Part number 84605841
1st edition English
May 2012
SERVICE MANUAL
621F
721F
Tier 4
Wheel Loader
from PIN NBF213602 and above
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
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 640 - 720 N·m (472 - 531 lb ft)
Front axle mounting bolts 651 - 678 N·m (480 - 500 lb ft)
Rear axle trunnion pin bolts 325 - 353 N·m (240 - 260 lb ft)
Chassis
Cab mounts 773 - 854 N·m (570 - 630 lb ft)
Exhaust stack to hood 36 - 44 N·m (27 - 32 lb ft)
Counterweight mounting bolts 955 - 1075 N·m (704 - 793 lb ft)
Articulation pivot pin bolts 224 - 278 N·m (165 - 205 lb ft)
Articulation mount pin retainer bolts 69 N·m (51 lb ft)
Seat mounting bolts 73 - 87 N·m (54 - 64 lb ft)
Steering wheel retaining nut 50 N·m (37 lb ft)
Hydraulic oil filter mounting bolts 23 - 27 N·m (17 - 20 lb ft)
Steering cylinder base end pin retaining bolt 290 - 375 N·m (214 - 277 lb ft)
Steering cylinder rod end pin retaining bolt Bolts must turn freely
Horn mounting bolt 53 - 62 N·m (39 - 46 lb ft)
Hood - rear grill bolts 9 - 11 N·m (7 - 8 lb ft)
Hood hinge bolts 65 - 79 N·m (48 - 58 lb ft)
Steps - lower entry strap bolts 27 - 31 N·m (20 - 23 lb ft)
Cooling
Fan to fan hub 40 - 48 N·m (30 - 35 lb ft)
Fan hub to motor shaft (no impact tools) 67 - 74 N·m (49 - 55 lb ft)
Radiator hose clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic tank cover nuts 14 - 18 N·m (10 - 13 lb ft)
Hydraulic tank sight gauge 2.7 - 5.5 N·m (2.0 - 4.1 lb ft)
Diesel Exhaust Fluid (DEF) System
Heater valve bolts 17 - 19 N·m (13 - 14 lb ft)
Dosing module bolts 7 - 8 N·m (58 - 68 lb in)
DEF control module/pump assembly mounting bolts 20 - 28 N·m (15 - 21 lb ft)
Driveshafts
Coupling to flywheel 53 - 62 N·m (39 - 46 lb ft)
Driveshaft to coupling 53 - 62 N·m (39 - 46 lb ft)
Front driveshaft yoke nut 339 - 373 N·m (250 - 275 lb ft)
Carrier bearing mounting bolts 99 - 128 N·m (73 - 94 lb ft)
550R U-joints 75 - 81 N·m (55 - 60 lb ft)
410R U-joints 61 - 81 N·m (45 - 60 lb ft)
Dust cover mounting bolts 20 - 27 N·m (15 - 20 lb ft)
84605841 14/05/2012
3
INTRODUCTION
Engine
Engine mounting brackets 118 - 133 N·m (87 - 98 lb ft)
Engine rubber isolator mounts (Qty 4) 244 - 298 N·m (180 - 220 lb ft)
Brake pump to engine mounting 57 - 65 N·m (42 - 48 lb ft)
Brake pump gear nut (no impact tools) 70 - 79 N·m (52 - 58 lb ft)
Turbo to turbo exhaust elbow clamp 5 N·m (4 lb ft)
Muffler to turbo elbow exhaust clamp 20 - 25 N·m (15 - 18 lb ft)
Front muffler bracket to engine block 118 - 133 N·m (87 - 98 lb ft)
Muffler brackets to muffler 114 - 128 N·m (84 - 94 lb ft)
Charge Air Cooler (CAC) hose clamps (Qty 8) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Air cleaner to turbo hose clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Alternator pulley (no impact tools) 60 - 70 N·m (44 - 52 lb ft)
Starter mounting nuts 40 - 50 N·m (30 - 37 lb ft)
Loader
XT loader linkage bolts 650 - 732 N·m (479 - 540 lb ft)
XT guide link nuts 240 - 305 N·m (177 - 225 lb ft)
Loader link pin keeper 325 - 373 N·m (240 - 275 lb ft)
Transmission
Transmission rubber isolator mounts (Qty 3) 890 - 1000 N·m (656 - 738 lb ft)
Transmission upper mounting bracket bolts 251 - 319 N·m (185 - 235 lb ft)
Transmission lower mounting bracket bolts (Qty 2) 481 - 590 N·m (355 - 435 lb ft)
Hydraulic pump to transmission mounting 335 - 375 N·m (247 - 277 lb ft)
Cooler clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic pump suction hose clamp flange 73 - 90 N·m (54 - 66 lb ft)
Steering priority manifold to pump 37 - 48 N·m (27 - 35 lb ft)
Transmission fill tube bolts 17 - 33 N·m (13 - 24 lb ft)
Transmission sight gauge bolts 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)
RCPH10WHL320AAH 1
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 640 - 720 N·m (472 - 531 lb ft)
Front axle mounting bolts 765 - 855 N·m (564 - 631 lb ft)
Rear axle trunnion pin bolts 651 - 678 N·m (480 - 500 lb ft)
Chassis
Cab mounts 773 - 854 N·m (570 - 630 lb ft)
Exhaust stack to hood 36 - 44 N·m (27 - 32 lb ft)
Counterweight mounting bolts 955 - 1075 N·m (704 - 793 lb ft)
Articulation pivot pin bolts 224 - 278 N·m (165 - 205 lb ft)
Articulation mount pin retainer bolts 69 N·m (51 lb ft)
Seat mounting bolts 73 - 87 N·m (54 - 64 lb ft)
Steering wheel retaining nut 50 N·m (37 lb ft)
Hydraulic oil filter mounting bolts 23 - 27 N·m (17 - 20 lb ft)
Steering cylinder base end pin retaining bolt 290 - 375 N·m (214 - 277 lb ft)
Steering cylinder rod end pin retaining bolt Bolts must turn freely
Horn mounting bolt 53 - 62 N·m (39 - 46 lb ft)
Hood - rear grill bolts 9 - 11 N·m (7 - 8 lb ft)
Hood hinge bolts 65 - 79 N·m (48 - 58 lb ft)
Steps - lower entry strap bolts 27 - 31 N·m (20 - 23 lb ft)
Cooling
Fan to fan hub 40 - 48 N·m (30 - 35 lb ft)
Fan hub to motor shaft (no impact tools) 67 - 74 N·m (49 - 55 lb ft)
Radiator hose clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic tank cover nuts 14 - 18 N·m (10 - 13 lb ft)
Hydraulic tank sight gauge 2.7 - 5.5 N·m (2.0 - 4.1 lb ft)
Diesel Exhaust Fluid (DEF) System
Heater valve bolts 17 - 19 N·m (13 - 14 lb ft)
Dosing module bolts 7 - 8 N·m (58 - 68 lb in)
DEF control module/pump assembly mounting bolts 20 - 28 N·m (15 - 21 lb ft)
Driveshafts
Coupling to flywheel 53 - 62 N·m (39 - 46 lb ft)
Driveshaft to coupling 53 - 62 N·m (39 - 46 lb ft)
Front driveshaft yoke nut 339 - 373 N·m (250 - 275 lb ft)
Carrier bearing mounting bolts 99 - 128 N·m (73 - 94 lb ft)
550R U-joints 75 - 81 N·m (55 - 60 lb ft)
Dust cover mounting bolts 20 - 27 N·m (15 - 20 lb ft)
Flex plate to flywheel bolts 33 - 41 N·m (24 - 30 lb ft)
Carrier bearing bolt 150 - 164 N·m (111 - 121 lb ft)
Drive line mounting bolts 136 - 149 N·m (100 - 110 lb ft)
84605841 14/05/2012
5
INTRODUCTION
Engine
Engine mounting brackets 118 - 133 N·m (87 - 98 lb ft)
Engine rubber isolator mounts (Qty 4) 244 - 298 N·m (180 - 220 lb ft)
Brake pump to engine mounting 57 - 65 N·m (42 - 48 lb ft)
Brake pump gear nut (no impact tools) 70 - 79 N·m (52 - 58 lb ft)
Turbo to turbo exhaust elbow clamp 5 N·m (4 lb ft)
Muffler to turbo elbow exhaust clamp 20 - 25 N·m (15 - 18 lb ft)
Muffler bracket to muffler 114 - 128 N·m (84 - 94 lb ft)
Charge Air Cooler (CAC) hose clamps (Qty 8) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Air cleaner to turbo hose clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Alternator pulley (no impact tools) 60 - 70 N·m (44 - 52 lb ft)
Starter mounting nuts 40 - 50 N·m (30 - 37 lb ft)
Loader
XT loader linkage bolts 650 - 732 N·m (479 - 540 lb ft)
XT guide link nuts 240 - 305 N·m (177 - 225 lb ft)
Loader link pin keeper 325 - 373 N·m (240 - 275 lb ft)
Transmission
Transmission rubber isolator mounts (Qty 3) 890 - 1000 N·m (656 - 738 lb ft)
Transmission upper mounting bracket bolts 251 - 319 N·m (185 - 235 lb ft)
Transmission lower mounting bracket bolts (Qty 2) 481 - 590 N·m (355 - 435 lb ft)
Cooler clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic pump suction hose clamp flange 73 - 90 N·m (54 - 66 lb ft)
Steering priority manifold to pump 37 - 48 N·m (27 - 35 lb ft)
Transmission fill tube bolts 17 - 33 N·m (13 - 24 lb ft)
Transmission sight gauge bolts 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)
RCPH10WHL320AAH 1
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
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$62.99
CASE 621F Tier 4, 721F Tier 4 Wheel Loader Service Repair Manual
Viewed 24 Times Today
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$62.99
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
This is the complete service repair manual for the CASE 621F Tier 4 and 721F Tier 4 Wheel Loader. It contains comprehensive information about maintenance, assembly, disassembly, and servicing of the wheel loader models.
Models Covered:
- CASE 621F Tier 4 Wheel Loader
- CASE 721F Tier 4 Wheel Loader
This manual provides detailed specs, diagrams, real photo illustrations, and schemes for step-by-step repair, servicing, technical maintenance, and troubleshooting procedures for the machine. It includes information to help you identify issues and understand how to repair and maintain your machine without the need for professional service.
Table of Contents:
- INTRODUCTION
- Engine
- Transmission
- Four-Wheel Drive (4WD) system
- Front axle system
- Rear axle system
- Brakes and controls
- Hydraulic systems
- Steering
- Wheels
- Cab climate control
- Electrical systems
- Platform, cab, bodywork, and decals
- SPECIAL TOOL INDEX
- ELECTRICAL SCHEMATIC
- HYDRAULIC SCHEMATIC
Model Specification: CASE 621F Tier 4, 721F Tier 4 Wheel Loader
Language: English
Total Pages: 2286
File Format: PDF
Requirements: Adobe Reader
Specifications: Fully printable & bookmarked
Compatible: All versions of Windows & Mac, APP ISO, iPhone, iPad, Android, etc.
This quality manual is 100% complete and intact, with no missing or corrupt pages/sections. It is bookmarked and searchable for easy navigation. Detailed illustrations, exploded diagrams, drawings, and photos guide you through every service repair procedure.
The manual can be viewed on any computer, zoomed, and printed. It is in PDF format, compatible with all PC-based Windows operating systems and Mac. It can be saved to your hard drive and burned to a CD-ROM.
Instant access means there are no shipping costs or waiting for a CD or paper manual to arrive in the mail. You will receive this manual today via instant download upon completion of payment via our secure payment processor.
We accept all major credit/debit cards and PayPal. With this manual, you can perform the repairs yourself and save money.
