821F

921F
Tier 4
Wheel Loader

SERVICE MANUAL

Printed in U.S.A. Part number 84487565

1st edition English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. April 2011
Racine Wisconsin 53404 U.S.A.
 1001
Section
1001

GENERAL TORQUE SPECIFICATIONS

1001-2

TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
 1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
Pound- Newton
used.
Size Inches metres
1/4 inch 144 to 180 16 to 20
Grade 5 Bolts, Nuts, and Studs
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73

Pound- Newton Pound- Newton

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/16 inch 204 to 252 23 to 28 1/2 inch 110 to 132 149 to 179
3/8 inch 420 to 504 48 to 57 9/16 inch 160 to 192 217 to 260
5/8 inch 220 to 264 298 to 358
Pound- Newton 3/4 inch 380 to 456 515 to 618
Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
3/4 inch 270 to 324 366 to 439
1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983
1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or 10.9
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is Pound- Newton
used. Size Inches metres
M4 36 to 48 4 to 5
Grade 8.8 Bolts, Nuts, and Studs M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
8.8
M8 324 to 384 37 to 43

Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres

M5 60 to 72 7 to 8 M10 54 to 64 73 to 87

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

M20 450 to 540 610 to 730

Pound- Newton M24 780 to 940 1050 to 1275

Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
Grade 12.9 Bolts, Nuts, and Studs
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9
fasteners.
 1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Inches metres Hose ID Size Inches metres
1/4 inch 7/16-20 72 to 144 8 to 16 1/4 inch 7/16-20 144 to 228 16 to 26
6.4 mm 6.4 mm
5/16 inch 1/2-20 96 to 192 11 to 22 5/16 inch 1/2-20 192 to 300 22 to 34
7.9 mm 7.9 mm
3/8 inch 9/16-18 120 to 300 14 to 34 3/8 inch 9/16-18 300 to 480 34 to 54
9.5 mm 9.5 mm
1/2 inch 3/4-16 180 to 504 20 to 57 1/2 inch 3/4-16 540 to 804 57 to 91
12.7 mm 12.7 mm
5/8 inch 7/8-14 300 to 696 34 to 79
15.9 mm Tube OD Thread Pound- Newton
Hose ID Size Feet metres
Tube OD Thread Pound- Newton 5/8 inch 7/8-14 58 to 92 79 to 124
Hose ID Size Feet metres 15.9 mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 3/4 inch 1-1/16-12 80 to 128 108 to 174
19.0 mm 19.0 mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 7/8 inch 1-3/16-12 100 to 160 136 to 216
22.2 mm 22.2 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1.0 inch 1-5/16-12 117 to 187 159 to 253
25.4 mm 25.4 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
31.8 mm 31.8 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
38.1 mm 38.1 mm

Split Flange Mounting Bolts

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61

Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

O-ring Face Seal End Fitting or Lock Nut
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
6.4 mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm

Thread Pound- Newton

Size Feet metres
-10 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
15.9 mm

Nom. 1-1/16-12 85 to 90 115 to 122

SAE
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Feet metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm
 1002
Section
1002

FLUIDS AND LUBRICANTS

1002-2

TABLE OF CONTENTS
821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
 1002-3

821F - CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts
Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts)
Type of oil .........................................Case AKCELA No. 1 engine oil see engine oil recommendations on page 4
Engine Cooling System
Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
DEF (Diesel Exhaust Fluid) Tank
Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts)
Hydraulic System
Hydraulic Reservoir Refill Capacity ..........................................................................90.8 liters (24.0 U.S. Gallons)
Total System Capacity............................................................................................... 178 liters (47.0 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts)
Type of Oil ....................................................................................................................................... Case Nexplore
Axles
Capacity
Front...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Type of Lubricant ............................................................................................................................. Case Nexplore
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System)................................................................ Case AKCELA Hy-Tran Ultra®
1002-4

921F - CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts)
Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts)
Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
DEF (Diesel Exhaust Fluid) Tank
Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts)

Hydraulic System
Hydraulic Reservoir Refill Capacity ........................................................................... 110 liters (29.0 U.S. Gallons)
Total System Capacity............................................................................................... 200 liters (53.0 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts)
Type of Oil ....................................................................................................................................... Case Nexplore
Axles
Capacity
Front...................................................................................................................... 42.0 liters (44.4 U.S. Quarts)
Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Type of Lubricant............................................................................................................................. Case Nexplore
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
 1002-5

ENGINE OIL RECOMMENDATIONS

Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CH-4 (preferred) or CG-4.
S e e t h e c h a r t b e l ow fo r
recommended viscosity at
ambient air temperature
ranges.
BD03A102
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
RH99K130
intervals given in this manual
are according to tests with Case
AKCELA lubricants.

BC02N250
1002-6

TRANSMISSION TEMPERATURE CHART

RCPH10WHL435BAH3

DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
power and high fuel consumption. If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following Note.
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel as cool as possible. Remove water from the storage
requirements in your area. If the temperature of the container at regular periods of time.
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel Fill the fuel tank at the end of the daily operating
filter and cause the engine to lose power or not start. period to prevent condensation in the fuel tank.

The diesel fuel used in this machine must meet the

specifications as shown below in, “Specifications for
Acceptable No. 2 Diesel Fuel”, or “Specification
D975-81” of the American Society for Testing and
Materials.

Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%
 1002-7

What is Selective Catalytic Reduction (SCR)?

The main components of the SCR system include the • Keep container tightly closed.
SCR catalyst, the Diesel Exhaust Fluid (DEF)/ • Keep container in a cool, well-ventilated area.
AdBlue® injection unit, the DEF/AdBlue® tank, and
the DEF/AdBlue® dosing control unit. • Keep away from heat and direct sunlight.
Thawing
How does Selective Catalytic Reduction
• The machine is equipped with an internal tank
(SCR) work?
heater to thaw frozen DEF/AdBlue®. The machine
During combustion, harmful Nitrogen Oxide (NOx) will still function until the DEF/AdBlue® begins to
molecules are formed in the exhaust. By injecting a flow. The SCR system will then function normally.
DEF/AdBlue® solution into the exhaust prior to a
• Do not heat DEF/AdBlue® for long periods of time
catalyst, the NOx can be converted to harmless
at temperatures above 30 °C (86 °F). This causes the
elemental Nitrogen and water. This happens when
solution to decompose, which very slowly decreases
the NOx molecules react inside the catalyst with the
the expected shelf life.
heat generated by the engine and the ammonia in
the DEF/AdBlue® solution. NOTICE: Do not use an anti-gelling or freeze point
improver in your DEF/AdBlue®. The 32.5 % solution
During cold engine operation at low engine coolant
and ambient air temperatures, water vapor will be is specifically designed to provide the optimum NOx
visible from the exhaust when the engine operates. reduction properties. Any further blending or adjust-
This water vapor will resemble steam or light white ing of the DEF/AdBlue® mixture will lessen its ability
smoke and will dissipate as the engine and machine to perform correctly and may cause damage to the
components warm and is considered normal. SCR components.
NOTE: After engine shutdown, the SCR system will Handling and supply of additives, if any.
perform a purge cycle, which permits the supply • Personal Protective Equipment (PPE) is not
module to continue to run for up to 70 seconds. This required under normal conditions. If splashing is
is to be considered normal and requires no action likely, wear eye protection. For prolonged or repeated
from the operator. contact, imper vious gloves are recommended.
Follow the precautions listed in the SAFETY
What is Diesel Exhaust Fluid
INFORMATION chapter when handling any service
(DEF)/AdBlue®? fluid.
DEF/AdBlue® is a non-toxic aqueous urea solution ( • No additives are required.
3 2 .5 % ) w i th a s l i g h t a m m o n i a o d o r u s e d to
NOTICE: Contaminated DEF/AdBlue® can affect the
chemically reduce NOx emissions from heavy-duty
diesel powered vehicles. performance of your machine. Follow all instructions
in this manual when handling DEF/AdBlue®.
DEF/AdBlue® is neither explosive nor harmful to the
environment and is classified under the minimum-risk Shelf life
category of transpor table fluids. DEF/AdBlue® Constant ambient storage temperature and
quality is defined by ISO 22241-1. The
minimum shelf life
American Petroleum Institute (API®) has a Less than or equal to 10 °C (50 °F) 36 months
voluntary certification program for DEF/AdBlue®. To
Less than or equal to 25 °C (77 °F) ¹ 18 months
ensure DEF/ AdBlue® satisfies the requirements of
Less than or equal to 30 °C (86 °F) 12 months
ISO 22241. DEF/AdBlue®. API Diesel Exhaust Fluid
Certification Mark is a registered trademark of API in Less than or equal to 35 °C (95 °F) 6 months
the United States and or other countries. Greater than 35 °C (95 °F) -²
¹ To prevent decomposition of DEF/AdBlue®,
Storage, handling, and transport
prolonged transportation or storage above 25 °C (77
NOTICE: Storage temperatures above 30 °C (86 °F) °F) should
greatly reduce the shelf life of DEF/AdBlue®. be avoided.
DEF/AdBlue® has a typical shelf life of 6-12 months.
² Significant loss of shelf life: check every batch
Refer to the SHELF LIFE table below. In order for before use. See your [Brand] dealer for more
DEF/AdBlue® to remain in a usable condition, stor- information on testing.
age requirements need to be met.
• Store between -11 °C (12 °F) and 30 °C (86 °F).
• Use only an approved DEF/AdBlue® container.
1002-8

NOTE: The main factors taken into account to define Glossary Acronym Definition
the shelf life in the previous figures are the ambient DEF Diesel Exhaust Fluid
storage temperature and the initial alkalinity of ISO International Organization
DEF/AdBlue®. The difference in evaporation for Standardization
between vented and non-vented storage containers
is an additional factor. MSDS Material Safety Data Sheet
NOTE: The information in this table is for reference NOx Nitrogen Oxide
only and has been provided by the International
PPE Pe r s o n a l Protective
Organization for Standardization, Document number Equipment
ISO 22241-3 Diesel engines - NOx reduction agent
AUS 32 - Part 3: Handling, transportation and stor- SCR Selective Catalytic
Reduction
age.
Disposal ULSD Ultra Low Sulfur Diesel
• Dispose of DEF/AdBlue® and any filter
accumulations in accordance with all applicable
Federal, State, and local laws governing waste
disposal.
For machines sold in California CNH must warrant
the diesel emission control system in the application
for which it is sold or leased to be free from defects in
design, materials, workmanship, or operation of the
diesel emission control system which cause the
diesel emission control system to fail to conform to
the emission control performance level it was verified
to, or to the requirements in the California Code of
Regulations, Title 13, Sections 2700 to 2706, and
2710, for the periods of time listed below, provided
there has been no abuse, neglect, or improper
maintenance of your diesel emission control system,
vehicle or equipment, as specified in the owner’s
manuals. Where a warrantable condition exists, this
warranty also covers the engine from damage
caused by the diesel emission control system,
subject to the same exclusions for abuse, neglect or
improper maintenance of your vehicle or equipment.
Please review your owner’s manual for other
warranty information. The diesel emission control
system may include a core part (e.g., particulate
filter, diesel oxidation catalyst, selective catalytic
reduction converter) as well as hoses, connectors,
and other emission-related assemblies.
 1002-9

SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS

Requirements Diesel Exhaust Fluid (DEF)/AdBlue®
The operator must maintain appropriate consumption
DEF/AdBlue® levels at all times. The SCR system is NOTE: DEF/AdBlue® consumption is highly
compatible with up to 7% bio-diesel fuel. dependent on engine loads, humidity levels,
Diesel Exhaust Fluid (DEF)/AdBlue® DEF/AdBlue® fluid concentration, and engine speed.
The “typical” consumption is only a guideline to verify
refilling
proper function of the SCR system. CNH
The DEF/AdBlue® tank cap (1) can be identified by recommends to fill the DEF/AdBlue® tanks at every
the “blue” color of the cap. A fitting under the cap fuel refilling interval.
prevents the insertion of a diesel fill nozzle.
NOTE: If any DEF/AdBlue® spills or contacts any
surface other than the storage tanks, immediately
clean the affected surface with clear water.
DEF/AdBlue® will cause corrosion on painted and
unpainted metallic surfaces, and may distort some
plastic and rubber components.
It i s r e c o m m e n d e d t h a t D E F /A d B l u e ® f i l l i n g
equipment should be used having a fill nozzle/pump
with the correct length and diameter, triggered by the
magnet in the tank filler neck and with overfill flow cut
out.
This will ensure that:
● The screen in the filler neck will not be damaged.
● Impurities are not entering the DEF/AdBlue® tank.
The standardized DEF/AdBlue® nozzle matches
the filler neck diameter.
● The DEF/AdBlue® tank is not overfilled, as the
DEF/AdBlue® pump will stop when the
DEF/AdBlue® tank is full.
● DEF/AdBlue® is not pumped in the fuel tank, as
the DEF/AdBlue® nozzle cannot pump when the
magnet is not sensed.
NOTICE: Refilling with a funnel is not recommended
as this may lead to damage of the screen in the filler
neck.
NOTE: The information above has been provided by
the International Organization for Standardization
(ISO), Document number ISO 22241-4 Diesel
engines - NOx reduction agent AUS 32 - Part 4:
Refilling interface.
1002-10

MAINTENANCE SCHEDULE
FREQUENCY IN HOURS

Initial Service

LUBRICATE
SERVICE

REPLACE
NUMBER

CHANGE
SERVICE POINTS

ADJUST
INTERVAL

CHECK

CLEAN

DRAIN
ITEM

2 Radiator Coolant Level *

13 Tires *
16 Hydraulic Filter *
Variable 12 Alternator, AC, Drive Belt *
Periodic
(* ) 31 Air cleaner * *
19 Bleed Fuel Filter of Condensation *
28 Clean SCR system DEF tank filter *
XX Fire extinguisher *
Every 10 Hours 1 Check Engine Oil Level 10

13 Check Engine Coolant Level 50

3 Check Transmission Oil Level 50
Every 50 Hours 4 Check Hydraulic Oil Level 50
5&6 Grease Bucket Mounting Fittings 50
7 Grease machine and attachments 50
16 Change Engine Oil and Filters 100
18 Replace Fuel Filters 100
20 Change Hydraulic Filter 100
First 100 Hours
25 Change Oil in Axles 100
13 Check wheel torque 100
28 Clean in-line DEF supply filter 100
Lubricate The Steering Cylinder Pivots - Rod And
8 100
Closed End (4 Fittings)

Every 100 Hours 9 Grease Front Drive Shaft Support Bearing 100
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
10 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
11 Check Cab Air Filter 250

Every 250 14 Check Tire Pressure & Wheel Torque 4 250

Hours 12 Check Drive Belt 250
XX Trans Clutch Calibration (See Section 6002) 250 1000
14 Check Axle Oil Level 500
15 Check Battery Electrolyte Level 500

Every 500 16 Change Engine Oil and Filter 500

Hours XX Check ROPS 500
18 Drain Fuel Tank Condensation & Water Separator 500
19 Replace Fuel Filter 500
 1002-11

20 Replace Hydraulic Oil filter 1000

21 Grease Articulation Fittings 1000
24 Change crankcase filter 1000 1000
23 Replace Drive Belt
Every 1000
11 Replace Cab Air Filter 1000
Hours
26 Change Transmission Oil and Filter 1000
XX Check Injector Calibration 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 1000
21 Change Front & Rear Axle Oil 1500
Every 1500
26 Change Transmission Oil and Filter 1500
Hours
28 Clean in-line DEF filter
29 Change Hydraulic Oil 2000
30 Change Coolant 2000
Every 2000
31 Replace Engine Air Cleaner 2000
Hours
32 Lubricate cab and door 2000
XX Valve Clearance (Engine Manual) 2000

Every 3000
XX Replace DEF supply module filter 3000
Hours

Every 6000 XX Engine Injectors (Engine Manual) 6000

Hours XX Fuel Pump (Engine Manual) 6000 6000
1002-12

MAINTENANCE POINTS

84397762

See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the ser vice items on this char t. Operators and
service manuals are available for this machine from
your dealer.
 Section
1003

1003
METRIC CONVERSION CHART
1003-2

TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
 1003-3

CONVERSION FACTORS

Metric to U.S.
MULTIPLY BY TO OBTAIN

Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre

Force: newton 3.596 942 ounce force

newton 0.224 809 pound force

Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)
1003-4

U.S. to Metric
MULTIPLY BY TO OBTAIN

Area: square foot 0.092 903 square meter

acre 0.404 686 hectare

Force: ounce force 0.278 014 newton

pound force 4.448 222 newton

Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer

Mass: pound 0.453 592 kilogram

ounce 28.35 gram

Mass/Area: ton/acre 2241 702 kilogram/hectare

Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr

Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter

Power: horsepower 0.745 700 kilowatt

Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter

Velocity: miles/hr. 1.609 344 * kilometer/hr.

Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre

Volume/Time: gallon/min. 3.785 412 litre/min.

* = exact
 Section
2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000
2000-2

TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 2000-3

ENGINE

Removal STEP 5

STEP 1

BD02N160

Put a 30 liter (32 U.S. quart) container below radiator

BD03A040
drain. Remove radiator cap. Remove cap and drain
Park machine on a level surface and lower bucket to coolant into container. Install cap after coolant has
ground. Put articulation lock in LOCKED position. drained. Install radiator cap.

STEP 2 STEP 6
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.

STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.

STEP 4
BD02N160

Put a 15.1 liter (16 U.S. quart) container below

engine oil drain. Remove cap and drain oil into
container. Install cap after oil has drained.
NOTE: After draining oil disconnect drain hose from
frame for removal with engine.

BD06F108

The master and hood raise switch are located by the

battery box. Raise the hood with the hood lift motor.
Put master disconnect switch in OFF position.
Remove both batte r y cove rs and disconn ec t
batteries from the machine.
2000-4
STEP 7 STEP 10

BD03A231 BD06F109

Double up a nylon lifting strap (1) and slide through Tag and disconnect hood wiring harness connector
the exhaust stack (2) on the hood. from rear chassis wiring harness connector.

STEP 8 STEP 11

1
BD03A230 BD03A227

Place a solid steel bar through the strap, raise the

hood and release tension on the lifting motor.

STEP 9

BD03A226

Remove mount bolt (1) and backup alarm wiring

harness clamp from cooler housing. Have another
person balance the hood and remove the hood hinge
BD03A228 mounting bolts (2) from the cooler frame.
Remove the pin from the top of the lifting motor.
 2000-5
STEP 12 STEP 15

BD03A232 BD06F110

Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner,
hood onto suitable platform and disconnect lifting remove the intake hose.
equipment.
STEP 16
STEP 13

BD06F110

BD03A224 Loosen the clamp on the turbocharger for the after

Tag and disconnect engine wiring harness connector cooler inlet hose.
from air filter restriction switch.
STEP 17
STEP 14

BD03A115

BD03A225 Loosen the clamp on the after cooler and remove the
Loosen clamp on air cleaner intake hose and remove after cooler inlet hose from the machine.
the crankcase ventilation hose.
2000-6
STEP 18 STEP 21

BD06F112
BD06F111

Loosen the clamp on the intake manifold for the after Remove the air cleaner and muffler from the bracket.
cooler output hose.
STEP 22
STEP 19

BD06F113

BD03A118

Loosen the clamp on the after cooler and remove the

after cooler outlet hose from the machine.

STEP 20

BD06F114

Remove the four mounting bolts from the belt cover,

remove the cover.
NOTE: After removing the belt cover remove the
cover mounting brackets from the machine frame.
BD06F110

Loosen the exhaust clamp from the turbocharger.

 2000-7
STEP 23 STEP 26

BD06F115 BD06F118

Remove the drive belt from the engine. Tag and disconnect the wiring from the alternator.

STEP 24 STEP 27

BD06F116 BD06F119
Loosen clamps and remove lower cooler hose from Remove bolt securing wiring harness clamp to
the engine. engine.

STEP 25 STEP 28

1
1
2
2

BD06F117 BD06F120

If loader is equipped with air conditioning, identify, Remove bolt securing wiring harness clamp (1) to the
tag, and disconnect the engine wiring harness engine. Remove ground wires (2) from the engine.
connectors from air compressor clutch connector (1).
Remove the thre e m oun tin g b olts (2) for the
compressor and set the compressor on the left
battery cover.
2000-8
STEP 29 STEP 32

2 3

BD06F121 BD06F111

Tag and remove the wires from the starter solenoid Tag and remove the grid heater cable.
(3), remove the ground cable (2), and ground strap
(1) from the starter. STEP 33
NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.

STEP 30

BD03A142

Disconnect the wiring harness from the EDC 7

controller.
NOTE: Lifting up on the lever will release the
connector from the controller.
BD06F146

Disconnect the engine coolant vent hose and root to STEP 34

the rear of the engine.

STEP 31

BD06F123

Remove the fuel line from the top of the EDC 7

controller, plug the line and cap the fitting.
BD06F122

Remove the radiator hose (1) from the rear of the

engine, remove the heater hose from the rear of the
engine (2), remove the clamp bolts and clamps (3)
from the bell housing.
 2000-9
STEP 35 STEP 38

BD06F127
BD06F124

Tag and disconnect the fuel filter heater wires (1), Remove the lower cover for the drive shaft.
disconnect the fuel line (2) from the fuel filter head,
plug the line and cap the fitting. STEP 39

STEP 36

BD03A172

Remove the drive shaft bolts from the flywheel. Move

BD06F125 the drive shaft clear of the flywheel.
Remove bolt and clamp.
STEP 40
STEP 37 Connect suitable lifting equipment to engine lifting
brackets. Take up all slack in lifting equipment.
Remove the engine mounting bolts and lift the engine
enough to gain access to the drain hose, pull the
drain hose with the engine.

STEP 41
Slowly raise engine from rear chassis. Be sure all
h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n
disconnected and are clear of the engine. Remove
engine from machine.

BD06F126

Connect and turn on vacuum pump to hydraulic

reservoir. Tag and remove the hydraulic lines from
the brake system pump, plug the lines and cap the
fittings.
2000-10

Installation

1
2 1
3 2
3

1 4
4 5
2
5
3 6
6
7
7
8 4
5
6
7
BS03B035

1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT

2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE

STEP 42 STEP 47
If engine rubber isolators require replacement,
remove and discard isolators (3 and 4). Install new
rubber isolator (4), then rubber isolator (3).

STEP 43
Slowly raise engine and move into position over rear
chassis. Be sure all harness connections and hoses
are out of the way then lower engine. Put washer (5)
between front rubber isolator (4) and chassis. Install
washer (2), bolt (1), washer (6), and nut (7) in engine
isolators. Lower engine into position.
BD03A172

STEP 44 At front of engine, position drive shaft on engine

Tighten engine mounting bolts to a torque of 244 to coupling. Install six bolts to secure drive shaft to
298 Nm (180 to 220 lb-ft). engine coupling. Tighten the six bolts to a torque of
53 to 62 Nm (39 to 46 lb-ft).
STEP 45
Disconnect lifting equipment from engine lifting
brackets.

STEP 46
Connect engine oil drain hose to frame bracket.
 2000-11
STEP 48 STEP 51

BD06F127 BD06F124
Install the lower cover for the drive shaft. Remove cap from fitting and plug from the hose,
connect fuel line (2). Connect fuel filter heater wires
STEP 49 (1). Remove and discard tag.

STEP 52

BD06F126

Connect and turn on vacuum pump to the hydraulic

reservoir. Remove caps from fittings and plugs from BD06F123
hoses. Connect hoses to brake pump following tags Remove cap from fitting and plug from the hose,
installed during removal. Remove and discard tags. connect fuel line to EDC 7.
Turn off and disconnect vacuum pump from hydraulic
reservoir. STEP 53
STEP 50

BD03A142

Connect wiring harness to EDC 7 controller.

BD06F125

Install bolt and clamp for fuel return hose. NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector
into position.
2000-12
STEP 54 STEP 57

2 3

BD06F111 BD06F121

Connect grid heater cable to grid heater. Remove Install the wires to the starter solenoid (3), install the
and discard tag. ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.
STEP 55
STEP 58
3
1
2
2
1

BD06F122
BD06F120
Install the heater hose (2) to the rear of the engine,
mount the clamps (3), install the radiator hose (1). Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.
STEP 56
STEP 59

BD06F146

Connect the engine coolant vent hose. BD06F119

Install bolt securing wiring harness clamp to engine.

 2000-13
STEP 60 STEP 63

BD06F118 BD06F115

Connect the wiring to the alternator. Remove and Install the drive belt.
discard tags.
STEP 64
STEP 61

BD06F113

BD06F117

If loader is equipped with air conditioning, mount the

compressor using the three mounting bolts (2),
connect the engine wiring harness connectors to air
compressor clutch connector (1). Remove and
discard tags.

STEP 62

BD06F114

Install the cover mounting brackets to the machine

frame. Install the belt cover, install the four mounting
bolts for the belt cover.

BD06F116

Install lower cooler hose to the engine and tighten the

clamps to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch).
2000-14
STEP 65 STEP 68

BD06F112 BD06F111
Place the muffler and air cleaner on the bracket. Tighten the clamp on the intake manifold for the after
Install mounting bolts in air cleaner and tighten, cooler output hose.
install the mounting bolts in the muffler and leave
loose at this time. STEP 69
STEP 66

BD03A115

Place the after cooler inlet hose on the machine.

BD06F110
Tighten the clamp on the after cooler.
Install and tighten the exhaust clamp on the
turbocharger, tighten the muffler mounting bolts. STEP 70
STEP 67

BD06F110

Tighten the clamp on the turbocharger for the after

BD03A118 cooler inlet hose.
Place the after cooler outlet hose on the machine.
Tighten the clamp on the after cooler.
 2000-15
STEP 71 STEP 74

BD06F110 BD03A232

Install the intake hose and tighten the clamps on Carefully raise and place hood over loader.
turbocharger and air cleaner.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 72
STEP 75

BD03A225
1
Install the crankcase ventilation hose and tighten the
BD03A227
clamp on air cleaner intake hose.

STEP 73

BD03A226

Have another person balance the hood, install the

hood hinge mounting bolts (2) to the cooler frame.
BD03A224 Install mount bolt (1) and backup alarm wiring
Connect engine wiring harness connector to air filter harness clamp to cooler housing.
restriction switch. Remove and discard tag.
2000-16
STEP 76 STEP 78

BD03A221
BD03A228

Install the pin from the top of the lifting motor, lower NOTE: If hood strut is not adjusted properly the
and remove lifting equipment. hood will be damaged.
When a hood is removed and replaced an initial
STEP 77 adjustment on the strut is necessary. Adjust between
the top of the lift motor adjusting jam nut (1) to the top
of the threads (2) to 20 mm (X). With the motor down
to its lowest point take a measurement between the
left hand side hood bumper and the counter weight,
record this measurement (Y). Use the following table
to adjust the strut (X).
Hood Adjustment Table
Y X Y X Y X Y X
(MM) (MM) (MM) (MM) (MM) (MM) (MM) (MM)
1 19 21 14 41 9 61 5
2 19 22 14 42 9 62 5
BD06F109
3 18 23 14 43 9 63 4
Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and 4 18 24 13 44 9 64 4
discard tag. 5 25 45 65
18 13 9 4
6 18 26 13 46 8 66 4
7 17 27 13 47 8 67 3
8 17 28 12 48 8 68 3
9 17 29 12 49 8 69 3
10 17 30 12 50 7 70 3
11 16 31 12 51 7 71 2
12 16 32 12 52 7 72 2
13 16 33 11 53 7 73 2
14 16 34 11 54 6 74 2
15 16 35 11 55 6 75 2
16 15 36 11 56 6 76 1
17 15 37 10 57 6 77 1
18 15 38 10 58 6 78 1
19 15 39 10 59 5 79 1
20 14 40 10 60 5 80 0
 2000-17
STEP 79 STEP 85

BD02N160 BD06F108

Check and make sure that drain caps are tight. Lower the hood with the hood lift motor.

STEP 80 STEP 86
Install a new oil filter on engine. Fill engine with 13.25 Put articulation lock in OPERATING position.
liters (14 U.S. quarts) of Case AKCELA Engine Oil
(SAE 15W-40).

STEP 81
If hydraulic reservoir was drained, fill reservoir of the
821F with 90.8 liters (24.0 U.S. gallons) of Case
AKCELA Hy-Tran Ultra® fluid. Fill the reservoir of the
921F with 110 liters (29.0 U.S. gallons) of Case
AKCELA Hy-Tran Ultra® fluid.

STEP 82
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 30 liters (32 U.S. quarts). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.

STEP 83
Connect the batteries, install battery covers, put
master disconnect switch in ON position.

STEP 84
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
an d wat er. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
2000-18

RADIATOR

Removal STEP 5

STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.

STEP 2

BD06F128

Remove bolt and washer securing LH fender.

Remove LH fender.

STEP 6

BD03A040

Put articulation lock in LOCKED position.

STEP 3
Put master disconnect switch in OFF position.

STEP 4

BD02N160

Put a 30.0 liter (32.0 U.S. quart) container below

radiator drain. Remove radiator cap then remove cap
and drain coolant into container. Install cap after
coolant has drained. Install radiator cap.

STEP 7

BD03A120

Have another person raise and hold the side panel

up into the raised position. Remove the two mounting
screws for the side panel, remove the panel.
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.

BD03A109

Release catch and tilt air conditioning condenser

core up to gain access to upper radiator hose.
 2000-19
STEP 8 STEP 11

2 2

BD03A108 BD03A106

Loosen the upper radiator hose clamps, remove the Remove screws and install lifting eyes (1). Attach
hose. suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.
STEP 9

BD06F129

Loose and remove the lower radiator hose from the

radiator.

STEP 10

BD03A113

Disconnect overflow hose from radiator. Disconnect

connector from coolant level sender.
2000-20

Installation STEP 15

STEP 12
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.

STEP 13

1
BD06F129

At bottom of radiator, install bottom radiator hose.

2 2
Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 16

BD03A106

Install four lock washers and bolts (2) to secure

ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g
equipment from lifting eyes. Remove lifting eyes and
install screws (1).

STEP 14

BD03A108

At top of cooling system frame, install hose. Position

hose clamps and tighten to a torque of 10.1 to 11.3
Nm (90 to 100 lb-inch).

STEP 17

BD03A113

Connect connector to coolant level sender, connect

overflow hose to radiator.

BD06F130

When installing fender make sure it is behind the

fender mounting bolt.
 2000-21
STEP 18 STEP 21

BD06F131 BD03A120

Align the whole in the fender on the bolt. Have another person raise and hold the side panel
up into position. Apply Loctite 242 to the threads,
STEP 19 install the two mounting screws for the side panel
and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5
pound-inches).
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.

STEP 22

BD06F132

Align the slots in the fender with the tabs on the body
of the machine.

STEP 20

BD02N160

Check that coolant drain cap is tight.

STEP 23
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 30 liters (32.0 U.S. quarts). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.

DSC00105.TIF

Push the fender towards the front of the machine and

secure it using washer and bolt.
2000-22
STEP 24 WARNING: Hot coolant can spray out if radiator cap
Put master disconnect switch in ON position. is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
STEP 25
radiator cap.
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately STEP 26
five minutes to completely mix the Ethylene Glycol
Put articulation lock in OPERATING position.
an d wate r. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
 2002
Section
2002

STALL TEST
2002-2

TABLE OF CONTENTS
821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
 2002-3

821F SPECIFICATIONS
Engine with 4 Speed Transmission
A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm
C. Converter Stall ............................................................................................................................1883 to 1963 rpm
D. Hydraulic Stall .............................................................................................................................1883 to 1963 rpm
E. Converter & Hydraulic Stall .........................................................................................................1497 to 1577 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

Engine with 5 Speed Transmission

A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm
C. Converter Stall ............................................................................................................................1860 to 1900 rpm
D. Hydraulic Stall .............................................................................................................................1923 to 2003 rpm
E. Converter & Hydraulic Stall .........................................................................................................1524 to 1604 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.

STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
2002-4

921F SPECIFICATIONS
Engine with 4 Speed Transmission
A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm
C. Converter Stall ............................................................................................................................1900 to 1940 rpm
D. Hydraulic Stall .............................................................................................................................1860 to 1940 rpm
E. Converter & Hydraulic Stall .........................................................................................................1525 to 1605 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

Engine with 5 Speed Transmission

A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2135 to 2185 rpm
C. Converter Stall ............................................................................................................................1945 to 1985 rpm
D. Hydraulic Stall .............................................................................................................................2017 to 2097 rpm
E. Converter & Hydraulic Stall .........................................................................................................1531 to 1611 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.

STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
 2002-5

INSTRUMENT CLUSTER DISPLAYS

1. With the engine running, press the up or down
key and scroll through the information screens
and trip screens. The following sequence is using
the down key only.
NOTE: Pressing the escape key will return the LCD
back to the normal driving screen.

BD06F027

4. Info 2 will be displayed next. The Info 2 screen

will display coolant temperature, engine oil
temperature in either Fahrenheit or Celsius, as
well as oil pressure.

BD06F188

2. From the driving screen push the down arrow, as

shown.

BD06F184

5. Push the down button again for the Info 3 screen.

T h i s s c r e e n d i s p l ay s t h e t e m p e ra t u r e i n
Fahrenheit or Celsius of the transmission oil,
hydraulic oil, sump oil.
BD06F183

3. Info 1 is the first information screen using the

down arrow from the driving screen. It displays
engine RPM’s, speed, and fuel level.
2002-6

BD06F169

6. Press the down button again and the Trip 1

screen will display. The LCD provides two trip
computers. These will display since last reset the
total time in hours, the total fuel, and the average
fuel consumption per hour.

BD06F170

7. By continuing to scroll down, the fifth screen will

display the Trip 2 screen. Trip 1 and Trip 2
screens can be reset independently. The
previous screen can be accessed by using the
up arrow key.
 2002-7

PROCEDURE TO HEAT THE OIL

Torque Converter Hydraulic System

1. Sit in the seat. 1. Apply the parking brake.
2. Start the engine and run the engine at low idle. 2. Start the engine and run at full throttle.
3. To measure the oil temperature with the 3. To measure the oil temperature with the
instrument cluster: instrument cluster:
A. Press the up or down arrow key. A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures B. Stop at the info screen with the temperatures
that need to be monitored. that need to be monitored are on.
4. Place the declutch switch in the OFF position. 4. Hold the bucket control lever in the ROLLBACK
position while raising and lowering the lift arms
5. Place the automatic switch in the manual mode
from ground level to full height.
position. Push down and hold the brake pedal for
the remainder of this procedure. 5. Continue this procedure until the temperature of
the hydraulic oil is 54° to 57°C (129° to 134°F).
6. Release the parking brake.
7. Move the transmission control lever to Forward
and turn the transmission control lever to 3rd
gear.
8. Increase the engine speed to full throttle and run
the engine at this speed for 30 seconds.
9. Decrease the engine speed to low idle and move
the transmission control lever to the Neutral
position for 15 seconds.
10. Repeat steps 7, 8, and 9 until the temperature of
the torque converter oil is 82° to 104°C (180° to
220°F).
2002-8

POWER MODE SELECTION

1. After the oil temperatures have been raised to 3. Use down arrow to scroll through the menu’s.
operating temperatures the power mode must be
4. High light Power Mode and press the enter key.
set to “Auto”.
5. Power Mode Menu
A. Max - Maximum power possible
B. Standard - Standard operation
C. Auto - Will cycle between Max and Standard
D. Eco - Limited power for economy
6. High light Auto mode and press the enter key.
7. Press the escape key to return to the normal
driving screen.

BD06H038

2. Press and hold the confirmation “enter” button for

two seconds to arrive at the above ser vice
screen.
 2002-9

PERFORMING STALL TESTS

Test No. 1 - Torque Converter and Test No. 2 - Torque Converter Stall
Hydraulic Stall Together 1. Sit in the seat.
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
3. Press the brake pedal, release the park brake, shift into Forward.
shift into Forward.
4. Run the engine at low idle.
4. Run engine at low idle. Push the clutch cutout
5. Push down and hold the brake pedal for the
switch to OFF. Put the transmission in manual
remainder of this test.
mode. Push down and hold the brake pedal for
the remainder of this procedure. 6. Turn the transmission control lever to third gear.
5. Turn the transmission control lever to third gear. 7. Increase the engine speed to full throttle.
6. Increase the engine speed to full throttle. 8. Check the engine speed.
7. Hold the bucket control lever in the ROLLBACK 9. Decrease the engine speed to low idle.
position and raise the lift arms.
10. Place the transmission in neutral and apply the
NOTE: The stall speed must be read while the lift parking brake.
arms are in motion.
11. Stop the engine.
8. Check the engine speed.
9. Release the bucket control lever. Understanding the Results of Test
No. 2
10. Decrease the engine speed to low idle.
1. If the engine speed was as specified, the engine,
11. Lower the bucket to the ground, place the torque converter and transmission are probably
transmission in neutral and apply the parking good.
brake.
2. If the engine speed was more than specified, the
12. Stop the engine. problem can be in the torque converter or the
t r a n s m i s s i o n . S e e S e c t i o n 6 0 0 2 fo r
Understanding the Results of Test troubleshooting information.
No. 1 3. If the engine speed was less than specified, do
1. If the engine speed was as specified, the engine, Test No. 3.
torque converter, transmission and hydraulic
system are probably good.
2. If the engine speed was not as specified, do Test
No. 2 and 3.
2002-10

Test No. 3 - Hydraulic Stall Understanding the Results of Test

1. Sit in the seat. No. 3
1. If the engine speed was as specified, the engine
2. Start the engine and run the engine at low idle.
and hydraulic system are good.
3. Increase the engine speed to full throttle.
2. If the engine speed was more or less than
4. Hold the bucket control lever in the ROLLBACK specified the main relieef setting may be too low
position and raise the lift arms. or too high. See Section 8002 for troubleshooting
information.
NOTE: The stall speed must be read while the lift
arms are in motion. 3. If the engine speed was less than specified in all
tests, the engine is probably the cause.
5. Check the engine speed.
6. Release the bucket control lever.
7. Decrease the engine speed to low idle.
8. Lower the bucket to the ground.
9. Stop the engine.
Section
2003

2003
AFTER COOLER
2003-2

TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
 2003-3

TROUBLESHOOTING AFTER COOLER

STEP 1
Park machine on level ground, lower the bucket. Put
transmission in neutral, apply the parking brake. Turn
off engine.

STEP 2
Raise hood. Install ‘T’ fitting in waste gate valve hose.
Attach pressure gauge. Install another pressure
gauge into the intake manifold port.

STEP 3
Have assistant start engine and run at 2000 r/min BD03A118
(rpm). Record pressure readings for both gauges. If Inspect the after cooler outlet flex hose for leaks or
the pressure difference is greater than 60 mbar holes and insure that the clamps are tight.
(0.87 psi), inspect cooler components for damaged
or missing parts.
STEP 6
STEP 4

BD03A119

Inspect the intake manifold flex hose for leaks or

BD03A116
holes and insure that the clamps are tight.
Inspect the turbocharger flex hose for leaks or holes
and insure that the clamps are tight.
STEP 7
STEP 5

BD03A109

Visually inspect top of after cooler for damage or

BD03A115
leaks
Inspect the after cooler inlet flex hose for leaks or
holes and insure that the clamps are tight. NOTE: If the leak source has not been located,
remove and test the after cooler.
2003-4

AFTERCOOLER REMOVAL

Removal STEP 4

STEP 1

BD03A118

Loosen clamps and remove air cooler outlet hose.

BD03A116

Loosen clamps and remove turbocharger outlet STEP 5

components.

STEP 2

BD03112

Raise air conditioning/air cooler cover. Support cover

with appropriate lifting device. Remove cover support
BD03A115 latch.
Loosen clamps and remove air cooler inlet hose.
STEP 6
STEP 3

BD03A111
BD03A119 Remove three cover mounting bolts and lift cover off.
Loosen clamps and remove Intake hose.
 2003-5
STEP 7 STEP 10

BD03A109 BD03A113

Unlatch air conditioning condenser clamp. Remove two bolts, one from each side of the after
cooler mounting frame.
STEP 8
STEP 11
L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h
appropriate lifting devise.

STEP 12

BD03A107

Rotate air conditioning condenser up and remove the

two retaining bolts, one on each side. Move the air
conditioning condenser back away from the air cooler

STEP 9 BD03A111

Remove four bolts that mount air cooler in the air

cooler frame. Remove air cooler from frame.

BD03A117

Remove the two bolts at the rear of the after cooler

mounting frame.
2003-6

Leak Test Installation

STEP 1

BD03A111

BS03B028 Install after cooler in its frame. Install four mounting

Check the core for leaks by closing off the outlet tube bolts. Support after cooler with appropriate lifting
and attaching regulated air pressure 550kPa (80psi) device. Install the after cooler and frame in the
to the inlet tube. Submerge the cooler in water and machine.
watch for air leakage.
STEP 2
NOTE: If leakage is detected replace the after
cooler.

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

Install two bolts at the rear of the after cooler

mounting frame.
 2003-7
STEP 4 STEP 7

BD03A107 BD03A116

Position air conditioner condenser and install Install air cooler inlet hose. Tighten clamps at
mounting bolts. Rotate the condenser down and turbocharger outlet.
latch.
STEP 8
STEP 5

BD03A115

BD03112 Tighten clamps at air cooler inlet.

Support cover with appropriate lifting device. Raise
air conditioning/air cooler cover over machine. Install STEP 9
cover support latch.

STEP 6

BD03A119

Install air cooler outlet hose and tighten clamps at

engine intake.
BD03A111

Install three cover mounting bolts.

2003-8
STEP 10 STEP 11
Install ‘T’ fitting in waste gate valve hose. Attach
pressure gauge. Install another pressure gauge into
the intake manifold port.

STEP 12
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges.
confirm that the pressure difference is less than 60
mBar (0.87 psi).

BD03A118

Tighten clamps at air cooler outlet.

 Section
2010

ENGINE INTAKE AIR FILTRATION

2010
2010-2

TABLE OF CONTENTS
Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
 2010-3

AIR FILTRATION

Pre-cleaner Disassembly & STEP 3

Reassembly
STEP 1

IMG_1682.AI.TIF

Disassemble and remove precleaner from machine.

721F-8469.PNG

Access pre-cleaner located on top of engine

STEP 4
compartment hood.

STEP 2

IMG_1680.AI.TIF

Empty debris and clean wipe precleaner with a damp

clean cloth. Reassemble/install unit on machine.

IMG_1683.AI.TIF

Loosen wing nut.

2010-4

Primary/Secondary Fillter Element STEP 3

Disassembly
STEP 1

1 2

IMG_0115.PNGD

Release all clips securing air filter element housing

cover.
721F-8469.PNG
STEP 4
Raise engine compartment hood using controls
located behind access cover (1). Air filter
housing/element (2) is located in main engine
compartment on left hand side of engine.

STEP 2

IMG_0142.PNG

Remove cover from air filter element housing.

STEP 5

IMG_0099.PNG

Turn master electric switch “off”.

IMG_0143A.PNG

Remove primary filter element by lifting up on handle

 2010-5
STEP 6 STEP 2

IMG_0144A.PNG IMG_0143A.PNG

Remove secondary filter element from right side of Install new primary filter element by sliding it down
housing. Remove debris from inside filter element into housing.
housing before installing new filter elements.
NOTE: Make sure primary and secondary filter
NOTE: Do not clean the seconday filter element. It elements form an effective seal.
must be replaced if damaged or clogged.
STEP 3
Primary/Secondary Element
Reassembly
STEP 1

IMG_0142.PNG

Install housing cover.

STEP 4
IMG_0144A.PNG

Install new secondary filter element by inserting it

into positioning slot.
NOTE: Make sure filter element is firmly seated into
housing.

721F-8508.PNG

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.
2010-6
STEP 5

IMG_0099.PNG

Turn master electric power switch “on”. Clear any

fault codes. Start machine and confirm problem has
been corrected.
 Section
2020

SCR SYSTEM SENSORS

2020
2020-2

TABLE OF CONTENTS
SCR System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NOx Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
 2020-3

SCR SYSTEM SENSORS

Upstream Exhaust Temperature STEP 3

Sensor Removal
2
NOTE: Do not use impact wrenches on the exhaust 1
system unless the sensors are removed.”

STEP 1

IMG_0912.TIF

Locate exhaust temperature sensor (1) on exhaust

system before the catalyst (2).

721F-8469.PNG STEP 4
Raise the hood using controls located behind the
access cover.

STEP 2

IMG_1507.TIF

Loosen hex nut on sensor.

IMG_0099.PNG

Turn master electric switch to the “off” position.

2020-4
STEP 5 Upstream Exhaust Temperature
Sensor Reinstall
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.”

STEP 1

IMG_1510.JPG

Remove temperature sensor from exhaust system.

STEP 6

IMG_1510.TIF

Install temperature sensor into exhaust pipe.

STEP 2

IMG_1514.TIF

Remove wire ties securing wire harness to support

brackets. Unplug sensor from machine wiring
harness and remove it.

IMG_1507.TIF

Secure sensor into exhaust pipe. Sensor torque 40 to

50 Nm (30 to 36 lb ft.). Reconnect sensor to wire
harness and secure harness to support brackets
using new wire ties.
 2020-5
STEP 3 STEP 2

IMG_0099.PNG IMG_0099.PNG

Turn master electric switch to “on” position. Clear any Turn master electric switch to the “off” position.
fault code. Start engine and check to see if problem
has been corrected. STEP 3

Downstream Exhaust Temperature 1 2

Sensor Removal
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.”

STEP 1

IMG_1465.TIF

Locate the exhaust temperature sensor (1) on

exhaust system after catalyst (2).

STEP 4

721F-8469.PNG

Raise the hood using controls located behind the

access panel.

GRAPHIC_ID

Loosen hex nut and remove sensor from exhaust

system.
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