Month: August 2018

Case 845B, 865B, 885B

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Case 845B, 845B DHP, 865B, 865B VHP, 865B AWD, 885B, 885B DHP, 885B AWD Grader. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your 845B/845B DHP/865B/865B VHP/865B AWD/885B/885B DHP/885B AWD like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Case 845B, 845B DHP, 865B, 865B VHP, 865B AWD, 885B, 885B DHP, 885B AWD Grader is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

FILELIST:
71114392 – 845B, 845B DHP, 865B, 865B VHP, 865B AWD, 885B, 885B DHP, 885B AWD Grader Service Manual.pdf
84300294 – 845B, 865B, 885B Grader Operators’s Manual.pdf

EXCERPT:

6000-48
INPUT SHAFT, OUTPUT SHAFT AND CLUTCHES KV / KR / K1 / K2 / K3 / K4
Removal
Force out both cylindrical pins (1).
Loosen bolted connection (2) between housing front and rear part and separate housing rear part by means of lifting device.
(S) Eye bolt M20 0636 804 003
(S) Eye nut M12 0664 462 774
Loosen bolted connection (1) of oil screen sheets.
Remove output shaft (1) and lower oil screen sheet (2) from housing.
FIGURE 75
FIGURE 76
FIGURE 77
Remove all rectangular rings (1) from the clutches and all Orings (2) from the oil tubes.
Use lifting device to bring housing rear part (1) into contact position with housing front part (2) again.
(S) Eye bolt M20 0636 804 003
(S) Eye nut M12 0664 462 774
Due to the installation conditions, the removal of single clutches without using the special tool is not possible. Risk of injury.
Fix all clutches by means of handle (1).
(S) Handle 5870 260 010
Separate housing rear part incl. clutches from housing front part by means of the lifting device and attach it to the assembly truck.
Loosen cylindrical screws of oil tubes (1) in the housing front part and remove them.
NOTE: The suction tube (2) and the lubrication lines
(3) are rolled in and are highly difficult to remove. In case of damage, use of the appropriate ZF special tool is imperative for fitting or replacing these components.
(S) Suction tube 0501 210 712
(S) Rolling tool 5870 600 003
Remove bearing outer rings (arrows) from the housing front part.
NOTE: If, contrary to the ZF recommendation, the tapered roller bearings of clutches, input and output are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/ bearing inner ring).
Bearing outer ring and bearing inner ring must be marked.
Lift the clutches out of the housing in numerical order as described in the legend.
Remove bearing outer rings (arrows) from the housing rear part.
NOTE: If, contrary to the ZF recommendation, the tapered roller bearings of clutches, input and output are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/ bearing inner ring).
Bearing outer ring and bearing inner ring must be marked.
…

Case 721D

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Case 750L, 850L Crawler Dozer. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Case 750L, 850L Crawler Dozer like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Case 750L, 850L Crawler Dozer is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

“87728445.pdf”
750L, 850L TIER 3 Crawler Dozer Repair Manual
1,513 pages

“87479855.pdf”
750L, 850L TIER 3 Crawler Dozer Operator’s Manual
144 pages

EXCERPT:
POWER PRODUCTION – STARTING SYSTEM
Engine starter- Remove
1. Park the machine on a level surface.
2. Lower the attachments to the floor.
3. Apply the parking brake and stop the engine, remove the key from the ignition switch.
4. Fasten a Do Not Operate tag to the instrument panel.
5. Open the left rear ROPS door.
6. Put the battery disconnect switch in the off position.
7. Open the right-hand side engine panel.
8. Remove the right-hand side lower panel.
NOTE: If two batteries are installed, there are two battery cables connected to the starter.
9. Fasten identification tags to the wires for the starter.
Disconnect the wire from the bottom of the starter solenoid. Pull the rubber boot away from the terminal
and disconnect the battery cable(s) and the three wiring harness from the side of the starter solenoid.
10. Support the starter. Loosen and remove the two bolts, washers and clamp. Remove the starter.
Next operation:
Engine starter- Disassemble (B.SO.A) or Engine starter- Preliminary test (B.SO.A).
Engine starter- Install
Prior operation:
Engine starter- Electrical test (B.80.A),
1. Position the starter in the flywheel housing.
2. Install the two bolts, washers, and clamp to fasten the starter to the flywheel housing. Torque the bolts to 68 – 77 Nm (50 – 57 lb ft).
3. Connect the battery cable(s) and the three wiring harness wires to the side of the starter solenoid and torque to 2.6 – 4.6 Nm (23 – 41 lb in). Connect the wire to the bottom of the starter solenoid and torque to 17.7- 24.5 Nm (13- 18 lb ft). Push the rubber boot onto the terminal.
4. Install the right-hand side lower panel.
5. Close the right-hand side engine panel.
6. Put the battery disconnect switch in the on position.
7. Close the left rear ROPS door.
8. Remove the Do Not Operate tag from the instrument panel.
Engine starter – Preliminary test
Prior operation:
Engine starter – Remove (B.SO.A).
Prior operation:
Before starting the No-Load Test the following testing equipment must be obtained:
(a) One Sun Electric CAS10147 Tester, an equivalent tester, or separate pieces oftest equipment.
(b) One hand held tachometer to measure the speed of the armature shaft.
(c) One remote starter button to actuate the starter.
(d) One fully charged 12 volt battery to supply the electricity to turn the starter.
Prior operation:
Before starting the No-Load test, check to see if:
(a) The gear on the starter drive can be pulled out of the starter housing.
(b) The starter drive can be turned. To do this, pull the gear on the starter drive out of the starter drive housing. Turn the gear to turn the starter drive and the armature. If the starter can not be turned, disassemble the starter and make repairs as needed.
NOTE: The starter needs to be removed from the engine before the No-Load Test can be done.
NOTE: The No-Load Test should be done at 20 oc ( 68 °F).
1. If the Sun Electric CAS10147 is being used, turn the AMP Range switch to ( 0- 100 amps), turn the Volt
2. Range switch to ( 18 – 40 volts), flip the Volt Lead switch to the “EXT.” position and turn the Load Control dial to the “OFF” position.
3. If the other test equipment is being used, connect the test equipment according to the above procedure and follow the manufacturer’s instructions.
Fasten the starter in a vise or use another method to prevent the starter from moving. This must be done to prevent personal injury.
Connect the positive battery cable to the battery terminal on the starter solenoid and the negative battery cable to the mounting flange of the starter.
(1) Positive battery cable
(2) Battery terminal
(3) Negative battery cable
…

Case 721D

Complete workshop & service manual with electrical wiring diagrams for Case 721D Loader. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Case 721D Loader service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

“6-47281.pdf”
Case 721D Loader Service Manual; 6-47281; 762 pages

EXCERPT:
STEERING CYLINDER LEAK TEST
NOTE: Make sure all persons are clear of the area of the center pivot. Make sure the center pivot is free of any obstructions.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
3. Stop the engine and apply the parking brake.
4. Find the tube that is connected to the rod end of the left-hand steering cylinder. Disconnect the tube from the left-hand cylinder.
5. Install a plug in the tube.
6. Start and run the engine at full throttle.
7. Turn the steering wheel to the right. Hold the steering wheel for a full right turn. Have another person check for leakage from the opening of the rod end of the left-hand steering cylinder.
8. If there is constant leakage from the rod end, the piston packing in the left-hand steering cylinder is damaged. Repairs must be made. See Section 5005.
9. Connect the tube to the rod end of the left-hand steering cylinder.
10. Turn the machine all the way to the left.
11. Stop the engine.
12. Find the tube that is connected to the rod end of the right-hand steering cylinder. Disconnect the tube from the right-hand steering cylinder.
13. Install a plug in the tube.
14. Start and run the engine at full throttle.
15. Turn the steering wheel to the left. Hold the steering wheel for a full left turn. Have another person check for leakage at the opening of the rod end of the right-hand steering cylinder.
16. If there is constant leakage from the rod end, the piston packing in the right-hand steering cylinder is damaged. Repairs must be made. See Section 5005.
17. Connect the tube to the rod end of the right-hand steering cylinder.
…

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Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Case 621F, 721F Wheel Loader.Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Case 621F, 721F Wheel Loader like a professional mechanic in local service/repair workshop.This cost-effective quality manual is 100% complete and intact as should be without any missing pages.It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Case 621F, 721F Wheel Loader is divided into different sections.Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.A table of contents is placed at the beginning of each section.Pages are easily found by category, and each page is expandable for great detail.It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices.You do not need to be skilled with a computer to use the manual.

FILELIST:
47387703 – 621F Tier 4 Wheel Loader Service Manual.pdf
84474094 – 621F, 721F Tier 4 Wheel Loader Operator’s Manual (Replaces part number 84376871).pdf
84487558 – 721F Tier 4 Wheel Loader Service Manual (1-2-4 GeneralInformation_Engine_ElectricalSystem).pdf
84487559 – 721F Tier 4 Wheel Loader Service Manual (5-6 Undercarriage_DriveTrain).pdf
84487560 – 721F Tier 4 Wheel Loader Service Manual (7-8-9 UndercarriageHydraulics_UpperstructureHydraulics_Upperstructure).pdf
84488413 – 721F Tier 4 Wheel Loader Service Manual.pdf
84605841 – 621F, 721F Tier 4 Wheel Loader Service Manual (from PIN NBF213602 and above).pdf

EXCERPT:
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
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
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

Front axle system – Front bevel gear set and differential
Limited slip differential – Assemble – DL-2400
721F
CAUTION: Burn hazard! Always wear heat-resistant protective gloves when handling heated parts. Failure to comply could result in minor or moderate injury.
Prior operation:
Limited slip differential – Disassemble — DL-2400 (25.102)
1. Mount two M16 x 1.5 locating pins (S) and press heated crown wheel onto differential housing until contact is made.
2. Insert thrust washer into differential housing.
3. Mount outer and inner discs in alternating order starting with an outer disk.
NOTE: The installation clearance of internal parts is corrected by mounting outer discs of different thicknesses.
NOTE: The difference in thickness between the left and right disc package must be less than 0.1 mm (0.004 in).
4. Install pressure ring.
5. Install axle bevel gear until contact is made. Then install inner discs with teeth.
6. Preassemble the differential spider and insert it into the differential housing/pressure ring.
7. Install second axle bevel gear.
8. Install second thrust ring into differential housing.
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Case 721E

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INSTANT DOWNLOAD

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Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Case 721E Wheel Loader. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Case 721E like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Case 721E is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

“84243980.pdf”
721E TIER 3 Wheel loader Service Manual
970 pages
84243980
(Replaces 87634099)
Revised December 2009
Issued September 2007

“5-3070.pdf”
721E Wheel Loader Electrical Schematic
Part Number: 5-3070
BC06J371-00A

“87479861 NA.pdf”
721E, 821E Tier 3 Operator’s Manual
268 pages
87479861 NA
Issued 03-2008
Replaces 87364251 NA

EXCERPT:
721E Wheel Loader
Service Manual 84243980
(Replaces 87364099)
Table of Contents
General Tab 1
Section Index – General 5-2670
Standard Torque Specifications 1001 8-71603
Fluids and Lubricants 1002 5-2680
Metric Conversion Chart 1003 7-52950
Engines Tab 2
Section Index – Engines 5-2690
Engine and Radiator Removal and Installation 2000 5-2700
Stall Tests 2002 5-2710
After Cooler 2003 6-49850
For Engine Repair, See the Engine Service Manual 87519803
Fuel System Tab 3
Section Index – Fuel System 5-2720
For Fuel System Repair, See the Engine Service Manual
Electrical Tab 4
Section Index – Electrical 5-2730
Removal and Installation of Starter and Alternator 4001 5-2740
Electrical Specifications and Troubleshooting 4002 5-2750
Batteries 4003 6-42330
Instrument Cluster 4005 5-2760
Steering Tab 5
Section Index – Steering 84298386
(Replaces 5-2770)
Removal and Installation of Steering Components 5001 5-2780
Steering Specifications, Pressure Checks, and Troubleshooting 5002 5-2790
Steering Cylinders 5005 5-2800
Center Pivot 5006 5-2810
Auxiliary Steering Motor and Pump 5008 6-42430
Joystick Steering 5009 5-17020
Section Index – Power Train 84251801
(Replaces 5-2820)
Removal and Installation of Power Train Components 6001 5-2830
Transmission Specifications, Pressure Checks, and Troubleshooting 6002 5-2840
Transmission 6003 5-2850
Front Axle 6004 5-2860
Rear Axle 6004 5-2870
Rear Axle, Serial Number N8F203816 and After 6004 84243983
Drive Shafts, Center Bearing, and Universal Joints 6005 5-2880
Wheels and Tires 6006 6-47730
Transmission Control Valve 6007 6-81450
Brakes Tab 7
Section Index – Brakes 5-2890
Removal and Installation of Brake Components 7001 5-2900
Hydraulic Brake Troubleshooting 7002 5-2910
Brake Pump 7003 5-2920
Brake Accumulators 7004 6-47761
Parking Brake 7008 5-2930
Hydraulics Tab 8
Section Index – Hydraulics 5-2940
Removal and Installation of Hydraulic Components 8001 5-2950
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 5-2960
Cleaning the Hydraulic System 8003 7-49641
Hydraulic Pump 8004 5-2970
Loader Control Valve 8005 5-2980
Cylinders 8006 5-2990
Coupler Solenoid Locking Valve 8007 6-42600
Ride Control Accumulator 8013 5-3000
Ride Control Valve 8014 5-3010
Mounted Equipment Tab 9
Section Index – Mounted Equipment 5-3020
Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a
Refrigerant 9002 5-4030
Air Conditioner System Service 9003 5-3030
Removal And Installation Of Air Conditioning And Heater Components 9004 5-3040
Loader 9006 5-3050
Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF) 9007 5-3060
Cab Glass Installation 9010 6-42710
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 5-3070

TROUBLESHOOTING THE STEERING SYSTEM
NOTE: The steering hydraulic schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual.
1. Make sure the oil level in the hydraulic reservoir is correct. Visually inspect the steering system for leakage and damage.
2. The loader/steering pump differential pressure must be properly adjusted. Refer to Section 8002
Testing and Adjusting the Loader/Steering Pump differential Pressure.
3. Do the steering limit valve pressure test. Refer to page 6. If the pressure is above or below specifications, adjust the steering limit valve.
4. Do the main hydraulic pump test. See Section 8002. If the main pump is bad, repair or replace the main hydraulic pump.
5. Test the steering cylinders for leakage, refer to instructions on page 8. If a steering cylinder is leaking, repair or replace the steering cylinder.
6. If the steering system is noisy test the back pressure relief valve, refer to instructions on page 9.
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
1. CAS- 10280 Flowmeter
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1. Install articulation lock.
BD03A040
NOTE: When performing this pressure check,
always be sure the articulation lock is in place,
especially when working in the articulation joint
areas.
2. Loosen and remove the outlet hose to the
Auxiliary Steering Pump from the Auxiliary
Steering Priority Valve.
3. Install a plug into the Auxiliary Steering Priority Valve.
4. Connect the inlet of the flowmeter to the outlet line of the Auxiliary Steering Pump.
5. Install the outlet hose of the flowmeter in the hydraulic reservoir and hold in place with wire.
6. Connect the ammeter clamp (1) to the cable as in illustration.
7. Make sure that the parking brake is applied and the bucket is on the floor.
8. Make sure that the oil is at operating temperature.
9. Make sure that the load valve for the flowmeter is open (zero pressure).
10. Start and run the engine.
11. Stop the engine and turn the key back to the On position.
12. Turn the steering wheel, this will activate the auxiliary steering pump.
13. Turn the load valve on the flowmeter towards CLOSED until the pressure is 104 bar (1500 psi).
14. Read the flowmeter and ammeter gauges and record the readings.
15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter reading must be 315 amps.
16. Turn the key switch to the OFF position. If the flow was less than the specification, or if the amperage was more than 315 amperes, remove the auxiliary steering motor and pump. Test the auxiliary steering motor. If the motor is good, make repairs to the pump.
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