Case 1021G Bedienungsanleitung

1/2 SERVICE MANUAL

1021G

1121G

Tier 2

Wheel Loader

Part number 48083742

English

July 2018

1021G

1121G

Wheel Loader

Part number 48083742

SERVICE MANUAL

SERVICEMANUAL

1021GZBAR-EH,NEWCABTIER2

1121GZBAR-EH,NEWCABTIER2

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Contents

INTRODUCTION

Engine.......................................................................................10

[10.001]Engineandcrankcase.............................................................10.1

[10.216]Fueltanks..........................................................................10.2

[10.202]Aircleanersandlines..............................................................10.3

[10.400]Enginecoolingsystem.............................................................10.4

[10.414]Fananddrive......................................................................10.5

[10.310]Aftercooler..........................................................................10.6

[10.304]Enginelubricationsystem..........................................................10.7

Transmission..............................................................................21

[21.113]Powershifttransmission............................................................21.1

[21.135]Powershifttransmissionexternalcontrols..........................................21.2

[21.105]Powershifttransmissionhydrauliccomponents....................................21.3

[21.155]Powershifttransmissioninternalcomponents......................................21.4

Four-WheelDrive(4WD)system..................................................23

[23.314]Driveshaft..........................................................................23.1

Frontaxlesystem.......................................................................25

[25.100]Poweredfrontaxle.................................................................25.1

[25.102]Frontbevelgearsetanddifferential...............................................25.2

[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3

Rearaxlesystem........................................................................27

[27.100]Poweredrearaxle..................................................................27.1

[27.106]Rearbevelgearsetanddifferential................................................27.2

[27.120]Planetaryandnaldrives..........................................................27.3

Brakesandcontrols....................................................................33

[33.202]Hydraulicservicebrakes...........................................................33.1

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[33.110]Parkingbrakeorparkinglock......................................................33.2

Hydraulicsystems.......................................................................35

[35.000]Hydraulicsystems..................................................................35.1

[35.300]Reservoir,cooler,andlters........................................................35.2

[35.106]Variabledisplacementpump.......................................................35.3

[35.359]Maincontrolvalve..................................................................35.4

[35.357]Pilotsystem........................................................................35.5

[35.204]Remotecontrolvalves.............................................................35.6

[35.752]Hydraulicfandrivecoolingsystem.................................................35.7

[35.701]Frontloaderarmhydraulicsystem.................................................35.8

[35.723]Frontloaderbuckethydraulicsystem..............................................35.9

Framesandballasting.................................................................39

[39.100]Frame..............................................................................39.1

Steering.....................................................................................41

[41.101]Steeringcontrol....................................................................41.1

[41.200]Hydrauliccontrolcomponents......................................................41.2

[41.216]Cylinders...........................................................................41.3

[41.910]Auxiliarysteering...................................................................41.4

Wheels......................................................................................44

[44.511]Frontwheels........................................................................44.1

[44.520]Rearwheels........................................................................44.2

Cabclimatecontrol.....................................................................50

[50.100]Heating.............................................................................50.1

[50.200]Airconditioning.....................................................................50.2

Electricalsystems.......................................................................55

[55.100]Harnessesandconnectors.........................................................55.1

[55.201]Enginestartingsystem.............................................................55.2

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[55.301]Alternator...........................................................................55.3

[55.512]Cabcontrols........................................................................55.4

[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.5

[55.415]Loaderarmandbucketcontrolsystem............................................55.6

[55.530]Camera.............................................................................55.7

[55.518]Wiperandwashersystem..........................................................55.8

[55.DTC]FAULTCODES....................................................................55.9

Frontloaderandbucket...............................................................82

[82.100]Arm.................................................................................82.1

[82.300]Bucket..............................................................................82.2

Platform,cab,bodywork,anddecals.............................................90

[90.150]Cab.................................................................................90.1

[90.118]Protectionsandfootboards.........................................................90.2

[90.120]Mechanically-adjustedoperatorseat...............................................90.3

[90.124]Pneumatically-adjustedoperatorseat..............................................90.4

[90.105]Machineshieldsandguards.......................................................90.5

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INTRODUCTION

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Contents

INTRODUCTION

Safetyrules.....................................................................................3

Personalsafety.................................................................................4

Basicinstructions-Importantnoticeregardingequipmentservicing.........................13

Basicinstructions-Howtousethemaintenancestandardandprecautions.................14

Basicinstructions-Precautionfordisassemblyandassembly...............................16

Basicinstructions-Electricalequipmentprecautions........................................18

Consumables-BiodieselFuel................................................................19

Consumables.................................................................................20

Hydrauliccontamination......................................................................22

Productidentication-Machineorientation..................................................23

Productidentication..........................................................................24

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INTRODUCTION

Safetyrules

Personalsafety

Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall

safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.

ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-

structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.

Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.

DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.

WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.

CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.

FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT

INDEATHORSERIOUSINJURY .

Machinesafety

NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.

ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor

propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.

Information

NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.

ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or

otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.

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INTRODUCTION

Personalsafety

CarefullyreadthisManualbeforeproceedingwithmain-

tenance,repairs,refuellingorothermachineoperations.

Repairshavetobecarriedoutonlybyauthorizedandin-

structedstaff;specicprecautionshavetobetakenwhen

grinding,weldingorwhenusingmalletsorheavyham-

mers.

Non-authorizedpersonsarenotallowedtorepairorcarry

outmaintenanceonthismachine.Donotcarryoutany

workontheequipmentwithoutpriorauthorization.

Askyouremployeraboutthesafetyinstructionsinforce

andsafetyequipment.

Nobodyshouldbeallowedinthecabduringmachine

maintenanceunlessheisaqualiedoperatorhelping

withthemaintenancework.

Ifitisnecessarytomovetheequipmenttocarryoutre-

pairsormaintenance,donotliftorlowertheequipment

fromanyotherpositionthantheoperator’sseat.

TULI12WEX2004AA1

Nevercarryoutanyoperationonthemachinewhenthe

engineisrunning,exceptwhenspecicallyindicated.

Stoptheengineandensurethatallpressureisrelieved

fromhydrauliccircuitsbeforeremovingcaps,covers,

valves,etc.

Allrepairandmaintenanceoperationsshouldbecarried

outwiththegreatestcareandattention.

Servicestairsandplatformsusedinaworkshoporinthe

eldshouldbebuiltincompliancewiththesafetyrulesin

force.

Anyfunctionaldisorders,especiallythoseaffectingthe

safetyofthemachine,shouldthereforeberectiedim-

mediately.

DANGER

Unexpectedmovement!

Makesureparkingbrakeisapplied.Secure

machinewithwheelchocks.

Failuretocomplywillresultindeathorserious

injury.D0013A

TULI12WEX2005AA2

Beforeperforminganyworkonthemachine,attacha

maintenanceinprogresstag.Thistagcanbeappliedon

theleft-handcontrollever,safetyleverorcabdoor.

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INTRODUCTION

Emergency

Bepreparedforemergencies.Alwayskeepareextin-

guisherandrstaidkitreadilyavailable.Ensurethatthe

reextinguisherisservicedinaccordancewiththeman-

ufacturer’sinstructions.

SMIL12WEX0174AA3

Equipment

Wearclosettingclothingandsafetyequipmentappropri-

ateforthejob:

•Safetyhelmet

•Safetyshoes

•Heavygloves

•Reectiveclothing

•Wetweatherclothing

Ifworkingconditionsrequire,thefollowingpersonalsafety

equipmentshouldbeonhand:

•Respirators(ordustproofmasks)

•Earplugsoracousticearsprotections

•Goggleswithlateralshieldormasksforeyeprotection

Donotwearrings,wristwatches,jewelry,unbuttonedor

appingclothingsuchasties,tornclothes,scarves,open

jacketsorshirtswithopenzipswhichcouldgetcaughtinto

movingparts.

TULI12WEX2008AA4

Engine-Radiator

Neverleavetheenginerunninginenclosedspaceswith-

outproperventilationwhichisabletoevacuatetoxicex-

haustgases-Keeptheexhaustmanifoldandtubefree

fromcombustiblematerials.

Donotrefuelwiththeenginerunning,especiallyifhot,as

thisincreasesrehazardincaseoffuelspillage.

Neverattempttocheckoradjustthebeltswhentheen-

gineisrunning.

Neverlubricatethemachinewiththeenginerunning.

TULI12WEX2009AA5

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