CASE 721F TIER 4 WHEEL LOADER Service Repair Manual

Printed in U.S.A.
Copyright © 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
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
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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
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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
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INTRODUCTION
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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
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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)
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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
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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)
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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
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INTRODUCTION
Capacities
621F WE, 621F NA, 721F WE, 721F NA
621F Capacities and Specifications
Engine
Type of oil CASE AKCELA ENGINE OIL 15W-40
Capacity (with filter change) 13.25 l (14.0 US qt)
Total system capacity 15.1 l (16 US qt)
Cooling System
System capacity 26.8 l (28.4 US qt)
Hydraulic System
Type of fluid CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION
OIL
Total system capacity 147.6 l (39.0 US gal)
Reservoir capacity 90.8 l (24.0 US gal)
Fuel System
System capacity 246 l (65.0 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Service capacity (with filter change) 26.7 l (28.2 US qt)
Axles
Standard front axle 22 l (23.2 US qt)
Standard rear axle 22 l (23.2 US qt)
Optional front axle 35 l (37.0 US qt)
Optional rear axle 35 l (37.0 US qt)
Diesel Exhaust Fluid (DEF)
Total capacity 41.3 l (10.9 US gal)
Grease Fittings
As required CASE AKCELA MOLY GREASE
NOTE: Machines are shipped from the factory with break-in oil.
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INTRODUCTION
721F Capacities and Specifications
Engine
Type of oil CASE AKCELA ENGINE OIL 15W-40
Capacity (with filter change) 13.25 l (14.0 US qt)
Total system capacity 15.1 l (16 US qt)
Cooling System
System capacity 28.4 l (30.0 US qt)
Hydraulic System
Type of fluid CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION
OIL
Total system capacity 177.8 l (47.0 US gal)
Reservoir capacity 90.8 l (24.0 US gal)
Fuel System
System capacity 253 l (66.8 US gal)
Transmission
Service capacity (with filter change) 34 l (35.9 US qt)
Axles
Standard front axle 35 l (37.0 US qt)
Standard rear axle 23 l (24.3 US qt)
Optional front axle 35 l (37.0 US qt)
Optional rear axle 35 l (37.0 US qt)
Diesel Exhaust Fluid (DEF)
Total capacity 41.3 l (10.9 US gal)
Grease Fittings
As required CASE AKCELA MOLY GREASE
NOTE: Machines are shipped from the factory with break-in oil.
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INTRODUCTION
Engine Oil Viscosity/Temperature Range
RCPH11WHL023FAH 1
NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures
are in Winter or Arctic conditions.
Transmission Oil Viscosity/Temperature Range
RCPH10WHL453BAH 2
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INTRODUCTION
Hydraulic/Brake System Temperature Range
RCPH10WHL006EAL 3
Coolant Solution
Only use ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high
boiling point with no additives to prevent leakage. Do not use non-approved anti-rust additives.
NOTICE: Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion pro-
tection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your
dealer who can supply you with the suitable coolant solution.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the
ambient temperature is over -36 °C (-32.8 °F) use a blend of 50 % ethylene-glycol based anti-freeze.
For areas where the temperature is below -36 °C (-32.8 °F)- it is advisable to use a blend of 40 % water and 60 %
anti-freeze.
Fuel
• Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).
• Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.
• Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause
high fuel consumption.
• For very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel
supplier for appropriate fuel supply.
• If the temperature falls below the fuel cloud point (point at which wax begins to form, the wax crystals will cause
power loss or will prevent the engine from starting.
• In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.
Fuel Storage
Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
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INTRODUCTION
Hydraulic Fluid
CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL is specifically designed for high pressure applica-
tions and for Case hydraulic systems. Your Case Dealer can provide hydraulic fluid to fulfill different climate/temper-
ature conditions. Refer to the charts at the beginning of this section.
Transmission Component Oil
Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for
your climate/temperature conditions such as CASE AKCELA NEXPLORE™ FLUID. See charts at the beginning of this
section.
Grease
The type of grease to use depends on ambient temperature such as: CASE AKCELA MOLY GREASE.
Environment
Before servicing machine and disposing oil, fluids, and lubricants, follow all environmental regulations. Do not drain
oil or fluids on to the ground or into containers that leak. Check with your local environmental recycling center or your
dealer for correct disposal information.
Engine Oil
CASE AKCELA ENGINE OIL 15W-40 is recommended for
your engine. This oil insures correct lubrication of your en-
gine in all working conditions. See charts at the beginning
of this section to choose the correct oil for climate/temper-
atures.
If CASE AKCELA ENGINE OIL 15W-40 cannot be obtained,
use only oil of the API SERVICE CI-4 category.
NOTE: Do not put any Performance Additive or other ad-
ditive in the sump. Oil change intervals shown in this man-
ual are based on tests carried out utilizing Case lubricants. RCPH10WHL012AAD 4
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INTRODUCTION
Consumables - Biodiesel Fuel
Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with
methyl esters.
NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN
14214 or ASTM D6751.
NOTICE: Verify with your local dealer which blends are approved for your engine. Use of biodiesel fuel that does not
comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to engine and fuel system. Use
of non-approved biodiesel fuels may void warranty coverage.
Biodiesel Fuel Usage Conditions
Biodiesel fuels must be purchased from a trusted supplier that understands the product and maintains good fuel
quality. Biodiesel fuels must be pre-blended by the supplier. Mixing biodiesel fuels on site can result in an incorrect
mixture which can damage engine and fuel system.
Engine performance is effected by the use of biodiesel fuels. There may be up to 12 percent reduction in power or
torque depending on the blend used.
NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.
The reduced power must be accepted if using any biodiesel fuel blends.
NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.
Using biodiesel fuels may require changing engine oil, engine oil filters, and fuel filter elements more frequently.
Biodiesel fuels can remove rust and other particles that adhere to the inside of the fuel tank. These particles are
trapped by vehicle filters and may cause shortened filter life or filter blockages. Blockages are more common in cold
weather conditions. Consult your dealer for information on cold weather operation and proper maintenance intervals
when using any biodiesel fuel blend.
Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel. Frequently
inspect hoses and other engine components when using biodiesel fuel.
DO NOT allow water to collect in the fuel or storage tanks. Biodiesel fuel attracts moisture from the atmosphere.
Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary
to drain machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in
the machine.
Biodiesel Storage
NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT
store biodiesel fuel in on-site storage tanks for more than three months.
If long periods of storage are required, run the machine for 20 hours using regular diesel fuel to flush the biodiesel
fuel from the engine fuel system.
NOTICE: Biodiesel fuels must not be stored in on-site storage tanks for more than 3 months. Any spillage of biodiesel
fuels must be cleaned up immediately before it can cause damage to the environment or the paint finish of the ma-
chine. Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the
approved blend for your machine and any detailed conditions of its usage. Failure to follow the requirements and
conditions of biodiesel fuel usage will void your machine’s warranty.
NOTE: B7 is the highest biodiesel (7% blend) that should be used in this machine.
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12

INTRODUCTION
Hydraulic contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.
(A) When you drain the oil or disconnect any line.
(B) When you disassemble a component.
(C) From normal wear of the hydraulic components.
(D) From damaged or worn seals.
(E) From a damaged component in the hydraulic system.
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system per-
mits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause
problems in the hydraulic system. The following list includes some of these problems.
(A) Cylinder rod seals leak.
(B) Control valve spools do not return to neutral.
(C) Movement of control valve spools is difficult.
(D) Hydraulic oil becomes too hot.
(E) Pump gears, housing, and other parts wear rapidly.
(F) Relief valves or check valves held open by dirt.
(G) Quick failure of components that have been repaired.
(H) Cycle times are slow; machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination. There are two types of contam-
ination, microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory. Examples of the problems:
(A) Cylinder rod seal leak.
(B) Control valve spools do not return to NEUTRAL.
(C) The hydraulic system has a high operating temperature.
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components. Examples of visible contamination:
(A) Particles of metal or dirt in the oil.
(B) Air in the oil.
(C) The oil is dark and thick.
(D)The oil has an odor of burned oil.
(E) Water in the oil.
If you find contamination, use a Portable Filter to clean the hydraulic system.
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CONSUMABLES INDEX
Consumable IU PAGE
CASE Akcela Engine oil
15W-40
Capacities 7
CASE Akcela HY-TRAN®
Ultra™ hydraulic transmission
oil
Capacities 7
CASE Akcela NEXPLORE™
fluid
Capacities 7
fluid
Capacities 7
CASE Akcela Moly grease Capacities 7
15W-40
Capacities 8
oil
Capacities 8
fluid
Capacities 8
fluid
Capacities 8
oil
Capacities 11
fluid
Capacities 11
15W-40
Capacities 11
15W-40
Capacities 11
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SERVICE MANUAL
Engine
621F
721F
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10

Contents
Engine - 10
Engine and crankcase...................................................................... 10.001
621F , 721F
Air cleaners and lines....................................................................... 10.202
621F , 721F
Engine lubrication system .................................................................. 10.304
621F , 721F
Aftercooler .................................................................................. 10.310
621F , 721F
Engine cooling system ..................................................................... 10.400
621F , 721F
Fan and drive............................................................................... 10.414
621F , 721F
Selective Catalytic Reduction (SCR) exhaust treatment ................................... 10.500
621F NA, 621F WE, 721F NA, 721F WE
Engine generic sub-group ................................................................. 10.AAA
621F , 721F
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CONSUMABLES INDEX
Consumable IU PAGE
DEF/AdBlue® Engine - Remove 10.001 / 22
DEF/AdBlue® Engine - Install 10.001 / 33
15W-40
Engine - Install 10.001 / 50
Loctite® 242 Radiator - Install 10.400 / 16
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 20
DEF/AdBlue® Coolant control valve - Remove 10.500 / 29
DEF/AdBlue® Coolant control valve - Remove 10.500 / 29
DEF/AdBlue® Coolant control valve - Install 10.500 / 31
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Engine - 10
Engine and crankcase - 001
621F
721F
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10.001 / 1

Contents
Engine - 10
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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CONSUMABLES INDEX
Consumable IU PAGE
15W-40
Engine - Install 10.001 / 50
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Engine - Engine and crankcase
Engine - Remove
NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
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
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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
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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
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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
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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
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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
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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
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23. Tag and disconnect engine wiring harness connector
from air inlet humidity sensor.
RAPH12WEL0611AA 23
24. Loosen clamp (1) on the crankcase ventilation hose
(2) and disconnect hose.
RAPH12WEL0612AA 24
25. Loosen clamps on turbocharger and air filter hous-
ing. Then remove the intake air hose. Cover tur-
bocharger inlet to prevent debris entry.
RAPH12WEL0613AA 25
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26. Loosen the clamp on the turbocharger for the after
cooler inlet elbow.
RAPH12WEL0614AA 26
27. Loosen the clamp on the hose at the after cooler inlet
and remove the tube.
RAPH12WEL0615AA 27
28. Loosen clamp on the air inlet hose at the air filter
housing.
RAPH12WEL0616AA 28
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29. 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 29
30. Remove four the bolts securing the air filter housing
to the mounting support bracket. Then remove air
filter housing.
RAPH12WEL0618AA 30
31. 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 31
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32. Remove the drive belt from the engine.
RAPH12WEL0620AA 32
33. 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 33
34. Tag and disconnect the wiring from the alternator.
RAPH12WEL0622AA 34
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35. Remove SCR coolant return line.
RAPH12WEL0623AA 35
36. 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 36
37. Remove bolts securing wiring harness clamps to en-
gine.
RAPH12WEL0625AA 37
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38. Remove ground wires from the engine.
NOTE: Move the wiring harness away from the engine.
RAPH12WEL0625AA 38
39. If the machine is so equipped, unplug the engine
block heater and set it aside.
RAPH12WEL0626AA 39
40. Loosen the exhaust clamp from the turbocharger.
RAPH12WEL0627AA 40
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41. Disconnect the engine coolant vent hose from the
engine.
RAPH12WEL0628AA 41
42. Loosen clamps and remove lower coolant hose from
the engine.
RAPH12WEL0629AA 42
43. Remove the radiator hose from the engine.
RAPH12WEL0630AA 43
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44. Remove the return radiator hose (1) and the engine
coolant vent hose (2) from the top of the radiator.
RAPH12WEL0631AA 44
45. Remove hood wire harness clamp from the fan
shroud.
RAPH12WEL0632AA 45
46. Remove engine coolant overflow bottle.
RAPH12WEL0633AA 46
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47. Remove engine coolant overflow bottle support
bracket.
RAPH12WEL0634AA 47
48. Remove cooling fan screen.
RAPH12WEL0635AA 48
49. Remove heater hose (1) and the SCR heater supply
line (2) from the engine.
RAPH12WEL0636AA 49
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50. Loosen the clamp on the intake manifold for the after
cooler output hose.
RAPH12WEL0637AA 50
51. Loosen the clamp on the after cooler, and remove
the after cooler outlet tube from the machine.
RAPH12WEL0638AA 51
52. 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 52
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53. Remove ground wire and fuel filter head attachment
bolt (1). Then remove fuel line support clamp (2).
RAPH12WEL0640AA 53
54. Tag and disconnect the post SCR catalyst EGT sen-
sor from machine wire harness (1) and the post SCR
catalyst NOx sensor (2). Then tag and remove the
grid heater cable (3).
NOTE: Hold the rear nut with a second wrench to prevent
grid heater damage.
RAPH12WEL0063AA 54
55. Remove wire harness support clamp.
RAPH12WEL0064AA 55
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56. Tag and disconnect Pre-SCR catalyst EGT sensor
(1). Then remove tie wrap, wire harness bolts and
wire harness support clamp (2).
RAPH12WEL0065AA 56
57. Tag and disconnect wire harness from DEF/
ADBLUE® Dosing Module.
RAPH12WEL0066AA 57
58. Tag and disconnect wire harness from DEF/
ADBLUE® Control Module (1) and the coolant flow
control valve (2).
RAPH12WEL0067AA 58
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59. Tag and disconnect wire harness from primary fuel
filter.
RAPH12WEL0068AA 59
60. Remove DEF/ADBLUE® storage tank cover located
on the Right Hand side of the machine.
RAPH12WEL0069AA 60
61. Tag and disconnect wire harness and DEF/ADBLUE®
supply and return lines from the DEF/ADBLUE® stor-
age tank. Cap the supply lines.
RAPH12WEL0070AA 61
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62. Remove hood lift cylinder support bracket.
RAPH12WEL0071AA 62
63. Attach suitable lifting straps to the SCR Catalyst sup-
port structure.
RAPH12WEL0072AA 63
64. Remove bolts securing the SCR Catalyst 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 64
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65. Using suitable lifting device, carefully lift SCR cata-
lyst support structure (with SCR system components
attached) from the machine.
RAPH12WEL0075AA 65
66. Disconnect the wiring harness from the EDC 7 con-
troller.
NOTE: Lifting up on the lever will release the connector
from the controller.
RAPH12WEL0076AA 66
67. 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 67
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68. Remove the fuel line support clamp.
NOTE: Make note on how fuel lines are routed.
RAPH12WEL0078AA 68
69. Remove the upper and lower covers for the drive
shaft.
RAPH12WEL0079AA 69
70. Remove the drive shaft bolts (1) from the flywheel.
Move the drive shaft clear of the flywheel.
RAPH12WEL0080AA 70
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71. 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 71
72. Connect suitable lifting equipment to engine lifting
brackets. Take up all slack in lifting equipment. Re-
move the engine mounting bolts.
73. 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 72
Next operation:
Engine - Install (10.001)
84605841 14/05/2012
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Engine - Install
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)
NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
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).
84605841 14/05/2012
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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 N·m (180 - 220 lb ft).
RAPH12WEL0080AA 3
4. Disconnect lifting equipment from engine lifting
brackets.
RAPH12WEL0082AA 4
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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 N·m (39
- 46 lb ft).
RAPH12WEL0080AA 7
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8. Install the upper and lower drive shaft dust covers.
Torque to 20 - 27 N·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
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11. Connect wiring harness to EDC 7 controller.
NOTE: Start the connector on the EDC 7 with lever straight
out from EDC 7. Use lever to pull connector into position.
RAPH12WEL0076AA 11
12. Connect a suitable lifting device to the SCR catalyst
support structure and carefully lift it (with SCR sys-
tem components attached) and position it over the
rear chassis of the machine. Lower support struc-
ture into position on the machine.
NOTE: Be sure all wire harness connections and hoses are
out of the way or positioned correctly for reconnecting.
RAPH12WEL0075AA 12
13. Install bolts securing the SCR Catalyst support struc-
ture at the front (right hand side pictured) and rear
mounting points. Torque bolts to 125 - 150 N·m (92
- 111 lb ft).
NOTE: Emissions sensors mounted in the exhaust stream
are sensitive to extreme vibrations. Use of tools that gener-
ate extreme vibrations, such as impact wrenches and ham-
mers, will result in damage to emission sensors. Avoid us-
ing these tools during any service procedure in close prox-
imity of emission sensors. If the use of these tools can-
not be avoided, remove the sensors using extreme caution
prior to performing any service procedure.
RAPH12WEL0073AA 13
84605841 14/05/2012
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14. Remove lifting straps from the SCR Catalyst support
structure.
RAPH12WEL0072AA 14
15. Install hood lift cylinder support bracket. Torque bolts
to 310 - 380 N·m (229 - 280 lb ft).
RAPH12WEL0071AA 15
16. Remove caps and plugs from lines and tag from wire
harness. Connect wire harness and DEF/ADBLUE®
supply and return lines to the DEF/ADBLUE® storage
tank.
RAPH12WEL0070AA 16
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10.001 / 33

17. Install DEF/ADBLUE® storage tank cover.
RAPH12WEL0069AA 17
18. Connect wire harness to the primary fuel filter.
RAPH12WEL0068AA 18
19. Connect the wire harness to the DEF/ADBLUE® Con-
trol Module (1) and the coolant flow control valve (2).
NOTE: Start the connector on the Control Module with
lever straight out from the Control Module. Use lever to
pull connector into position.
RAPH12WEL0067AA 19
84605841 14/05/2012
10.001 / 34

20. Connect the wire harness to the DEF/ADBLUE® Dos-
ing Module.
RAPH12WEL0066AA 20
21. Connect the Pre-SCR catalyst EGT sensor (1). Then
secure with a tie wrap (2), and wire harness clamps
(3). Install wire harness support clamp.
RAPH12WEL0065AA 21
22. Attach wire harness support clamp.
RAPH12WEL0064AA 22
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23. Connect the post SCR catalyst EGT sensor (1) and
the post SCR catalyst NOx sensor (2) to the machine
wire harness. Then connect the grid heater cable (3)
NOTE: Hold the rear nut with a second wrench to prevent
grid heater damage.
RAPH12WEL0063AA 23
24. Connect the ground wire and attach fuel filter head
mounting bolt (1). Install fuel line support clamp (2).
RAPH12WEL0640AA 24
25. Connect the fuel filter heater wire (1) and water sen-
sor (2). Then remove the plugs and caps and con-
nect the fuel inlet line (3) and fuel outlet line (4) to the
fuel filter head.
RAPH12WEL0639AA 25
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26. Connect the after cooler outlet hose to the after
cooler and secure the clamp. Torque to 10.1 - 11.3
N·m (7.4 - 8.3 lb ft).
RAPH12WEL0638AA 26
27. Connect the after cooler outlet hose to the intake
manifold and secure clamp. Torque to 10.1 - 11.3
N·m (7.4 - 8.3 lb ft).
RAPH12WEL0637AA 27
28. Connect the heater hose (1) and the SCR heater sup-
ply line (2) to the engine and secure clamps. Torque
to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0636AA 28
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29. Install cooling fan screen.
RAPH12WEL0635AA 29
30. Install engine coolant overflow bottle support
bracket.
RAPH12WEL0634AA 30
31. Install engine coolant overflow bottle.
RAPH12WEL0633AA 31
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32. Install hood wire harness clamp on the fan shroud.
RAPH12WEL0632AA 32
33. Connect the radiator hose (1) and the engine coolant
vent hose (2) to the top of the radiator. Torque clamp
to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0631AA 33
34. Connect the radiator hose to the engine. Torque
clamp to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0630AA 34
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35. Connect lower coolant hose to the engine and tighten
clamps. Torque clamp to 10.1 - 11.3 N·m (7.4 - 8.3
lb ft).
RAPH12WEL0629AA 35
36. Connect the engine coolant vent hose to the engine
and secure clamp. Torque clamp to 10.1 - 11.3 N·m
(7.4 - 8.3 lb ft).
RAPH12WEL0628AA 36
37. Connect exhaust hose to the turbocharger and se-
cure clamp. Torque clamp to 5 N·m (4 lb ft).
RAPH12WEL0627AA 37
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38. Connect engine block heater if machine is so
equipped.
RAPH12WEL0626AA 38
39. Connect ground wires to the engine.
RAPH12WEL0625AA 39
40. Install bolts securing wiring harness clamps to the
engine.
RAPH12WEL0625AA 40
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41. Connect the wires to the starter solenoid (1), con-
nect the ground cable (2) and ground strap (3) to the
starter.
RAPH12WEL0624AA 41
42. Connect SCR coolant return line and secure clamp.
Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0623AA 42
43. Connect the wiring harness to the alternator.
RAPH12WEL0622AA 43
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44. If loader is equipped with air conditioning, secure
compressor to support bracket with mounting bolts
(1). Then connect the engine wiring harness to the
high pressure switch (2) and air compressor clutch
connector (3).
RAPH12WEL0621AA 44
45. Install the drive belt.
RAPH12WEL0620AA 45
46. Secure belt cover mounting bracket to the machine
frame. Then Install the belt cover.
RAPH12WEL0619AA 46
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47. Position air filter housing on mounting support
bracket and secure it with four bolts.
RAPH12WEL0618AA 47
48. Position the air inlet hose, then install the center sup-
port bracket (2) attached to the air inlet hose and se-
cure it to the cooler box (1).
RAPH12WEL0617AA 48
49. Connect air inlet hose on the air filter housing and
secure clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3
lb ft).
RAPH12WEL0616AA 49
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50. Connect hose on the after cooler inlet and secure
clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0615AA 50
51. Connect the after cooler inlet hose to the tur-
bocharger and secure clamp. Torque to 10.1 - 11.3
N·m (7.4 - 8.3 lb ft).
RAPH12WEL0614AA 51
52. Connect the intake air hose to the turbocharger and
air filter housing. Secure clamps and torque to 10.1
- 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0613AA 52
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53. Connect the crankcase ventilation hose (2). Secure
with clamp (1) and torque to 10.1 - 11.3 N·m (7.4 -
8.3 lb ft).
RAPH12WEL0612AA 53
54. Connect wiring harness to air inlet humidity sensor,
then remove tag.
RAPH12WEL0611AA 54
55. Connect engine wiring harness to air filter restriction
switch and remove tag.
RAPH12WEL0610AA 55
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56. Connect suitable lifting device to the hood. Carefully
raise the hood over the machine and lower it into
position.
NOTE: Radiator overflow hose may interfere with left hand
hood hinge movement and hood removal.
RAPH12WEL0609AA 56
57. Have another person balance the hood and install
the hood hinge mounting bolts to the cooler frame.
Torque bolts to 65 - 79 N·m (48 - 58 lb ft).
RAPH12WEL0605AA 57
58. Remove the battery cover and reconnect the ground
lead to batteries (2). Put the master disconnect
switch (1) in ON position.
RAPH12WEL0608AA 58
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59. Connect the hood lifting cylinder motor to the ma-
chine wiring harness (1). Extend the cylinder (2) and
remove pin from the bottom of the cylinder. Switch
the master disconnect switch to the OFF position.
RAPH12WEL0062AA 59
60. Attach lifting motor cylinder to the loader frame and
reinstall the pin at the bottom of the lifting motor cylin-
der.
RAPH12WEL0606AA 60
61. Remove lifting device from the hood.
RAPH12WEL0599AA 61
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62. Reconnect hood wiring harness to rear chassis
wiring harness connector. Remove tags.
RAPH12WEL0604AA 62
63. Attach backup alarm wiring harness clamp (1) and
hood ground wire (2) to the cooler housing. Then
remove marking tags.
RAPH12WEL0603AA 63
64. Reconnect the camera wire harness (if machine is
equipped with a camera). Remove marking tags.
RAPH12WEL0601AA 64
84605841 14/05/2012
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65. Reattach camera wire harness to hood (if machine is
equipped with a camera).
RAPH12WEL0602AA 65
66. Be sure engine oil drain cap is secured. Refill engine
with CASE AKCELA ENGINE OIL 15W-40.
RCPH10WHL054BAL 66
67. Be sure engine coolant drain cap is secure. Refill
cooling system with a 50 % ethylene-glycol and 50
% water coolant solution. Install radiator cap.
RCPH10WHL054BAL 67
68. Switch the master disconnect switch to the ON posi-
tion.
RCPH10WHL106AAH 68
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69. Start the engine and run it at low idle. Run the en-
gine at operating temperature for approximately five
minutes to completely mix the Ethylene Glycol and
water. Check machine for fluid leaks. When coolant
is at operating temperature, recheck the coolant level
at the reservoir.
NOTE: Hot coolant can spray out if radiator cap is removed.
To remove radiator cap: Let system cool, turn cap to first
notch, then wait until all pressure is released. Scalding can
result from fast removal of radiator cap.
70. Install the left and right side inner fender panels (2),
then lower left and right hand side panels (1). Close
the hood.
NOTE: Left side of the machine is shown. This operation
is repeated for the right side.
RAPH12WEL0597AA 69
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Index
Engine - 10
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Air cleaners and lines - 202
621F
721F
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10.202 / 1

Contents
Engine - 10
SERVICE
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Air cleaners and lines
Air cleaner - Remove
1. Access pre-cleaner located on top of engine com-
partment hood.
RCPH11WHL663BAU 1
2. Remove wing nut.
RCPH11WHL720BAU 2
3. Remove pre-cleaner assembly from machine.
RCPH11WHL719BAU 3
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10.202 / 3

4. Empty debris and wipe pre-cleaner with a damp
clean cloth. Reassemble and install assembly on
the machine.
RCPH11WHL718BAU 4
Primary/secondary filter element disassembly
5. Raise engine compartment hood using controls lo-
cated behind access cover (1). Air filter housing/el-
ement (2) is located in main engine compartment on
operator’s left hand side of engine.
RCPH11WHL663BAU 5
6. Turn master electric switch “off”.
RCPH11WHL653BAU 6
84605841 14/05/2012
10.202 / 4

7. Release all clips securing air filter element housing
cover.
RCPH11WHL746BAU 7
8. Remove cover from air filter element housing.
RCPH11WHL747BAU 8
9. Remove the primary filter element. To do this, push
filter element down to loosen the filter seal. Then
pull up on the handle to lift the filter element out of
the housing.
RCPH11WHL748BAU 9
10. Remove secondary filter element from the right side
of the filter element housing. Remove debris from in-
side the housing before installing new filter elements.
NOTE: Do not clean the secondary filter element. It must
be replaced if damaged or clogged.
RCPH11WHL749BAU 10
Next operation:
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10.202 / 5

Air cleaner - Install (10.202)
84605841 14/05/2012
10.202 / 6

Air cleaner - Install
Prior operation:
Air cleaner - Remove (10.202)
1. Install new secondary filter element.
NOTE: Make sure filter element is positioned correctly in
slot and firmly seated into housing.
RCPH11WHL749BAU 1
2. Install new primary filter element by sliding it down
into housing. With the handle, pull filter element rear-
ward to make the seal engage in the housing.
NOTE: Make sure primary and secondary filter elements
form an effective seal.
RCPH11WHL748BAU 2
3. Install housing cover.
RCPH11WHL747BAU 3
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4. Lock clips to secure filter housing cover.
NOTE: If cover does not fit properly, recheck filter element
installation. Cover will be difficult to install if filter elements
are not properly installed.
RCPH11WHL745BAU 4
5. Turn master electric power switch “on”. Clear any
fault codes. Start machine and confirm issue has
been corrected.
RCPH11WHL653BAU 5
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10.202 / 8

Index
Engine - 10
Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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10.202 / 10

Engine - 10
Engine lubrication system - 304
621F
721F
84605841 14/05/2012
10.304 / 1

Contents
Engine - 10
SERVICE
Blowby re-circulation system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84605841 14/05/2012
10.304 / 2

Engine - Engine lubrication system
Blowby re-circulation system - Remove
1. Locate the blowby recirculation system filter under
the hood on the engine in back of the cooling fan. It
can be accessed from the right side of the machine.
RCPH11WHL685BAU 1
2. Raise the hood using the controls located behind the
access cover. Then remove the inner fender panel.
RCPH11WHL663BAU 2
3. Turn the master electric switch to the “off” position.
RCPH11WHL653BAU 3
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10.304 / 3

4. Remove the screws on the filter housing cover plate.
It may be necessary to use an off-set screwdriver.
RAPH12WEL0089AA 4
5. Remove the filter housing cover plate.
RAPH12WEL0090AA 5
6. Remove the filters from the filter housing and replace
them.
RCPH10WHL467AAH 6
Next operation:
Blowby re-circulation system - Install (10.304)
84605841 14/05/2012
10.304 / 4

Blowby re-circulation system - Install
Prior operation:
Blowby re-circulation system - Remove (10.304)
1. Install the new filter elements into the filter housing.
Take care to fit the filter elements correctly.
RCPH10WHL467AAH 1
2. Install the filter housing cover plate.
RAPH12WEL0090AA 2
3. Secure the filter housing cover plate with screws. It
may be necessary to use an off-set screwdriver.
RAPH12WEL0089AA 3
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10.304 / 5

4. Turn the master electric switch to the “on” position.
RCPH11WHL653BAU 4
5. Install the inner fender panel. Then lower the hood
using the controls located behind the access cover.
RCPH11WHL663BAU 5
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Index
Engine - 10
Blowby re-circulation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Blowby re-circulation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Aftercooler - 310
621F
721F
84605841 14/05/2012
10.310 / 1

Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSTIC
Aftercooler
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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10.310 / 2

Engine - Aftercooler
Aftercooler - Remove
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
1. Raise hood using controls located behind the access
cover.
RCPH11WHL652BAU 1
2. After hood is raised, turn master electric switch to the
off position.
RCPH11WHL653BAU 2
84605841 14/05/2012
10.310 / 3

3. On the underside of hood, remove bolts (1) from ex-
haust stack, then remove plate (2).
4. Remove exhaust stack (3).
RAPH12WEL0194AA 3
5. Double up a nylon lifting strap. From the topside,
slide looped strap through the hood exhaust opening.
RAPH12WEL0170AA 4
6. Place a solid steel bar through the strap loop (see
arrow) and tighten. Attach the other end of the strap
to a suitable lifting device and remove any slack in
the line.
NOTE: Note the position of the lifting bar strap. It is offset
to even out the weight distribution of the hood.
RAPH12WEL0193AA 5
84605841 14/05/2012
10.310 / 4

7. Remove cotter pin and pin from the lift cylinder. Turn
electrical master switch back on and run lift cylinder
up. Once cylinder is retracted, return the electrical
master switch back to the OFF position.
RAPH12WEL0191AA 6
8. Remove the hood bracket bolts and move hood away
from back plate, allowing enough clearance to reach
air cooler unit front bolts.
RAPH12WEL0169AA 7
Turbocharger tube removal
9. Loosen top left side clamp of the air cooler outlet
hose.
NOTE: Loosen only the clamp closest to the air cooler.
RAPH12WEL0207AA 8
84605841 14/05/2012
10.310 / 5

10. Loosen the clamp at the elbow-turbocharger connec-
tion end. Remove tube and plug turbocharger.
RAPH12WEL0206AA 9
Intake port tube removal
11. Loosen top right side clamps of the air cooler intake
hose. Slide hose back far enough to clear air cooler
tube.
RAPH12WEL0200AA 10
12. Loosen end clamp on intake port side of the engine.
Remove tube with hose.
RAPH12WEL0202AA 11
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10.310 / 6

Screen cover removal
13. Unlatch the rubber T-handle from the screen cover.
NOTE: Screen cover may be different from what is shown.
RAPH12WEL0190AA 12
14. Lift screen cover part way. Pull cotter pin and washer
from screen tab and locking bar prop.
RAPH12WEL0189AA 13
84605841 14/05/2012
10.310 / 7

15. Open screen cover completely and remove the bolts.
Lift and remove cover.
NOTE: Always use proper lifting devices.
RAPH12WEL0181AA 14
air cooler unit removal
NOTE: For Commodity King, include instruction 16. For Standard 721F omit instruction 16 and go to instruction 17.
Commodity king only
16. Lift side panels. Unbolt and remove left and right
beam seals, then lower side panels.
NOTE: Left side shown.
RAPH12WEL0222AA 15
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10.310 / 8

17. With a sharp cutting tool, make a slice in the gasket
(arrowed) near the shoulder bolt.
RAPH12WEL0177AA 16
18. Remove shoulder bolt, washers and nut (1) from air
conditioner condenser unit (2).
RAPH12WEL0221AA 17
19. Lift air conditioner condenser up and angle toward
the back of the cab. Support in place if needed.
RAPH12WEL0146AA 18
84605841 14/05/2012
10.310 / 9

20. Lift up side panels. Remove the left and right side
bolt of air cooler unit.
RAPH12WEL0169AA 19
21. Remove front bolts of air cooler unit.
RAPH12WEL0174AA 20
22. Remove air cooler unit out of cooler package frame-
work.
RAPH12WEL0172AA 21
Next operation:
Aftercooler - Testing (10.310)
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10.310 / 10

Aftercooler - Install
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
Prior operation:
Aftercooler - Remove (10.310) Aftercooler - Testing (10.310)
1. Attach frame to air cooler assembly. Bolt in place
with four bolts and washers.
RAPH12WEL0172AA 1
2. Using proper lifting equipment, lift and position com-
pleted air cooler unit into the cooler package frame-
work with the tubes situated within the front plate
cut–out, facing the engine (1). Insert two bolts (2)
and partially set.
NOTE: Do not tighten bolts at this time.
RAPH12WEL0174AA 2
3. Raise side panel and insert bolt into each side of the
air cooler unit. Run bolt PART way.
4. Once air cooler unit is semi–secured, tighten sides
and front bolts, then lower side panels.
RAPH12WEL0169AA 3
84605841 14/05/2012
10.310 / 11

5. Slide air conditioner condenser unit back in place.
RAPH12WEL0145AA 4
6. Using a shoulder bolt, three washers and a nut (1),
secure air conditioner condenser unit (2) in place.
RAPH12WEL0221AA 5
7. Flip latch closed on air conditioner condenser unit.
RAPH12WEL0179AA 6
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10.310 / 12

8. Line up screen cover and run center bolt PART way
(1). Insert outer bolts (2) then securely tighten all
three bolts.
NOTE: Screen cover may be different than shown.
NOTE: For Commodity King, continue instructions. Stan-
dard 721F go to instruction 12.
RAPH12WEL0181AA 7
Commodity king only
9. Lift side panel. Attach hood beam seal with weather
stripping shield facing up.
NOTE: Left side panel shown.
RAPH12WEL0222AA 8
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10.310 / 13

10. Slide beam seal onto hood hinge stud and tighten in
place with washer and nut.
RAPH12WEL0184AA 9
11. Insert two bolts on opposite end of beam seal and
frame. Tighten in place with washers and nuts.
NOTE: Repeat procedure on right side.
RAPH12WEL0185AA 10
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10.310 / 14

Screen cover installed
12. Raise screen cover locking bar prop on left side.
RAPH12WEL0187AA 11
13. Partially lower screen cover, lining up screen tab with
locking bar prop.
RAPH12WEL0188AA 12
84605841 14/05/2012
10.310 / 15

14. Place washer on the outside of hinge followed with a
cotter pin to secure in place.
RAPH12WEL0189AA 13
15. Close screen cover, locking in place with the rubber
T–handle.
RAPH12WEL0190AA 14
84605841 14/05/2012
10.310 / 16

Hood installed
16. Line up hood hinge bolt holes to frame. Partially set
bolts to hold in place. Once hood lines up evenly,
tighten all bolts and torque to 65 - 79 N·m (48 - 58 lb
ft).
RAPH12WEL0169AA 15
17. Turn electrical master switch on and electrically lower
lift cylinder, lining up holes. Insert pin through both
holes.
18. Return electrical master switch to the off position.
RAPH12WEL0191AA 16
19. Insert cotter pin through rear of cylinder pin, securing
lift cylinder in place.
RAPH12WEL0192AA 17
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10.310 / 17

20. Remove hood lifting device.
RAPH12WEL0193AA 18
21. Replace exhaust stack. Insert stack studs through
the pre-drilled holes on the top of the hood.
NOTE: Exhaust stack opening faces toward the rear.
RAPH12WEL0195AA 19
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10.310 / 18

22. On underside of hood, place reinforce plate (1) over
stack studs (2), securing in place with washers and
nuts. Torque to 36 - 44 N·m (27 - 32 lb ft).
RAPH12WEL0194AA 20
Turbocharger tube installation
23. Remove plug from turbocharger. Place the upper
end of the hose onto the air cooler tube. DO NOT
CLAMP at this time.
NOTE: Note direction of clamps.
RAPH12WEL0207AA 21
24. On the opposite end, make sure that O–ring is in
elbow fitting.
RAPH12WEL0204AA 22
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10.310 / 19

25. Align O–ring end of tube to turbocharger.
RAPH12WEL0205AA 23
26. Clamp in place. Torque to 10.1 - 11.3 N·m (7.4 - 8.3
lb ft).
RAPH12WEL0206AA 24
27. Return to top air cooler tube connection and torque
clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) in place.
NOTE: Note direction of clamps.
RAPH12WEL0207AA 25
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10.310 / 20

Intake port tube installation
28. Lightly lubricate inside of hose (1). Slide hose over
top end of tube (2).
RAPH12WEL0199AA 26
29. Slide hose back far enough to clear right side air
cooler tube.
RAPH12WEL0200AA 27
30. Align opposite end of tube to the intake port manifold
side of the engine. Make sure there is clearance
between hood and exhaust stack on both sides of
tube.
RAPH12WEL0197AA 28
84605841 14/05/2012
10.310 / 21

31. Slide clamps in place and tighten. Torque to 10.1 -
11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0202AA 29
32. Line up top tube and slide hose over air cooler tube
until hose fits flush against the frame. Slide clamps
in place and tighten Torque to 10.1 - 11.3 N·m (7.4 -
8.3 lb ft).
NOTE: Note the direction of clamps.
RAPH12WEL0201AA 30
33. Turn power on (1), activate hood cylinder (2) and
close hood.
RCPH11WHL653BAU 31
Next operation:
Aftercooler - Pressure test (10.310)
84605841 14/05/2012
10.310 / 22

Aftercooler - Pressure test
CAUTION
Eye injury hazard!
Use caution when removing the cap due to possible air pressure.
Failure to comply could result in minor or moderate injury.
C0056A
CAUTION
Eye injury hazard!
Always wear eye or full face protection when performing this procedure.
C0081A
1. Park machine on a level surface and lower the bucket
to the ground. Put transmission in neutral, apply the
parking brake, then turn off engine.
RCPH10WHL350FAH 1
2. Raise hood. Remove the turbocharger outlet tube.
Plug tube and turbocharger.
NOTE: Plug is dealer fabricated.
RAPH12WEL0205AA 2
3. Remove inlet hose (1) from manifold (2). Plug inlet
hose and with pressurized air, pressurize the system
between 15 - 20 psi.
NOTE: Always wear eye or full face protection when per-
forming this procedure.
NOTE: Pressurized plug is dealer fabricated.
RAPH12WEL0202AA 3
84605841 14/05/2012
10.310 / 23

4. For air leaks or lack of pressure, inspect cooler com-
ponents for damage or missing parts.
RAPH12WEL0181AA 4
5. Inspect the turbocharger top air cooler outlet flex
hose for leaks or holes and ensure that the clamps
are tight.
RAPH12WEL0207AA 5
6. Inspect the manifold top air cooler inlet flex hose for
leaks or holes and ensure that the clamps are tight.
RAPH12WEL0201AA 6
84605841 14/05/2012
10.310 / 24

7. Visually inspect top of air cooler for damage or leaks.
NOTE: If the leak source has not been located, remove and
test the air cooler using Aftercooler - Testing (10.310).
RCPH10WHL139AAH 7
Pressure test reassemble
8. Unplug and remove pressurized air system from
manifold. Realign tube on manifold. Make sure
there is clearance between the hood and exhaust
stack on both sides of the tube. Tighten clamp and
torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0202AA 8
9. Remove plug from turbocharger tube. Remove plug
from turbocharger. Make sure gasket remained in-
side turbocharger tube.
RAPH12WEL0204AA 9
84605841 14/05/2012
10.310 / 25

10. Align tube ends and secure in place with clamp.
Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0206AA 10
11. Lower hood.
RCPH11WHL653BAU 11
12. Close screen and T-handle secure in place (if avail-
able). Put transmission in park and turn off.
RAPH12WEL0190AA 12
84605841 14/05/2012
10.310 / 26

Aftercooler - Testing
N° Test Point Expected Result Other Result (Possible Cause)
1 Condition
Check the core for leaks by clos-
ing off the outlet tube and attaching
regulated air pressure 550 kPa ( 80
psi) to the inlet tube. Submerge the
cooler in water and watch for air leak-
age.
Check
Result
Action
If leakage is detected replace the af-
ter cooler.
Action
bs03b028 1
84605841 14/05/2012
10.310 / 27

Index
Engine - 10
Aftercooler - 310
Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Aftercooler - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Aftercooler - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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10.310 / 28

Engine - 10
Engine cooling system - 400
621F
721F
84605841 14/05/2012
10.400 / 1

Contents
Engine - 10
Engine cooling system - 400
SERVICE
Radiator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84605841 14/05/2012
10.400 / 2

CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 242 Radiator - Install 10.400 / 16
84605841 14/05/2012
10.400 / 3

Engine - Engine cooling system
Radiator - Remove
1. Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
Then place articulation lock in locked position.
RCPH10WHL063BAL 1
2. Put master disconnect switch in OFF position.
RCPH11WHL653BAU 2
3. Raise the center cooler box cover (1). Have another
person lift and hold the cooler box side panel (2) up
into the raised position.
RAIL12WEL0099AA 3
84605841 14/05/2012
10.400 / 4

4. Remove the mounting screws for the side panel, and
remove the panel.
RAIL12WEL0097AA 4
RAIL12WEL0098AA 5
5. Remove the thumb screw and washer (1) securing
left hand inner fender panel (2) and remove fender.
RAIL12WEL0100AA 6
84605841 14/05/2012
10.400 / 5

6. Remove radiator cap.
NOTE: Machine pictured includes the heavy duty/high de-
bris cooling option. Your machine may differ slightly in ap-
pearance.
RAIL12WEL0103AA 7
7. Place a suitable container below radiator drain.
Then remove drain cap and drain coolant into con-
tainer. Install and secure both caps after coolant has
drained.
RCPH10WHL054BAL 8
8. Release catch and tilt air conditioning condenser
core up.
RAIL12WEL0101AA 9
84605841 14/05/2012
10.400 / 6

9. Loosen the upper radiator hose clamp and remove
the hose from radiator.
RAIL12WEL0102AA 10
10. Disconnect overflow hose from radiator.
pearance.
RAIL12WEL0103AA 11
11. Remove cooler box support brace bolts (1). Then
remove cooler box support brace (2).
NOTE: This step only required for machines equipped with
the heavy duty/high debris cooling option.
pearance.
RAIL12WEL0104AA 12
84605841 14/05/2012
10.400 / 7

12. Remove coolant overflow bottle.
RAIL12WEL0105AA 13
13. Remove coolant overflow bottle support bracket.
RAIL12WEL0107AA 14
14. Remove cooling fan screen shroud.
RAIL12WEL0109AA 15
84605841 14/05/2012
10.400 / 8

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