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Copyright Ā© 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 47388956
1st edition English
June 2012
Replaces part number 84487573
SERVICE MANUAL
621F
721F
Tier 2
Wheel Loader
from PIN NBF213588 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
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
Hydraulic systems ........................................................................ 35.000
47388956 22/05/2012
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
External lighting switches and relays..................................................... 55.405
47388956 22/05/2012
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
FAULT CODES .......................................................................... 55.DTC
Platform, cab, bodywork, and decals............................................. 90
Pneumatically-adjusted operator seat .................................................... 90.124
Cab ....................................................................................... 90.150
47388956 22/05/2012
INTRODUCTION
47388956 22/05/2012
1
INTRODUCTION
Torque ā€“ 621F Torque Specifications
621F INT
Axle
Wheel mounting nuts 640 - 720 NĀ·m (472 - 531 lb ft)
Front axle mounting bolts 651 - 678 NĀ·m (480 - 500 lb ft)
Rear axle trunnion pin bolts 325 - 353 NĀ·m (240 - 260 lb ft)
Chassis
Cab mounts 773 - 854 NĀ·m (570 - 630 lb ft)
Exhaust stack to hood 36 - 44 NĀ·m (27 - 32 lb ft)
Counterweight mounting bolts 955 - 1075 NĀ·m (704 - 793 lb ft)
Articulation pivot pin bolts 224 - 278 NĀ·m (165 - 205 lb ft)
Articulation mount pin retainer bolts 69 NĀ·m (51 lb ft)
Seat mounting bolts 73 - 87 NĀ·m (54 - 64 lb ft)
Steering wheel retaining nut 50 NĀ·m (37 lb ft)
Hydraulic oil filter mounting bolts 23 - 27 NĀ·m (17 - 20 lb ft)
Steering cylinder base end pin retaining bolt 290 - 375 NĀ·m (214 - 277 lb ft)
Steering cylinder rod end pin retaining bolt Bolts must turn freely
Horn mounting bolt 53 - 62 NĀ·m (39 - 46 lb ft)
Hood - rear grill bolts 9 - 11 NĀ·m (7 - 8 lb ft)
Hood hinge bolts 65 - 79 NĀ·m (48 - 58 lb ft)
Steps - lower entry strap bolts 27 - 31 NĀ·m (20 - 23 lb ft)
Cooling
Fan to fan hub 40 - 48 NĀ·m (30 - 35 lb ft)
Fan hub to motor shaft (no impact tools) 67 - 74 NĀ·m (49 - 55 lb ft)
Radiator hose clamps 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft)
Hydraulic tank cover nuts 14 - 18 NĀ·m (10 - 13 lb ft)
Hydraulic tank sight gauge 2.7 - 5.5 NĀ·m (2.0 - 4.1 lb ft)
Driveshafts
Coupling to flywheel 53 - 62 NĀ·m (39 - 46 lb ft)
Driveshaft to coupling 53 - 62 NĀ·m (39 - 46 lb ft)
Front driveshaft yoke nut 339 - 373 NĀ·m (250 - 275 lb ft)
Carrier bearing mounting bolts 99 - 128 NĀ·m (73 - 94 lb ft)
550R U-joints 75 - 81 NĀ·m (55 - 60 lb ft)
410R U-joints 61 - 81 NĀ·m (45 - 60 lb ft)
Dust cover mounting bolts 20 - 27 NĀ·m (15 - 20 lb ft)
47388956 22/05/2012
3
INTRODUCTION
Engine
Engine mounting brackets 118 - 133 NĀ·m (87 - 98 lb ft)
Engine rubber isolator mounts (Qty 4) 244 - 298 NĀ·m (180 - 220 lb ft)
Brake pump to engine mounting 57 - 65 NĀ·m (42 - 48 lb ft)
Brake pump gear nut (no impact tools) 70 - 79 NĀ·m (52 - 58 lb ft)
Turbo to turbo exhaust elbow clamp 5 NĀ·m (4 lb ft)
Muffler to turbo elbow exhaust clamp 20 - 25 NĀ·m (15 - 18 lb ft)
Front muffler bracket to engine block 118 - 133 NĀ·m (87 - 98 lb ft)
Muffler brackets to muffler 114 - 128 NĀ·m (84 - 94 lb ft)
Charge Air Cooler (CAC) hose clamps (Qty 8) 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft)
Air cleaner to turbo hose clamp 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft)
Alternator pulley (no impact tools) 60 - 70 NĀ·m (44 - 52 lb ft)
Starter mounting nuts 40 - 50 NĀ·m (30 - 37 lb ft)
Loader
XT loader linkage bolts 650 - 732 NĀ·m (479 - 540 lb ft)
XT guide link nuts 240 - 305 NĀ·m (177 - 225 lb ft)
Loader link pin keeper 325 - 373 NĀ·m (240 - 275 lb ft)
Transmission
Transmission rubber isolator mounts (Qty 3) 890 - 1000 NĀ·m (656 - 738 lb ft)
Transmission upper mounting bracket bolts 251 - 319 NĀ·m (185 - 235 lb ft)
Transmission lower mounting bracket bolts (Qty 2) 481 - 590 NĀ·m (355 - 435 lb ft)
Hydraulic pump to transmission mounting 335 - 375 NĀ·m (247 - 277 lb ft)
Cooler clamps 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft)
Hydraulic pump suction hose clamp flange 73 - 90 NĀ·m (54 - 66 lb ft)
Steering priority manifold to pump 37 - 48 NĀ·m (27 - 35 lb ft)
Transmission fill tube bolts 17 - 33 NĀ·m (13 - 24 lb ft)
Transmission sight gauge bolts 2.7 - 5.5 NĀ·m (2 - 4 lb ft)
Wheels
Wheel nuts Initial torque: 298 NĀ·m (220 lb ft)
Final torque: 640 - 720 NĀ·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 NĀ·m (220 lb ft) in sequence shown in figure
2. Tighten wheel nuts to a final torque of 640 - 720 NĀ·m (472 - 531 lb ft). in sequence shown in figure
47388956 22/05/2012
4
INTRODUCTION
Torque ā€“ 721F Torque Specifications
721F INT
Axle
Wheel mounting bolts 640 - 720 NĀ·m (472 - 531 lb ft)
Front axle mounting bolts 765 - 855 NĀ·m (564 - 631 lb ft)
Rear axle trunnion pin bolts 651 - 678 NĀ·m (480 - 500 lb ft)
Chassis
Cab mounts 773 - 854 NĀ·m (570 - 630 lb ft)
Exhaust stack to hood 36 - 44 NĀ·m (27 - 32 lb ft)
Counterweight mounting bolts 955 - 1075 NĀ·m (704 - 793 lb ft)
Articulation pivot pin bolts 224 - 278 NĀ·m (165 - 205 lb ft)
Articulation mount pin retainer bolts 69 NĀ·m (51 lb ft)
Seat mounting bolts 73 - 87 NĀ·m (54 - 64 lb ft)
Steering wheel retaining nut 50 NĀ·m (37 lb ft)
Hydraulic oil filter mounting bolts 23 - 27 NĀ·m (17 - 20 lb ft)
Steering cylinder base end pin retaining bolt 290 - 375 NĀ·m (214 - 277 lb ft)
Steering cylinder rod end pin retaining bolt Bolts must turn freely
Horn mounting bolt 53 - 62 NĀ·m (39 - 46 lb ft)
Hood - rear grill bolts 9 - 11 NĀ·m (7 - 8 lb ft)
Hood hinge bolts 65 - 79 NĀ·m (48 - 58 lb ft)
Steps - lower entry strap bolts 27 - 31 NĀ·m (20 - 23 lb ft)
Cooling
Fan to fan hub 40 - 48 NĀ·m (30 - 35 lb ft)
Fan hub to motor shaft (no impact tools) 67 - 74 NĀ·m (49 - 55 lb ft)
Radiator hose clamps 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft)
Hydraulic tank cover nuts 14 - 18 NĀ·m (10 - 13 lb ft)
Hydraulic tank sight gauge 2.7 - 5.5 NĀ·m (2.0 - 4.1 lb ft)
Driveshafts
Coupling to flywheel 53 - 62 NĀ·m (39 - 46 lb ft)
Driveshaft to coupling 53 - 62 NĀ·m (39 - 46 lb ft)
Front driveshaft yoke nut 339 - 373 NĀ·m (250 - 275 lb ft)
Carrier bearing mounting bolts 99 - 128 NĀ·m (73 - 94 lb ft)
550R U-joints 75 - 81 NĀ·m (55 - 60 lb ft)
Dust cover mounting bolts 20 - 27 NĀ·m (15 - 20 lb ft)
Flex plate to flywheel bolts 33 - 41 NĀ·m (24 - 30 lb ft)
Carrier bearing bolt 150 - 164 NĀ·m (111 - 121 lb ft)
Drive line mounting bolts 136 - 149 NĀ·m (100 - 110 lb ft)
47388956 22/05/2012
5
SERVICE MANUAL
Engine
621F
721F
47388956 22/05/2012
10
CONSUMABLES INDEX
Consumable IU PAGE
CASE Akcela Engine oil
15W-40
Engine - Install 10.001 / 45
47388956 22/05/2012
10.001 / 3
Engine - Engine and crankcase
Engine - Remove
621F INT, 721F INT
1. Park machine on a level surface and lower the bucket
to the ground. Put articulation lock in LOCKED posi-
tion and stop the engine.
RCPH10WHL063BAL 1
2. Actuate the brake pedal several times to discharge
brake accumulators.
RCPH10WHL435AAH 2
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.
RCPH10WHL119BAL 3
47388956 22/05/2012
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.
RCPH10WHL099BAL 4
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.
RCPH10WHL106AAH 5
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.
RAPH12WEL0597AA 6
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.
RCPH10WHL054BAL 7
47388956 22/05/2012
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.
RCPH10WHL054BAL 8
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)
RAPH12WEL0598AA 9
10. Double up a nylon lifting strap (1) and slide through
the exhaust stack (2) on the hood.
RAPH12WEL0599AA 10
47388956 22/05/2012
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.
RAPH12WEL0600AA 11
12. Tag and disconnect the camera wire harness (if ma-
chine is equipped with a camera.)
RAPH12WEL0601AA 12
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.)
RAPH12WEL0602AA 13
47388956 22/05/2012
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.
RAPH12WEL0603AA 14
15. Tag and disconnect hood wiring harness connector
from rear chassis wiring harness connector.
RAPH12WEL0604AA 15
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.
RAPH12WEL0605AA 16
47388956 22/05/2012
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.
RAPH12WEL0606AA 17
18. Put the master disconnect switch in the ON position.
Then, retract the lifting motor cylinder (2), replace pin
and disconnect wiring harness (1).
RAPH12WEL0062AA 18
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.
RAPH12WEL0608AA 19
47388956 22/05/2012
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.
RAPH12WEL0605AA 20
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.
RAPH12WEL0609AA 21
22. Tag and disconnect engine wiring harness connector
from air filter restriction switch.
RAPH12WEL0610AA 22
47388956 22/05/2012
10.001 / 10
Engine - Engine and crankcase
23. Tag and disconnect engine wiring harness connector
from air inlet humidity sensor.
RAPH12WEL0611AA 23
24. Loosen clamps on turbocharger and air filter hous-
ing. Then remove the intake air hose. Cover tur-
bocharger inlet to prevent debris entry.
RAPH12WEL0613AA 24
25. Loosen the clamp on the turbocharger for the after
cooler inlet elbow.
RAPH12WEL0614AA 25
47388956 22/05/2012
10.001 / 11
Engine - Engine and crankcase
26. Loosen the clamp on the hose at the after cooler inlet
and remove the tube.
RAPH12WEL0615AA 26
27. Loosen clamp on the air inlet hose at the air filter
housing.
RAPH12WEL0616AA 27
28. 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.
RAPH12WEL0617AA 28
47388956 22/05/2012
10.001 / 12
Engine - Engine and crankcase
29. Remove four the bolts securing the air filter housing
to the mounting support bracket. Then remove air
filter housing.
RAPH12WEL0618AA 29
30. 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.
RAPH12WEL0619AA 30
31. Remove the drive belt from the engine.
RAPH12WEL0620AA 31
47388956 22/05/2012
10.001 / 13
Engine - Engine and crankcase
32. 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.
RAPH12WEL0621AA 32
33. Tag and disconnect the wiring from the alternator.
RAPH12WEL0622AA 33
34. 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.
RAPH12WEL0624AA 34
47388956 22/05/2012
10.001 / 14
Engine - Engine and crankcase
35. Remove bolts securing wiring harness clamps to en-
gine.
RAPH12WEL0625AA 35
36. Remove ground wires from the engine.
NOTE: Move the wiring harness away from the engine.
RAPH12WEL0625AA 36
37. If the machine is so equipped, unplug the engine
block heater and set it aside.
RAPH12WEL0626AA 37
47388956 22/05/2012
10.001 / 15
Engine - Engine and crankcase
38. Loosen the exhaust clamp from the turbocharger.
RAPH12WEL0627AA 38
39. Disconnect the engine coolant vent hose from the
engine.
RAPH12WEL0628AA 39
40. Loosen clamps and remove lower coolant hose from
the engine.
RAPH12WEL0629AA 40
47388956 22/05/2012
10.001 / 16
Engine - Engine and crankcase
41. Remove the radiator hose from the engine.
RAPH12WEL0630AA 41
42. Remove the return radiator hose (1) and the engine
coolant vent hose (2) from the top of the radiator.
RAPH12WEL0631AA 42
43. Remove hood wire harness clamp from the fan
shroud.
RAPH12WEL0632AA 43
47388956 22/05/2012
10.001 / 17
Engine - Engine and crankcase
44. Remove engine coolant overflow bottle.
RAPH12WEL0633AA 44
45. Remove engine coolant overflow bottle support
bracket.
RAPH12WEL0634AA 45
46. Remove cooling fan screen.
RAPH12WEL0635AA 46
47388956 22/05/2012
10.001 / 18
Engine - Engine and crankcase
47. Remove the heater hose (1) from the engine.
RAPH12WEL0636AA 47
48. Loosen the clamp on the intake manifold for the after
cooler output hose.
RAPH12WEL0637AA 48
49. Loosen the clamp on the after cooler, and remove
the after cooler outlet tube from the machine.
RAPH12WEL0638AA 49
47388956 22/05/2012
10.001 / 19
Engine - Engine and crankcase
50. Tag and disconnect the fuel filter heater wire (1) and
water sensor (2). Then drain fuel filter and discon-
nect inlet (3) and outlet (4) fuel lines from the fuel
filter head. Plug the lines and cap the fittings.
RAPH12WEL0639AA 50
51. Remove ground wire and fuel filter head attachment
bolt (1). Then remove fuel line support clamp (2).
RAPH12WEL0640AA 51
52. Tag and remove the grid heater cable (1).
NOTE: Hold the rear nut with a second wrench to prevent
grid heater damage.
RAPH12WEL0063AA 52
47388956 22/05/2012
10.001 / 20
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Engine - Engine and crankcase
53. Remove wire harness support clamp.
RAPH12WEL0064AA 53
54. Tag and disconnect wire harness from primary fuel
filter.
RAPH12WEL0068AA 54
55. Remove hood lift cylinder support bracket.
RAPH12WEL0071AA 55
47388956 22/05/2012
10.001 / 21
Engine - Engine and crankcase
56. Attach suitable lifting straps to the muffler support
structure.
RAPH12WEL0072AA 56
57. Remove bolts securing the muffler support structure
at the front and rear of the structure. The mounting
points are positioned on the left and right side in the
front of the engine compartment, and in the center at
the rear of the engine compartment.
NOTE: The right front mount is shown.
RAPH12WEL0073AA 57
58. Use a suitable lifting device to carefully lift muffler
support structure (with muffler system components
attached) from the machine.
RAPH12WEL0075AA 58
47388956 22/05/2012
10.001 / 22
Engine - Engine and crankcase
59. Disconnect the wiring harness from the EDC 7 con-
troller.
NOTE: Lifting up on the lever will release the connector
from the controller.
RAPH12WEL0076AA 59
60. Remove the fuel line from the top of the primary fuel
filter, plug the line and cap the fitting.
NOTE: Make note on how fuel lines are routed.
RAPH12WEL0077AA 60
61. Remove the fuel line support clamp.
NOTE: Make note on how fuel lines are routed.
RAPH12WEL0078AA 61
47388956 22/05/2012
10.001 / 23
Engine - Engine and crankcase
62. Remove the upper and lower dust covers for the drive
shaft.
RAPH12WEL0079AA 62
63. Remove the drive shaft bolts (1) from the flywheel.
Move the drive shaft clear of the flywheel.
RAPH12WEL0080AA 63
64. Connect and turn on vacuum pump to hydraulic
reservoir. Tag and remove the hydraulic lines from
the brake system pump (arrow), plug the lines and
cap the fittings.
RAPH12WEL0081AA 64
47388956 22/05/2012
10.001 / 24
Engine - Engine and crankcase
65. Connect suitable lifting equipment to engine lifting
brackets. Take up all slack in lifting equipment. Re-
move the engine mounting bolts.
66. Slowly raise engine from rear chassis. Be sure all
wire harness connections and hoses have been dis-
connected and are clear of the engine. Guide the oil
drain hose from the frame as the engine is lifted. Re-
move engine from machine.
RAPH12WEL0082AA 65
Next operation:
Engine - Install (10.001)
47388956 22/05/2012
10.001 / 25
Engine - Engine and crankcase
Engine - Install
621F INT, 721F INT
WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.
Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then
remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.
Failure to comply could result in death or serious injury.
W0296A
Prior operation:
Engine - Remove (10.001)
RAIL12WEL0130FA 1
1. Engine mount bolt 5. Washers
2. Washer 6. Washer
3. Isolator upper 7. Nut
4. Isolator lower 8. Remote oil drain hose
1. Inspect engine mounts. If engine rubber isolators re-
quire replacement, remove and discard isolators (3)
and (4). Install new rubber isolator (4), then rubber
isolator (3).
47388956 22/05/2012
10.001 / 26
Engine - Engine and crankcase
2. Attach suitable lifting device to the engine and slowly
move it into position over the rear chassis. Be sure
all harness connections and hoses are out of the way
or positioned correctly for reconnecting, before low-
ering engine.
RAPH12WEL0082AA 2
3. Tighten engine mounting bolts to a torque of 244 -
298 NĀ·m (180 - 220 lb ft).
RAPH12WEL0080AA 3
4. Disconnect lifting equipment from engine lifting
brackets.
RAPH12WEL0082AA 4
47388956 22/05/2012
10.001 / 27
Engine - Engine and crankcase
5. Connect vacuum pump to the hydraulic reservoir and
turn it on. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags
installed during removal. Remove and discard tags.
Turn off and disconnect vacuum pump from hydraulic
reservoir.
RAPH12WEL0081AA 5
6. Connect engine oil drain hose (1) to frame bracket
(2).
RAPH12WEL0598AA 6
7. At front of engine, position drive shaft on engine cou-
pling. Install bolts to secure drive shaft to engine cou-
pling. Tighten the bolts to a torque of 53 - 62 NĀ·m (39
- 46 lb ft).
RAPH12WEL0080AA 7
47388956 22/05/2012
10.001 / 28
Engine - Engine and crankcase
8. Install the upper and lower drive shaft dust covers.
Torque to 20 - 27 NĀ·m (15 - 20 lb ft).
NOTE: Attach p-clamp, securing coolant line.
RAPH12WEL0079AA 8
9. Install bolt and clamp for fuel return hose.
RAPH12WEL0078AA 9
10. Remove cap from fitting and plug from the hose.
Then connect fuel line to the top of the primary fuel
filter.
RAPH12WEL0077AA 10
47388956 22/05/2012
10.001 / 29

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CASE 621F Tier 2 Wheel Loader Service Repair Manual PIN NBF213588 and above.pdf

  • 1. Printed in U.S.A. Copyright Ā© 2012 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A. Part number 47388956 1st edition English June 2012 Replaces part number 84487573 SERVICE MANUAL 621F 721F Tier 2 Wheel Loader from PIN NBF213588 and above
  • 2. 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 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 Hydraulic systems ........................................................................ 35.000 47388956 22/05/2012
  • 3. 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 External lighting switches and relays..................................................... 55.405 47388956 22/05/2012
  • 4. 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 FAULT CODES .......................................................................... 55.DTC Platform, cab, bodywork, and decals............................................. 90 Pneumatically-adjusted operator seat .................................................... 90.124 Cab ....................................................................................... 90.150 47388956 22/05/2012
  • 6. INTRODUCTION Torque ā€“ 621F Torque Specifications 621F INT Axle Wheel mounting nuts 640 - 720 NĀ·m (472 - 531 lb ft) Front axle mounting bolts 651 - 678 NĀ·m (480 - 500 lb ft) Rear axle trunnion pin bolts 325 - 353 NĀ·m (240 - 260 lb ft) Chassis Cab mounts 773 - 854 NĀ·m (570 - 630 lb ft) Exhaust stack to hood 36 - 44 NĀ·m (27 - 32 lb ft) Counterweight mounting bolts 955 - 1075 NĀ·m (704 - 793 lb ft) Articulation pivot pin bolts 224 - 278 NĀ·m (165 - 205 lb ft) Articulation mount pin retainer bolts 69 NĀ·m (51 lb ft) Seat mounting bolts 73 - 87 NĀ·m (54 - 64 lb ft) Steering wheel retaining nut 50 NĀ·m (37 lb ft) Hydraulic oil filter mounting bolts 23 - 27 NĀ·m (17 - 20 lb ft) Steering cylinder base end pin retaining bolt 290 - 375 NĀ·m (214 - 277 lb ft) Steering cylinder rod end pin retaining bolt Bolts must turn freely Horn mounting bolt 53 - 62 NĀ·m (39 - 46 lb ft) Hood - rear grill bolts 9 - 11 NĀ·m (7 - 8 lb ft) Hood hinge bolts 65 - 79 NĀ·m (48 - 58 lb ft) Steps - lower entry strap bolts 27 - 31 NĀ·m (20 - 23 lb ft) Cooling Fan to fan hub 40 - 48 NĀ·m (30 - 35 lb ft) Fan hub to motor shaft (no impact tools) 67 - 74 NĀ·m (49 - 55 lb ft) Radiator hose clamps 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft) Hydraulic tank cover nuts 14 - 18 NĀ·m (10 - 13 lb ft) Hydraulic tank sight gauge 2.7 - 5.5 NĀ·m (2.0 - 4.1 lb ft) Driveshafts Coupling to flywheel 53 - 62 NĀ·m (39 - 46 lb ft) Driveshaft to coupling 53 - 62 NĀ·m (39 - 46 lb ft) Front driveshaft yoke nut 339 - 373 NĀ·m (250 - 275 lb ft) Carrier bearing mounting bolts 99 - 128 NĀ·m (73 - 94 lb ft) 550R U-joints 75 - 81 NĀ·m (55 - 60 lb ft) 410R U-joints 61 - 81 NĀ·m (45 - 60 lb ft) Dust cover mounting bolts 20 - 27 NĀ·m (15 - 20 lb ft) 47388956 22/05/2012 3
  • 7. INTRODUCTION Engine Engine mounting brackets 118 - 133 NĀ·m (87 - 98 lb ft) Engine rubber isolator mounts (Qty 4) 244 - 298 NĀ·m (180 - 220 lb ft) Brake pump to engine mounting 57 - 65 NĀ·m (42 - 48 lb ft) Brake pump gear nut (no impact tools) 70 - 79 NĀ·m (52 - 58 lb ft) Turbo to turbo exhaust elbow clamp 5 NĀ·m (4 lb ft) Muffler to turbo elbow exhaust clamp 20 - 25 NĀ·m (15 - 18 lb ft) Front muffler bracket to engine block 118 - 133 NĀ·m (87 - 98 lb ft) Muffler brackets to muffler 114 - 128 NĀ·m (84 - 94 lb ft) Charge Air Cooler (CAC) hose clamps (Qty 8) 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft) Air cleaner to turbo hose clamp 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft) Alternator pulley (no impact tools) 60 - 70 NĀ·m (44 - 52 lb ft) Starter mounting nuts 40 - 50 NĀ·m (30 - 37 lb ft) Loader XT loader linkage bolts 650 - 732 NĀ·m (479 - 540 lb ft) XT guide link nuts 240 - 305 NĀ·m (177 - 225 lb ft) Loader link pin keeper 325 - 373 NĀ·m (240 - 275 lb ft) Transmission Transmission rubber isolator mounts (Qty 3) 890 - 1000 NĀ·m (656 - 738 lb ft) Transmission upper mounting bracket bolts 251 - 319 NĀ·m (185 - 235 lb ft) Transmission lower mounting bracket bolts (Qty 2) 481 - 590 NĀ·m (355 - 435 lb ft) Hydraulic pump to transmission mounting 335 - 375 NĀ·m (247 - 277 lb ft) Cooler clamps 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft) Hydraulic pump suction hose clamp flange 73 - 90 NĀ·m (54 - 66 lb ft) Steering priority manifold to pump 37 - 48 NĀ·m (27 - 35 lb ft) Transmission fill tube bolts 17 - 33 NĀ·m (13 - 24 lb ft) Transmission sight gauge bolts 2.7 - 5.5 NĀ·m (2 - 4 lb ft) Wheels Wheel nuts Initial torque: 298 NĀ·m (220 lb ft) Final torque: 640 - 720 NĀ·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 NĀ·m (220 lb ft) in sequence shown in figure 2. Tighten wheel nuts to a final torque of 640 - 720 NĀ·m (472 - 531 lb ft). in sequence shown in figure 47388956 22/05/2012 4
  • 8. INTRODUCTION Torque ā€“ 721F Torque Specifications 721F INT Axle Wheel mounting bolts 640 - 720 NĀ·m (472 - 531 lb ft) Front axle mounting bolts 765 - 855 NĀ·m (564 - 631 lb ft) Rear axle trunnion pin bolts 651 - 678 NĀ·m (480 - 500 lb ft) Chassis Cab mounts 773 - 854 NĀ·m (570 - 630 lb ft) Exhaust stack to hood 36 - 44 NĀ·m (27 - 32 lb ft) Counterweight mounting bolts 955 - 1075 NĀ·m (704 - 793 lb ft) Articulation pivot pin bolts 224 - 278 NĀ·m (165 - 205 lb ft) Articulation mount pin retainer bolts 69 NĀ·m (51 lb ft) Seat mounting bolts 73 - 87 NĀ·m (54 - 64 lb ft) Steering wheel retaining nut 50 NĀ·m (37 lb ft) Hydraulic oil filter mounting bolts 23 - 27 NĀ·m (17 - 20 lb ft) Steering cylinder base end pin retaining bolt 290 - 375 NĀ·m (214 - 277 lb ft) Steering cylinder rod end pin retaining bolt Bolts must turn freely Horn mounting bolt 53 - 62 NĀ·m (39 - 46 lb ft) Hood - rear grill bolts 9 - 11 NĀ·m (7 - 8 lb ft) Hood hinge bolts 65 - 79 NĀ·m (48 - 58 lb ft) Steps - lower entry strap bolts 27 - 31 NĀ·m (20 - 23 lb ft) Cooling Fan to fan hub 40 - 48 NĀ·m (30 - 35 lb ft) Fan hub to motor shaft (no impact tools) 67 - 74 NĀ·m (49 - 55 lb ft) Radiator hose clamps 10.1 - 11.3 NĀ·m (7.4 - 8.3 lb ft) Hydraulic tank cover nuts 14 - 18 NĀ·m (10 - 13 lb ft) Hydraulic tank sight gauge 2.7 - 5.5 NĀ·m (2.0 - 4.1 lb ft) Driveshafts Coupling to flywheel 53 - 62 NĀ·m (39 - 46 lb ft) Driveshaft to coupling 53 - 62 NĀ·m (39 - 46 lb ft) Front driveshaft yoke nut 339 - 373 NĀ·m (250 - 275 lb ft) Carrier bearing mounting bolts 99 - 128 NĀ·m (73 - 94 lb ft) 550R U-joints 75 - 81 NĀ·m (55 - 60 lb ft) Dust cover mounting bolts 20 - 27 NĀ·m (15 - 20 lb ft) Flex plate to flywheel bolts 33 - 41 NĀ·m (24 - 30 lb ft) Carrier bearing bolt 150 - 164 NĀ·m (111 - 121 lb ft) Drive line mounting bolts 136 - 149 NĀ·m (100 - 110 lb ft) 47388956 22/05/2012 5
  • 10. CONSUMABLES INDEX Consumable IU PAGE CASE Akcela Engine oil 15W-40 Engine - Install 10.001 / 45 47388956 22/05/2012 10.001 / 3
  • 11. Engine - Engine and crankcase Engine - Remove 621F INT, 721F INT 1. Park machine on a level surface and lower the bucket to the ground. Put articulation lock in LOCKED posi- tion and stop the engine. RCPH10WHL063BAL 1 2. Actuate the brake pedal several times to discharge brake accumulators. RCPH10WHL435AAH 2 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. RCPH10WHL119BAL 3 47388956 22/05/2012 10.001 / 4
  • 12. 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. RCPH10WHL099BAL 4 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. RCPH10WHL106AAH 5 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. RAPH12WEL0597AA 6 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. RCPH10WHL054BAL 7 47388956 22/05/2012 10.001 / 5
  • 13. 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. RCPH10WHL054BAL 8 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) RAPH12WEL0598AA 9 10. Double up a nylon lifting strap (1) and slide through the exhaust stack (2) on the hood. RAPH12WEL0599AA 10 47388956 22/05/2012 10.001 / 6
  • 14. 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. RAPH12WEL0600AA 11 12. Tag and disconnect the camera wire harness (if ma- chine is equipped with a camera.) RAPH12WEL0601AA 12 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.) RAPH12WEL0602AA 13 47388956 22/05/2012 10.001 / 7
  • 15. 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. RAPH12WEL0603AA 14 15. Tag and disconnect hood wiring harness connector from rear chassis wiring harness connector. RAPH12WEL0604AA 15 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. RAPH12WEL0605AA 16 47388956 22/05/2012 10.001 / 8
  • 16. Engine - Engine and crankcase 17. Remove the pin from the bottom of the lifting motor cylinder where it attaches to the loader frame. RAPH12WEL0606AA 17 18. Put the master disconnect switch in the ON position. Then, retract the lifting motor cylinder (2), replace pin and disconnect wiring harness (1). RAPH12WEL0062AA 18 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. RAPH12WEL0608AA 19 47388956 22/05/2012 10.001 / 9
  • 17. Engine - Engine and crankcase 20. Have another person balance the hood and remove the hood hinge mounting bolts (arrows) from the cooler frame. RAPH12WEL0605AA 20 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. RAPH12WEL0609AA 21 22. Tag and disconnect engine wiring harness connector from air filter restriction switch. RAPH12WEL0610AA 22 47388956 22/05/2012 10.001 / 10
  • 18. Engine - Engine and crankcase 23. Tag and disconnect engine wiring harness connector from air inlet humidity sensor. RAPH12WEL0611AA 23 24. Loosen clamps on turbocharger and air filter hous- ing. Then remove the intake air hose. Cover tur- bocharger inlet to prevent debris entry. RAPH12WEL0613AA 24 25. Loosen the clamp on the turbocharger for the after cooler inlet elbow. RAPH12WEL0614AA 25 47388956 22/05/2012 10.001 / 11
  • 19. Engine - Engine and crankcase 26. Loosen the clamp on the hose at the after cooler inlet and remove the tube. RAPH12WEL0615AA 26 27. Loosen clamp on the air inlet hose at the air filter housing. RAPH12WEL0616AA 27 28. 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. RAPH12WEL0617AA 28 47388956 22/05/2012 10.001 / 12
  • 20. Engine - Engine and crankcase 29. Remove four the bolts securing the air filter housing to the mounting support bracket. Then remove air filter housing. RAPH12WEL0618AA 29 30. 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. RAPH12WEL0619AA 30 31. Remove the drive belt from the engine. RAPH12WEL0620AA 31 47388956 22/05/2012 10.001 / 13
  • 21. Engine - Engine and crankcase 32. 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. RAPH12WEL0621AA 32 33. Tag and disconnect the wiring from the alternator. RAPH12WEL0622AA 33 34. 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. RAPH12WEL0624AA 34 47388956 22/05/2012 10.001 / 14
  • 22. Engine - Engine and crankcase 35. Remove bolts securing wiring harness clamps to en- gine. RAPH12WEL0625AA 35 36. Remove ground wires from the engine. NOTE: Move the wiring harness away from the engine. RAPH12WEL0625AA 36 37. If the machine is so equipped, unplug the engine block heater and set it aside. RAPH12WEL0626AA 37 47388956 22/05/2012 10.001 / 15
  • 23. Engine - Engine and crankcase 38. Loosen the exhaust clamp from the turbocharger. RAPH12WEL0627AA 38 39. Disconnect the engine coolant vent hose from the engine. RAPH12WEL0628AA 39 40. Loosen clamps and remove lower coolant hose from the engine. RAPH12WEL0629AA 40 47388956 22/05/2012 10.001 / 16
  • 24. Engine - Engine and crankcase 41. Remove the radiator hose from the engine. RAPH12WEL0630AA 41 42. Remove the return radiator hose (1) and the engine coolant vent hose (2) from the top of the radiator. RAPH12WEL0631AA 42 43. Remove hood wire harness clamp from the fan shroud. RAPH12WEL0632AA 43 47388956 22/05/2012 10.001 / 17
  • 25. Engine - Engine and crankcase 44. Remove engine coolant overflow bottle. RAPH12WEL0633AA 44 45. Remove engine coolant overflow bottle support bracket. RAPH12WEL0634AA 45 46. Remove cooling fan screen. RAPH12WEL0635AA 46 47388956 22/05/2012 10.001 / 18
  • 26. Engine - Engine and crankcase 47. Remove the heater hose (1) from the engine. RAPH12WEL0636AA 47 48. Loosen the clamp on the intake manifold for the after cooler output hose. RAPH12WEL0637AA 48 49. Loosen the clamp on the after cooler, and remove the after cooler outlet tube from the machine. RAPH12WEL0638AA 49 47388956 22/05/2012 10.001 / 19
  • 27. Engine - Engine and crankcase 50. Tag and disconnect the fuel filter heater wire (1) and water sensor (2). Then drain fuel filter and discon- nect inlet (3) and outlet (4) fuel lines from the fuel filter head. Plug the lines and cap the fittings. RAPH12WEL0639AA 50 51. Remove ground wire and fuel filter head attachment bolt (1). Then remove fuel line support clamp (2). RAPH12WEL0640AA 51 52. Tag and remove the grid heater cable (1). NOTE: Hold the rear nut with a second wrench to prevent grid heater damage. RAPH12WEL0063AA 52 47388956 22/05/2012 10.001 / 20
  • 28. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 29. Engine - Engine and crankcase 53. Remove wire harness support clamp. RAPH12WEL0064AA 53 54. Tag and disconnect wire harness from primary fuel filter. RAPH12WEL0068AA 54 55. Remove hood lift cylinder support bracket. RAPH12WEL0071AA 55 47388956 22/05/2012 10.001 / 21
  • 30. Engine - Engine and crankcase 56. Attach suitable lifting straps to the muffler support structure. RAPH12WEL0072AA 56 57. Remove bolts securing the muffler support structure at the front and rear of the structure. The mounting points are positioned on the left and right side in the front of the engine compartment, and in the center at the rear of the engine compartment. NOTE: The right front mount is shown. RAPH12WEL0073AA 57 58. Use a suitable lifting device to carefully lift muffler support structure (with muffler system components attached) from the machine. RAPH12WEL0075AA 58 47388956 22/05/2012 10.001 / 22
  • 31. Engine - Engine and crankcase 59. Disconnect the wiring harness from the EDC 7 con- troller. NOTE: Lifting up on the lever will release the connector from the controller. RAPH12WEL0076AA 59 60. Remove the fuel line from the top of the primary fuel filter, plug the line and cap the fitting. NOTE: Make note on how fuel lines are routed. RAPH12WEL0077AA 60 61. Remove the fuel line support clamp. NOTE: Make note on how fuel lines are routed. RAPH12WEL0078AA 61 47388956 22/05/2012 10.001 / 23
  • 32. Engine - Engine and crankcase 62. Remove the upper and lower dust covers for the drive shaft. RAPH12WEL0079AA 62 63. Remove the drive shaft bolts (1) from the flywheel. Move the drive shaft clear of the flywheel. RAPH12WEL0080AA 63 64. Connect and turn on vacuum pump to hydraulic reservoir. Tag and remove the hydraulic lines from the brake system pump (arrow), plug the lines and cap the fittings. RAPH12WEL0081AA 64 47388956 22/05/2012 10.001 / 24
  • 33. Engine - Engine and crankcase 65. Connect suitable lifting equipment to engine lifting brackets. Take up all slack in lifting equipment. Re- move the engine mounting bolts. 66. Slowly raise engine from rear chassis. Be sure all wire harness connections and hoses have been dis- connected and are clear of the engine. Guide the oil drain hose from the frame as the engine is lifted. Re- move engine from machine. RAPH12WEL0082AA 65 Next operation: Engine - Install (10.001) 47388956 22/05/2012 10.001 / 25
  • 34. Engine - Engine and crankcase Engine - Install 621F INT, 721F INT WARNING Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape. Failure to comply could result in death or serious injury. W0296A Prior operation: Engine - Remove (10.001) RAIL12WEL0130FA 1 1. Engine mount bolt 5. Washers 2. Washer 6. Washer 3. Isolator upper 7. Nut 4. Isolator lower 8. Remote oil drain hose 1. Inspect engine mounts. If engine rubber isolators re- quire replacement, remove and discard isolators (3) and (4). Install new rubber isolator (4), then rubber isolator (3). 47388956 22/05/2012 10.001 / 26
  • 35. Engine - Engine and crankcase 2. Attach suitable lifting device to the engine and slowly move it into position over the rear chassis. Be sure all harness connections and hoses are out of the way or positioned correctly for reconnecting, before low- ering engine. RAPH12WEL0082AA 2 3. Tighten engine mounting bolts to a torque of 244 - 298 NĀ·m (180 - 220 lb ft). RAPH12WEL0080AA 3 4. Disconnect lifting equipment from engine lifting brackets. RAPH12WEL0082AA 4 47388956 22/05/2012 10.001 / 27
  • 36. Engine - Engine and crankcase 5. Connect vacuum pump to the hydraulic reservoir and turn it on. Remove caps from fittings and plugs from hoses. Connect hoses to brake pump following tags installed during removal. Remove and discard tags. Turn off and disconnect vacuum pump from hydraulic reservoir. RAPH12WEL0081AA 5 6. Connect engine oil drain hose (1) to frame bracket (2). RAPH12WEL0598AA 6 7. At front of engine, position drive shaft on engine cou- pling. Install bolts to secure drive shaft to engine cou- pling. Tighten the bolts to a torque of 53 - 62 NĀ·m (39 - 46 lb ft). RAPH12WEL0080AA 7 47388956 22/05/2012 10.001 / 28
  • 37. Engine - Engine and crankcase 8. Install the upper and lower drive shaft dust covers. Torque to 20 - 27 NĀ·m (15 - 20 lb ft). NOTE: Attach p-clamp, securing coolant line. RAPH12WEL0079AA 8 9. Install bolt and clamp for fuel return hose. RAPH12WEL0078AA 9 10. Remove cap from fitting and plug from the hose. Then connect fuel line to the top of the primary fuel filter. RAPH12WEL0077AA 10 47388956 22/05/2012 10.001 / 29