the hose clamps disconnect t...

Page 31: ...harness mounting clamp bolts Disconnect the ether hose and move the hose to the engine side of the fire wall STEP 45 BD07B225 If equipped with ether disconnect the ether solenoid connector Remove mounting bolt for fuel cap chain remove mounting bolt for engine oil dipstick STEP 46 Attach lifting equipment to the fire wall and muffler mounting frame STEP 47 BD07B233 Remove the mounting bolts from t...

Page 32: ...ect the engine block vent hose STEP 51 BD07B232 Remove bolt securing alternator wiring to the engine STEP 52 BD07B210 Disconnect the heater hose and lower radiator hose STEP 53 BD07B211 Remove the mounting bolt for the deaeration tank to lower radiator hose STEP 54 BD07B220 Remove mounting bolts securing the heater hose and alternator wiring harness ...

Page 33: ...e harness to the right side of the machine away from the engine STEP 57 BD07B236 Disconnect the clamps mounting the fuel hoses STEP 58 BD07A222 If loader is equipped with air conditioning disconnect the low pressure hose from the compressor STEP 59 BD07B238 Remove the fuel hoses Remove the air conditioning hose mounting bracket Move the hoses clear of the engine STEP 60 BD07B240 Disconnect engine ...

Page 34: ...m the starter solenoid STEP 64 BD07B070 Tag and disconnect the ground cables from the starter STEP 65 Refer to section 6001 and prepare the transmission for removal STEP 66 Attach lifting equipment to the engine remove the mounting bolts on the engine and transmission STEP 67 Carefully raise and remove engine and transmission from loader Lower engine and transmission onto suitable platform and dis...

Page 35: ... 5410 Issued 2 07 Printed in U S A Installation BS07B492 1 NUT 4 ISOLATOR UPPER 7 ENGINE MOUNT BOLT 10 WASHER 2 WASHER 5 ISOLATOR LOWER 8 ENGINE MOUNT PLATE 11 BOLT 3 WASHER 6 WASHER 9 NUT 1 7 8 2 3 4 5 6 9 10 10 11 ...

Page 36: ...nstall washer 2 bolt 1 washer 6 and nut 7 in engine isolators Lower engine into position STEP 70 Tighten engine mounting bolts 7 to a torque of 397 to 447 Nm 293 to 330 pound feet STEP 71 If bolts 11 were removed torque to 386 to 434 Nm 285 to 320 pound feet STEP 72 Refer to section 6001 and complete the transmission installation procedures STEP 73 Disconnect lifting equipment from engine lifting ...

Page 37: ...connect the low pressure hose to the compressor STEP 80 BD07B236 Route the fuel hoses into position and install the clamps mounting the fuel hoses STEP 81 BD07B213 Install mounting bolts and clamps securing the heater hose and wiring harness Connect heater hose at bell housing side of engine STEP 82 BD07B231 Install mounting bolts and brackets Connect the grounding wires to the side of the engine ...

Page 38: ...d lower radiator hose STEP 86 BD07B232 Install bolt securing alternator wiring to the engine STEP 87 BD07B217 Connect the engine block vent hose STEP 88 BD07B072 Connect electrical connectors to the alternator make sure wires do not rub the engine STEP 89 Attach lifting equipment to fire wall and muffler and carefully raise over the loader Lower fire wall and muffler onto machine ...

Page 39: ...lenoid connector Install mounting bolt for fuel cap chain install mounting bolt for engine oil dipstick STEP 92 BD07B224 Place the wiring harness to the top of the fire wall Install wiring harness mounting clamp bolts Push the ether hose through the fire wall and connect the ether hose STEP 93 BD07B223 Connect air conditioning trinary switch put the air conditioner hoses back up through the fire w...

Page 40: ...t lifting equipment to the cooler pack Carefully raise and install the cooler pack on the loader STEP 98 BD07B208 Install the bushings and the mounting bolts for the cooler pack tighten the bolts Remove the lifting equipment from the cooler pack STEP 99 BD07B178 Install upper radiator hose and tube tighten hose clamp Install the hoses for the after cooler and torque hose clamps to 9 04 to 10 17 Nm...

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