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1. Printed in U.S.A.
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 84487565
1st edition English
April 2011
SERVICE MANUAL
821F
921F
Tier 4
Wheel Loader

2. Section
1001
1001
GENERAL TORQUE SPECIFICATIONS

3. 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

4. 1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE
Use the torques in this chart when special torques
are not given. These torques apply to fasteners with
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
used.
Grade 5 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
1/4 inch 108 to 132 12 to 15
5/16 inch 204 to 252 23 to 28
3/8 inch 420 to 504 48 to 57
Size
Pound-
Feet
Newton
metres
7/16 inch 54 to 64 73 to 87
1/2 inch 80 to 96 109 to 130
9/16 inch 110 to 132 149 to 179
5/8 inch 150 to 180 203 to 244
3/4 inch 270 to 324 366 to 439
7/8 inch 400 to 480 542 to 651
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
Grade 8 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
1/4 inch 144 to 180 16 to 20
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Size
Pound-
Feet
Newton
metres
7/16 inch 70 to 84 95 to 114
1/2 inch 110 to 132 149 to 179
9/16 inch 160 to 192 217 to 260
5/8 inch 220 to 264 298 to 358
3/4 inch 380 to 456 515 to 618
7/8 inch 600 to 720 814 to 976
1.0 inch 900 to 1080 1220 to 1465
1-1/8 inch 1280 to 1440 1736 to 1953
1-1/4 inch 1820 to 2000 2468 to 2712
1-3/8 inch 2380 to 2720 3227 to 3688
1-1/2 inch 3160 to 3560 4285 to 4827
NOTE: Use thick nuts with Grade 8 bolts.

5. 1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE
Use the following torques when specifications are not
given.
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is
used.
Grade 12.9 Bolts, Nuts, and Studs
Usually the torque values specified for grade 10.9
fasteners can be used satisfactorily on grade 12.9
fasteners.
Grade 8.8 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
M4 24 to 36 3 to 4
M5 60 to 72 7 to 8
M6 96 to 108 11 to 12
M8 228 to 276 26 to 31
M10 456 to 540 52 to 61
Size
Pound-
Feet
Newton
metres
M12 66 to 79 90 to 107
M14 106 to 127 144 to 172
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
M36 1600 to 1950 2175 to 2600
8.8
Grade 10.9 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
M4 36 to 48 4 to 5
M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
M8 324 to 384 37 to 43
Size
Pound-
Feet
Newton
metres
M10 54 to 64 73 to 87
M12 93 to 112 125 to 150
M14 149 to 179 200 to 245
M16 230 to 280 310 to 380
M20 450 to 540 610 to 730
M24 780 to 940 1050 to 1275
M30 1470 to 1770 2000 to 2400
M36 2580 to 3090 3500 to 4200
10.9
12.9

6. 1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting
Tube OD
Hose ID
Thread
Size
Pound-
Inches
Newton
metres
1/4 inch
6.4 mm
7/16-20 72 to 144 8 to 16
5/16 inch
7.9 mm
1/2-20 96 to 192 11 to 22
3/8 inch
9.5 mm
9/16-18 120 to 300 14 to 34
1/2 inch
12.7 mm
3/4-16 180 to 504 20 to 57
5/8 inch
15.9 mm
7/8-14 300 to 696 34 to 79
Tube OD
Hose ID
Thread
Size
Pound-
Feet
Newton
metres
3/4 inch
19.0 mm
1-1/16-12 40 to 80 54 to 108
7/8 inch
22.2 mm
1-3/16-12 60 to 100 81 to 135
1.0 inch
25.4 mm
1-5/16-12 75 to 117 102 to 158
1-1/4 inch
31.8 mm
1-5/8-12 125 to 165 169 to 223
1-1/2 inch
38.1 mm
1-7/8-12 210 to 250 285 to 338
Split Flange Mounting Bolts
Size
Pound-
Inches
Newton
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
Size
Pound-
Feet
Newton
metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
Straight Threads with O-ring
Tube OD
Hose ID
Thread
Size
Pound-
Inches
Newton
metres
1/4 inch
6.4 mm
7/16-20 144 to 228 16 to 26
5/16 inch
7.9 mm
1/2-20 192 to 300 22 to 34
3/8 inch
9.5 mm
9/16-18 300 to 480 34 to 54
1/2 inch
12.7 mm
3/4-16 540 to 804 57 to 91
Tube OD
Hose ID
Thread
Size
Pound-
Feet
Newton
metres
5/8 inch
15.9 mm
7/8-14 58 to 92 79 to 124
3/4 inch
19.0 mm
1-1/16-12 80 to 128 108 to 174
7/8 inch
22.2 mm
1-3/16-12 100 to 160 136 to 216
1.0 inch
25.4 mm
1-5/16-12 117 to 187 159 to 253
1-1/4 inch
31.8 mm
1-5/8-12 165 to 264 224 to 357
1-1/2 inch
38.1 mm
1-7/8-12 250 to 400 339 to 542

7. 1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Face Seal End
O-ring Boss End
Fitting or Lock Nut
Nom.
SAE
Dash
Size Tube OD
Thread
Size
Pound-
Inches
Newton
metres
Thread
Size
Pound-
Inches
Newton
metres
-4 1/4 inch
6.4 mm
9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
-6 3/8 inch
9.5 mm
11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
-8 1/2 inch
12.7 mm
13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
Thread
Size
Pound-
Feet
Newton
metres
-10 5/8 inch
15.9 mm
1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
Nom.
SAE
Dash
Size Tube OD
Thread
Size
Pound-
Feet
Newton
metres
1-1/16-12 85 to 90 115 to 122
1-3/16-12 95 to 100 129 to 136
-12 3/4 inch
19.0 mm
1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
-14 7/8 inch
22.2 mm
1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
-16 1.0 inch
25.4 mm
1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
-20 1-1/4 inch
31.8 mm
1-11/16-12 125 to 140 170 to 190
-24 1-1/2 inch
38.1 mm
2-12 150 to 180 200 to 254

8. Section
1002
1002
FLUIDS AND LUBRICANTS

9. 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

10. 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®

11. 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.

12. 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.
See the char t below for
recommended viscosity at
ambient air temperature
ranges.
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
intervals given in this manual
are according to tests with Case
AKCELA lubricants.
BD03A102
BC02N250
RH99K130

13. 1002-6
TRANSMISSION TEMPERATURE CHART
RCPH10WHL435BAH3
DIESEL FUEL SYSTEM
Use No. 2 diesel fuel in the engine of this machine.
The use of other fuels can cause the loss of engine
power and high fuel consumption.
In very cold temperatures, a mixture of No. 1 and No.
2 diesel fuels is temporarily permitted. See the
following Note.
NOTE: See your fuel dealer for winter fuel
requirements in your area. If the temperature of the
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel
filter and cause the engine to lose power or not start.
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.
Fuel Storage
If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
tank. Many engine problems are caused by water in
the fuel.
Keep the fuel storage tank outside and keep the fuel
as cool as possible. Remove water from the storage
container at regular periods of time.
Fill the fuel tank at the end of the daily operating
period to prevent condensation in the fuel tank.
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%

14. 1002-7
What is Selective Catalytic Reduction (SCR)?
The main components of the SCR system include the
SCR catalyst, the Diesel Exhaust Fluid (DEF)/
AdBlue® injection unit, the DEF/AdBlue® tank, and
the DEF/AdBlue® dosing control unit.
How does Selective Catalytic Reduction
(SCR) work?
During combustion, harmful Nitrogen Oxide (NOx)
molecules are formed in the exhaust. By injecting a
DEF/AdBlue® solution into the exhaust prior to a
catalyst, the NOx can be converted to harmless
elemental Nitrogen and water. This happens when
the NOx molecules react inside the catalyst with the
heat generated by the engine and the ammonia in
the DEF/AdBlue® solution.
During cold engine operation at low engine coolant
and ambient air temperatures, water vapor will be
visible from the exhaust when the engine operates.
This water vapor will resemble steam or light white
smoke and will dissipate as the engine and machine
components warm and is considered normal.
NOTE: After engine shutdown, the SCR system will
perform a purge cycle, which permits the supply
module to continue to run for up to 70 seconds. This
is to be considered normal and requires no action
from the operator.
What is Diesel Exhaust Fluid
(DEF)/AdBlue®?
DEF/AdBlue® is a non-toxic aqueous urea solution (
32.5 %) with a slight ammonia odor used to
chemically reduce NOx emissions from heavy-duty
diesel powered vehicles.
DEF/AdBlue® is neither explosive nor harmful to the
environment and is classified under the minimum-risk
category of transportable fluids. DEF/AdBlue®
quality is defined by ISO 22241-1. The
American Petroleum Institute (API®) has a
voluntary certification program for DEF/AdBlue®. To
ensure DEF/ AdBlue® satisfies the requirements of
ISO 22241. DEF/AdBlue®. API Diesel Exhaust Fluid
Certification Mark is a registered trademark of API in
the United States and or other countries.
Storage, handling, and transport
NOTICE: Storage temperatures above 30 °C (86 °F)
greatly reduce the shelf life of DEF/AdBlue®.
DEF/AdBlue® has a typical shelf life of 6-12 months.
Refer to the SHELF LIFE table below. In order for
DEF/AdBlue® to remain in a usable condition, stor-
age requirements need to be met.
• Store between -11 °C (12 °F) and 30 °C (86 °F).
• Use only an approved DEF/AdBlue® container.
• Keep container tightly closed.
• Keep container in a cool, well-ventilated area.
• Keep away from heat and direct sunlight.
Thawing
• The machine is equipped with an internal tank
heater to thaw frozen DEF/AdBlue®. The machine
will still function until the DEF/AdBlue® begins to
flow. The SCR system will then function normally.
• Do not heat DEF/AdBlue® for long periods of time
at temperatures above 30 °C (86 °F). This causes the
solution to decompose, which very slowly decreases
the expected shelf life.
NOTICE: Do not use an anti-gelling or freeze point
improver in your DEF/AdBlue®. The 32.5 % solution
is specifically designed to provide the optimum NOx
reduction properties. Any further blending or adjust-
ing of the DEF/AdBlue® mixture will lessen its ability
to perform correctly and may cause damage to the
SCR components.
Handling and supply of additives, if any.
• Personal Protective Equipment (PPE) is not
required under normal conditions. If splashing is
likely, wear eye protection. For prolonged or repeated
contact, impervious gloves are recommended.
Follow the precautions listed in the SAFETY
INFORMATION chapter when handling any service
fluid.
• No additives are required.
NOTICE: Contaminated DEF/AdBlue® can affect the
performance of your machine. Follow all instructions
in this manual when handling DEF/AdBlue®.
Shelf life
Constant ambient storage temperature and
minimum shelf life
Less than or equal to 10 °C (50 °F) 36 months
Less than or equal to 25 °C (77 °F) ¹ 18 months
Less than or equal to 30 °C (86 °F) 12 months
Less than or equal to 35 °C (95 °F) 6 months
Greater than 35 °C (95 °F) -²
¹ To prevent decomposition of DEF/AdBlue®,
prolonged transportation or storage above 25 °C (77
°F) should
be avoided.
² Significant loss of shelf life: check every batch
before use. See your [Brand] dealer for more
information on testing.

15. 1002-8
NOTE: The main factors taken into account to define
the shelf life in the previous figures are the ambient
storage temperature and the initial alkalinity of
DEF/AdBlue®. The difference in evaporation
between vented and non-vented storage containers
is an additional factor.
NOTE: The information in this table is for reference
only and has been provided by the International
Organization for Standardization, Document number
ISO 22241-3 Diesel engines - NOx reduction agent
AUS 32 - Part 3: Handling, transportation and stor-
age.
Disposal
• 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.
Glossary Acronym Definition
DEF Diesel Exhaust Fluid
ISO International Organization
for Standardization
MSDS Material Safety Data Sheet
NOx Nitrogen Oxide
PPE Personal Protective
Equipment
SCR Selective Catalytic
Reduction
ULSD Ultra Low Sulfur Diesel

16. 1002-9
SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS
Requirements
The operator must maintain appropriate
DEF/AdBlue® levels at all times. The SCR system is
compatible with up to 7% bio-diesel fuel.
Diesel Exhaust Fluid (DEF)/AdBlue®
refilling
The DEF/AdBlue® tank cap (1) can be identified by
the “blue” color of the cap. A fitting under the cap
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 is recommended that DEF/AdBlue® filling
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.
Diesel Exhaust Fluid (DEF)/AdBlue®
consumption
NOTE: DEF/AdBlue® consumption is highly
dependent on engine loads, humidity levels,
DEF/AdBlue® fluid concentration, and engine speed.
The “typical” consumption is only a guideline to verify
proper function of the SCR system. CNH
recommends to fill the DEF/AdBlue® tanks at every
fuel refilling interval.

17. 1002-10
MAINTENANCE SCHEDULE
SERVICE
INTERVAL ITEM
NUMBER
SERVICE POINTS
InitialService
FREQUENCY IN HOURS
CHECK
CLEAN
CHANGE
DRAIN
LUBRICATE
REPLACE
ADJUST
Variable
Periodic
(*)
2 Radiator Coolant Level *
13 Tires *
16 Hydraulic Filter *
12 Alternator, AC, Drive Belt *
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
Every 50 Hours
13 Check Engine Coolant Level 50
3 Check Transmission Oil Level 50
4 Check Hydraulic Oil Level 50
5 & 6 Grease Bucket Mounting Fittings 50
7 Grease machine and attachments 50
First 100 Hours
16 Change Engine Oil and Filters 100
18 Replace Fuel Filters 100
20 Change Hydraulic Filter 100
25 Change Oil in Axles 100
13 Check wheel torque 100
28 Clean in-line DEF supply filter 100
Every 100 Hours
8
Lubricate The Steering Cylinder Pivots - Rod And
Closed End (4 Fittings)
100
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
Every 250
Hours
11 Check Cab Air Filter 250
14 Check Tire Pressure & Wheel Torque 4 250
12 Check Drive Belt 250
XX Trans Clutch Calibration (See Section 6002) 250 1000
Every 500
Hours
14 Check Axle Oil Level 500
15 Check Battery Electrolyte Level 500
16 Change Engine Oil and Filter 500
XX Check ROPS 500
18 Drain Fuel Tank Condensation & Water Separator 500
19 Replace Fuel Filter 500

18. 1002-11
Every 1000
Hours
20 Replace Hydraulic Oil filter 1000
21 Grease Articulation Fittings 1000
24 Change crankcase filter 1000 1000
23 Replace Drive Belt
11 Replace Cab Air Filter 1000
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
Every 1500
Hours
21 Change Front & Rear Axle Oil 1500
26 Change Transmission Oil and Filter 1500
28 Clean in-line DEF filter
Every 2000
Hours
29 Change Hydraulic Oil 2000
30 Change Coolant 2000
31 Replace Engine Air Cleaner 2000
32 Lubricate cab and door 2000
XX Valve Clearance (Engine Manual) 2000
Every 3000
Hours
XX Replace DEF supply module filter 3000
Every 6000
Hours
XX Engine Injectors (Engine Manual) 6000
XX Fuel Pump (Engine Manual) 6000 6000

19. 1002-12
MAINTENANCE POINTS
84397762
See your Operators manual for maintenance of
safety related items and for detailed information of
the service items on this chart. Operators and
service manuals are available for this machine from
your dealer.
If you operate the machine in severe conditions,
lubricate and service the machine more frequently.

20. Section
1003
1003
METRIC CONVERSION CHART

21. 1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

22. 1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter
hectare
10.763 91
2.471 05
square foot
acre
Force: newton
newton
3.596 942
0.224 809
ounce force
pound force
Length: millimeter
meter
kilometer
0.039 370
3.280 840
0.621 371
inch
foot
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
bar
0.145 038
14.50385
lb/sq. inch
lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter
newton meter
8.850 748
0.737 562
lb/inch
lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.
Volume: cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
0.061 024
35.314 66
1.307 950
0.033 814
1.056 814
0.879 877
0.264 172
0.219 969
cubic inch
cubic foot
cubic yd.
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US liquid)
gallon (Imperial)
Volume/Time: litre/min.
litre/min.
0.264 172
0.219 969
gallon/min. (US liquid)
gallon/min. (Imperial)

23. 1003-4
U.S. to Metric
* = exact
MULTIPLY BY TO OBTAIN
Area: square foot
acre
0.092 903
0.404 686
square meter
hectare
Force: ounce force
pound force
0.278 014
4.448 222
newton
newton
Length: inch
foot
mile
25.4 *
0.304 8 *
1.609 344 *
millimeter
meter
kilometer
Mass: pound
ounce
0.453 592
28.35
kilogram
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.
lbs/sq. in.
lbs/sq. in.
6.894 757
0.069
0.070 303
kilopascal
bar
kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch
pound/foot
0.112 985
1.355 818
newton meter
newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.
Volume: cubic inch
cubic foot
cubic yard
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US)
gallons (Imperial)
16.387 06
0.028 317
0.764.555
29.573 53
0.946 353
1.136 523
3.785 412
4.546 092
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
Volume/Time: gallon/min. 3.785 412 litre/min.

24. Section
2000
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION

25. 2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

26. 2000-3
ENGINE
Removal
STEP 1
BD03A040
Park machine on a level surface and lower bucket to
ground. Put articulation lock in LOCKED position.
STEP 2
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
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 battery covers and disconnect
batteries from the machine.
STEP 5
BD02N160
Put a 30 liter (32 U.S. quart) container below radiator
drain. Remove radiator cap. Remove cap and drain
coolant into container. Install cap after coolant has
drained. Install radiator cap.
STEP 6
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.

27. 2000-4
STEP 7
BD03A231
Double up a nylon lifting strap (1) and slide through
the exhaust stack (2) on the hood.
STEP 8
BD03A230
Place a solid steel bar through the strap, raise the
hood and release tension on the lifting motor.
STEP 9
BD03A228
Remove the pin from the top of the lifting motor.
STEP 10
BD06F109
Tag and disconnect hood wiring harness connector
from rear chassis wiring harness connector.
STEP 11
BD03A227
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
mounting bolts (2) from the cooler frame.
1
2
1
2
2

28. 2000-5
STEP 12
BD03A232
Carefully raise and remove hood from loader. Lower
hood onto suitable platform and disconnect lifting
equipment.
STEP 13
BD03A224
Tag and disconnect engine wiring harness connector
from air filter restriction switch.
STEP 14
BD03A225
Loosen clamp on air cleaner intake hose and remove
the crankcase ventilation hose.
STEP 15
BD06F110
Loosen clamps on turbocharger and air cleaner,
remove the intake hose.
STEP 16
BD06F110
Loosen the clamp on the turbocharger for the after
cooler inlet hose.
STEP 17
BD03A115
Loosen the clamp on the after cooler and remove the
after cooler inlet hose from the machine.

29. 2000-6
STEP 18
BD06F111
Loosen the clamp on the intake manifold for the after
cooler output hose.
STEP 19
BD03A118
Loosen the clamp on the after cooler and remove the
after cooler outlet hose from the machine.
STEP 20
BD06F110
Loosen the exhaust clamp from the turbocharger.
STEP 21
BD06F112
Remove the air cleaner and muffler from the bracket.
STEP 22
BD06F113
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.

30. 2000-7
STEP 23
BD06F115
Remove the drive belt from the engine.
STEP 24
BD06F116
Loosen clamps and remove lower cooler hose from
the engine.
STEP 25
BD06F117
If loader is equipped with air conditioning, identify,
tag, and disconnect the engine wiring harness
connectors from air compressor clutch connector (1).
Remove the three mounting bolts (2) for the
compressor and set the compressor on the left
battery cover.
STEP 26
BD06F118
Tag and disconnect the wiring from the alternator.
STEP 27
BD06F119
Remove bolt securing wiring harness clamp to
engine.
STEP 28
BD06F120
Remove bolt securing wiring harness clamp (1) to the
engine. Remove ground wires (2) from the engine.
1
2
1
2

31. 2000-8
STEP 29
BD06F121
Tag and remove the wires from the starter solenoid
(3), remove the ground cable (2), and ground strap
(1) from the starter.
NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.
STEP 30
BD06F146
Disconnect the engine coolant vent hose and root to
the rear of the engine.
STEP 31
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.
STEP 32
BD06F111
Tag and remove the grid heater cable.
STEP 33
BD03A142
Disconnect the wiring harness from the EDC 7
controller.
NOTE: Lifting up on the lever will release the
connector from the controller.
STEP 34
BD06F123
Remove the fuel line from the top of the EDC 7
controller, plug the line and cap the fitting.
3
1
2
2
1
3

32. 2000-9
STEP 35
BD06F124
Tag and disconnect the fuel filter heater wires (1),
disconnect the fuel line (2) from the fuel filter head,
plug the line and cap the fitting.
STEP 36
BD06F125
Remove bolt and clamp.
STEP 37
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.
STEP 38
BD06F127
Remove the lower cover for the drive shaft.
STEP 39
BD03A172
Remove the drive shaft bolts from the flywheel. Move
the drive shaft clear of the flywheel.
STEP 40
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
harness connections and hoses have been
disconnected and are clear of the engine. Remove
engine from machine.
1
2

33. 2000-10
Installation
BS03B035
STEP 42
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.
STEP 44
Tighten engine mounting bolts to a torque of 244 to
298 Nm (180 to 220 lb-ft).
STEP 45
Disconnect lifting equipment from engine lifting
brackets.
STEP 46
Connect engine oil drain hose to frame bracket.
STEP 47
BD03A172
At front of engine, position drive shaft on engine
coupling. Install six bolts to secure drive shaft to
engine coupling. Tighten the six bolts to a torque of
53 to 62 Nm (39 to 46 lb-ft).
1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT
2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE
1
4
3
2
7
6
5
4
3
2
1
1
7
8
7
6
5
2
3
4
5
6

34. 2000-11
STEP 48
BD06F127
Install the lower cover for the drive shaft.
STEP 49
BD06F126
Connect and turn on vacuum pump to the hydraulic
reservoir. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags
installed during removal. Remove and discard tags.
Turn off and disconnect vacuum pump from hydraulic
reservoir.
STEP 50
BD06F125
Install bolt and clamp for fuel return hose.
STEP 51
BD06F124
Remove cap from fitting and plug from the hose,
connect fuel line (2). Connect fuel filter heater wires
(1). Remove and discard tag.
STEP 52
BD06F123
Remove cap from fitting and plug from the hose,
connect fuel line to EDC 7.
STEP 53
BD03A142
Connect wiring harness to EDC 7 controller.
NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector
into position.
1
2

35. 2000-12
STEP 54
BD06F111
Connect grid heater cable to grid heater. Remove
and discard tag.
STEP 55
BD06F122
Install the heater hose (2) to the rear of the engine,
mount the clamps (3), install the radiator hose (1).
STEP 56
BD06F146
Connect the engine coolant vent hose.
STEP 57
BD06F121
Install the wires to the starter solenoid (3), install the
ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.
STEP 58
BD06F120
Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.
STEP 59
BD06F119
Install bolt securing wiring harness clamp to engine.
2
1
3
3
1
2
1
2

36. 2000-13
STEP 60
BD06F118
Connect the wiring to the alternator. Remove and
discard tags.
STEP 61
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
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).
STEP 63
BD06F115
Install the drive belt.
STEP 64
BD06F113
BD06F114
Install the cover mounting brackets to the machine
frame. Install the belt cover, install the four mounting
bolts for the belt cover.
1
2

37. 2000-14
STEP 65
BD06F112
Place the muffler and air cleaner on the bracket.
Install mounting bolts in air cleaner and tighten,
install the mounting bolts in the muffler and leave
loose at this time.
STEP 66
BD06F110
Install and tighten the exhaust clamp on the
turbocharger, tighten the muffler mounting bolts.
STEP 67
BD03A118
Place the after cooler outlet hose on the machine.
Tighten the clamp on the after cooler.
STEP 68
BD06F111
Tighten the clamp on the intake manifold for the after
cooler output hose.
STEP 69
BD03A115
Place the after cooler inlet hose on the machine.
Tighten the clamp on the after cooler.
STEP 70
BD06F110
Tighten the clamp on the turbocharger for the after
cooler inlet hose.

38. 2000-15
STEP 71
BD06F110
Install the intake hose and tighten the clamps on
turbocharger and air cleaner.
STEP 72
BD03A225
Install the crankcase ventilation hose and tighten the
clamp on air cleaner intake hose.
STEP 73
BD03A224
Connect engine wiring harness connector to air filter
restriction switch. Remove and discard tag.
STEP 74
BD03A232
Carefully raise and place hood over loader.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 75
BD03A227
BD03A226
Have another person balance the hood, install the
hood hinge mounting bolts (2) to the cooler frame.
Install mount bolt (1) and backup alarm wiring
harness clamp to cooler housing.
1
2
2

39. 2000-16
STEP 76
BD03A228
Install the pin from the top of the lifting motor, lower
and remove lifting equipment.
STEP 77
BD06F109
Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and
discard tag.
STEP 78
BD03A221
NOTE: If hood strut is not adjusted properly the
hood will be damaged.
When a hood is removed and replaced an initial
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
(MM)
X
(MM)
Y
(MM)
X
(MM)
Y
(MM)
X
(MM)
Y
(MM)
X
(MM)
1 19 21 14 41 9 61 5
2 19 22 14 42 9 62 5
3 18 23 14 43 9 63 4
4 18 24 13 44 9 64 4
5 18 25 13 45 9 65 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
2
1

40. 2000-17
STEP 79
BD02N160
Check and make sure that drain caps are tight.
STEP 80
Install a new oil filter on engine. Fill engine with 13.25
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
and water. When the coolant is at operating
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.
STEP 85
BD06F108
Lower the hood with the hood lift motor.
STEP 86
Put articulation lock in OPERATING position.

41. 2000-18
RADIATOR
Removal
STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 2
BD03A040
Put articulation lock in LOCKED position.
STEP 3
Put master disconnect switch in OFF position.
STEP 4
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.
STEP 5
BD06F128
Remove bolt and washer securing LH fender.
Remove LH fender.
STEP 6
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
BD03A109
Release catch and tilt air conditioning condenser
core up to gain access to upper radiator hose.

42. 2000-19
STEP 8
BD03A108
Loosen the upper radiator hose clamps, remove the
hose.
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.
STEP 11
BD03A106
Remove screws and install lifting eyes (1). Attach
suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.
1
22

43. 2000-20
Installation
STEP 12
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
STEP 13
BD03A106
Install four lock washers and bolts (2) to secure
radiator to cooling frame. Disconnect lifting
equipment from lifting eyes. Remove lifting eyes and
install screws (1).
STEP 14
BD03A113
Connect connector to coolant level sender, connect
overflow hose to radiator.
STEP 15
BD06F129
At bottom of radiator, install bottom radiator hose.
Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
STEP 16
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
BD06F130
When installing fender make sure it is behind the
fender mounting bolt.
1
22

44. 2000-21
STEP 18
BD06F131
Align the whole in the fender on the bolt.
STEP 19
BD06F132
Align the slots in the fender with the tabs on the body
of the machine.
STEP 20
DSC00105.TIF
Push the fender towards the front of the machine and
secure it using washer and bolt.
STEP 21
BD03A120
Have another person raise and hold the side panel
up into position. Apply Loctite 242 to the threads,
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
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.

45. 2000-22
STEP 24
Put master disconnect switch in ON position.
STEP 25
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
and water. When the coolant is at operating
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.
STEP 26
Put articulation lock in OPERATING position.

46. Section
2002
2002
STALL TEST

47. 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

48. 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.

49. 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.

50. 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.
BD06F188
2. From the driving screen push the down arrow, as
shown.
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.
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.
BD06F184
5. Push the down button again for the Info 3 screen.
This screen displays the temperature in
Fahrenheit or Celsius of the transmission oil,
hydraulic oil, sump oil.

51. 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.

52. 2002-7
PROCEDURE TO HEAT THE OIL
Torque Converter
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. To measure the oil temperature with the
instrument cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored.
4. Place the declutch switch in the OFF position.
5. Place the automatic switch in the manual mode
position. Push down and hold the brake pedal for
the remainder of this procedure.
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).
Hydraulic System
1. Apply the parking brake.
2. Start the engine and run at full throttle.
3. To measure the oil temperature with the
instrument cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored are on.
4. Hold the bucket control lever in the ROLLBACK
position while raising and lowering the lift arms
from ground level to full height.
5. Continue this procedure until the temperature of
the hydraulic oil is 54° to 57°C (129° to 134°F).

53. 2002-8
POWER MODE SELECTION
1. After the oil temperatures have been raised to
operating temperatures the power mode must be
set to “Auto”.
BD06H038
2. Press and hold the confirmation “enter” button for
two seconds to arrive at the above service
screen.
3. Use down arrow to scroll through the menu’s.
4. High light Power Mode and press the enter key.
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.

54. 2002-9
PERFORMING STALL TESTS
Test No. 1 - Torque Converter and
Hydraulic Stall Together
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
shift into Forward.
4. Run engine at low idle. Push the clutch cutout
switch to OFF. Put the transmission in manual
mode. Push down and hold the brake pedal for
the remainder of this procedure.
5. Turn the transmission control lever to third gear.
6. Increase the engine speed to full throttle.
7. Hold the bucket control lever in the ROLLBACK
position and raise the lift arms.
NOTE: The stall speed must be read while the lift
arms are in motion.
8. Check the engine speed.
9. Release the bucket control lever.
10. Decrease the engine speed to low idle.
11. Lower the bucket to the ground, place the
transmission in neutral and apply the parking
brake.
12. Stop the engine.
Understanding the Results of Test
No. 1
1. If the engine speed was as specified, the engine,
torque converter, transmission and hydraulic
system are probably good.
2. If the engine speed was not as specified, do Test
No. 2 and 3.
Test No. 2 - Torque Converter Stall
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
shift into Forward.
4. Run the engine at low idle.
5. Push down and hold the brake pedal for the
remainder of this test.
6. Turn the transmission control lever to third gear.
7. Increase the engine speed to full throttle.
8. Check the engine speed.
9. Decrease the engine speed to low idle.
10. Place the transmission in neutral and apply the
parking brake.
11. Stop the engine.
Understanding the Results of Test
No. 2
1. If the engine speed was as specified, the engine,
torque converter and transmission are probably
good.
2. If the engine speed was more than specified, the
problem can be in the torque converter or the
transmission. See Section 6002 for
troubleshooting information.
3. If the engine speed was less than specified, do
Test No. 3.

55. 2002-10
Test No. 3 - Hydraulic Stall
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Increase the engine speed to full throttle.
4. Hold the bucket control lever in the ROLLBACK
position and raise the lift arms.
NOTE: The stall speed must be read while the lift
arms are in motion.
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.
Understanding the Results of Test
No. 3
1. If the engine speed was as specified, the engine
and hydraulic system are good.
2. If the engine speed was more or less than
specified the main relieef setting may be too low
or too high. See Section 8002 for troubleshooting
information.
3. If the engine speed was less than specified in all
tests, the engine is probably the cause.

56. Section
2003
2003
AFTER COOLER

57. 2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

58. 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
(rpm). Record pressure readings for both gauges. If
the pressure difference is greater than 60 mbar
(0.87 psi), inspect cooler components for damaged
or missing parts.
STEP 4
BD03A116
Inspect the turbocharger flex hose for leaks or holes
and insure that the clamps are tight.
STEP 5
BD03A115
Inspect the after cooler inlet flex hose for leaks or
holes and insure that the clamps are tight.
BD03A118
Inspect the after cooler outlet flex hose for leaks or
holes and insure that the clamps are tight.
STEP 6
BD03A119
Inspect the intake manifold flex hose for leaks or
holes and insure that the clamps are tight.
STEP 7
BD03A109
Visually inspect top of after cooler for damage or
leaks
NOTE: If the leak source has not been located,
remove and test the after cooler.

59. 2003-4
AFTERCOOLER REMOVAL
Removal
STEP 1
BD03A116
Loosen clamps and remove turbocharger outlet
components.
STEP 2
BD03A115
Loosen clamps and remove air cooler inlet hose.
STEP 3
BD03A119
Loosen clamps and remove Intake hose.
STEP 4
BD03A118
Loosen clamps and remove air cooler outlet hose.
STEP 5
BD03112
Raise air conditioning/air cooler cover. Support cover
with appropriate lifting device. Remove cover support
latch.
STEP 6
BD03A111
Remove three cover mounting bolts and lift cover off.

60. 2003-5
STEP 7
BD03A109
Unlatch air conditioning condenser clamp.
STEP 8
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
BD03A117
Remove the two bolts at the rear of the after cooler
mounting frame.
STEP 10
BD03A113
Remove two bolts, one from each side of the after
cooler mounting frame.
STEP 11
Lift air cooler and frame from machine with
appropriate lifting devise.
STEP 12
BD03A111
Remove four bolts that mount air cooler in the air
cooler frame. Remove air cooler from frame.

61. 2003-6
Leak Test
BS03B028
Check the core for leaks by closing off the outlet tube
and attaching regulated air pressure 550kPa (80psi)
to the inlet tube. Submerge the cooler in water and
watch for air leakage.
NOTE: If leakage is detected replace the after
cooler.
Installation
STEP 1
BD03A111
Install after cooler in its frame. Install four mounting
bolts. Support after cooler with appropriate lifting
device. Install the after cooler and frame in the
machine.
STEP 2
BD03A113
Install two side mounting bolts
STEP 3
BD03A117
Install two bolts at the rear of the after cooler
mounting frame.

62. 2003-7
STEP 4
BD03A107
Position air conditioner condenser and install
mounting bolts. Rotate the condenser down and
latch.
STEP 5
BD03112
Support cover with appropriate lifting device. Raise
air conditioning/air cooler cover over machine. Install
cover support latch.
STEP 6
BD03A111
Install three cover mounting bolts.
STEP 7
BD03A116
Install air cooler inlet hose. Tighten clamps at
turbocharger outlet.
STEP 8
BD03A115
Tighten clamps at air cooler inlet.
STEP 9
BD03A119
Install air cooler outlet hose and tighten clamps at
engine intake.

63. 2003-8
STEP 10
BD03A118
Tighten clamps at air cooler outlet.
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).

64. Section
2010
2010
ENGINE INTAKE AIR FILTRATION

65. 2010-2
TABLE OF CONTENTS
Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

66. 2010-3
AIR FILTRATION
Pre-cleaner Disassembly &
Reassembly
STEP 1
721F-8469.PNG
Access pre-cleaner located on top of engine
compartment hood.
STEP 2
IMG_1683.AI.TIF
Loosen wing nut.
STEP 3
IMG_1682.AI.TIF
Disassemble and remove precleaner from machine.
STEP 4
IMG_1680.AI.TIF
Empty debris and clean wipe precleaner with a damp
clean cloth. Reassemble/install unit on machine.

67. 2010-4
Primary/Secondary Fillter Element
Disassembly
STEP 1
721F-8469.PNG
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_0099.PNG
Turn master electric switch “off”.
STEP 3
IMG_0115.PNGD
Release all clips securing air filter element housing
cover.
STEP 4
IMG_0142.PNG
Remove cover from air filter element housing.
STEP 5
IMG_0143A.PNG
Remove primary filter element by lifting up on handle
1 2

68. 2010-5
STEP 6
IMG_0144A.PNG
Remove secondary filter element from right side of
housing. Remove debris from inside filter element
housing before installing new filter elements.
NOTE: Do not clean the seconday filter element. It
must be replaced if damaged or clogged.
Primary/Secondary Element
Reassembly
STEP 1
IMG_0144A.PNG
Install new secondary filter element by inserting it
into positioning slot.
NOTE: Make sure filter element is firmly seated into
housing.
STEP 2
IMG_0143A.PNG
Install new primary filter element by sliding it down
into housing.
NOTE: Make sure primary and secondary filter
elements form an effective seal.
STEP 3
IMG_0142.PNG
Install housing cover.
STEP 4
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.

69. 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.

70. Section
2020
2020
SCR SYSTEM SENSORS

71. 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

72. 2020-3
SCR SYSTEM SENSORS
Upstream Exhaust Temperature
Sensor Removal
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.”
STEP 1
721F-8469.PNG
Raise the hood using controls located behind the
access cover.
STEP 2
IMG_0099.PNG
Turn master electric switch to the “off” position.
STEP 3
IMG_0912.TIF
Locate exhaust temperature sensor (1) on exhaust
system before the catalyst (2).
STEP 4
IMG_1507.TIF
Loosen hex nut on sensor.
2
1

73. 2020-4
STEP 5
IMG_1510.JPG
Remove temperature sensor from exhaust system.
STEP 6
IMG_1514.TIF
Remove wire ties securing wire harness to support
brackets. Unplug sensor from machine wiring
harness and remove it.
Upstream Exhaust Temperature
Sensor Reinstall
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.”
STEP 1
IMG_1510.TIF
Install temperature sensor into exhaust pipe.
STEP 2
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.

74. 2020-5
STEP 3
IMG_0099.PNG
Turn master electric switch to “on” position. Clear any
fault code. Start engine and check to see if problem
has been corrected.
Downstream Exhaust Temperature
Sensor Removal
NOTE: Do not use impact wrenches on the exhaust
system unless the sensors are removed.”
STEP 1
721F-8469.PNG
Raise the hood using controls located behind the
access panel.
STEP 2
IMG_0099.PNG
Turn master electric switch to the “off” position.
STEP 3
IMG_1465.TIF
Locate the exhaust temperature sensor (1) on
exhaust system after catalyst (2).
STEP 4
GRAPHIC_ID
Loosen hex nut and remove sensor from exhaust
system.
1 2

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