Case 821G 921G Tier 4B Wheel Loader Service Manual 51428267 2nd Edition

Description

Case 821G 921G Tier 4B Wheel Loader Service Manual – 2nd Edition

This is the complete Case 821G 921G Tier 4B Wheel Loader Service Manual, part number 51428267, 2nd edition, published December 2017. It covers the 821G and 921G wheel loaders in XR-EH and ZBAR-EH configurations with the new cab, built for the North American market with Tier 4B final engines. Across 2935 pages, this manual gives technicians the complete disassembly, assembly, testing, adjustment, and troubleshooting procedures needed to service these machines from front to back.

File Details

• Manual type: Service Manual
• Brand: Case Construction
• Models covered: 821G Wheel Loader XR-EH, New Cab Tier 4B NA; 821G Wheel Loader ZBAR-EH, New Cab Tier 4B NA; 921G Wheel Loader XR-EH, New Cab Tier 4B NA; 921G Wheel Loader ZBAR-EH, New Cab Tier 4B NA
• Engines covered: F4HFE613SB003 (821G); F4HFE613RB005 (921G)
• Document number: 51428267
• Edition: 2nd edition
• Publication date: December 2017
• Language: English
• Page count: 2935
• File format: PDF

Chapters Covered

• Engine 10: Engine and crankcase, fuel tanks, air cleaners and lines, Selective Catalytic Reduction (SCR) exhaust treatment, engine cooling system, fan and drive, aftercooler, engine lubrication system
• Transmission 21: Powershift transmission, powershift transmission internal components, torque converter
• Four-Wheel Drive (4WD) system 23: Drive shaft
• Front axle system 25: Powered front axle, front bevel gear set and differential, final drive hub, steering knuckles, and shafts
• Rear axle system 27: Powered rear axle, rear bevel gear set and differential, planetary and final drives
• Brakes and controls 33: Hydraulic service brakes, parking brake or parking lock
• Hydraulic systems 35: Hydraulic systems, reservoir, cooler and filters, variable displacement pump, main control valve, pilot system, remote control valves, hydraulic fan drive cooling system, front loader arm hydraulic system, front loader bucket hydraulic system, tool quick coupler hydraulic system
• Frames and ballasting 39: Frame
• Steering 41: Steering control, hydraulic control components, cylinders, auxiliary steering
• Wheels 44: Front wheels, rear wheels
• Cab climate control 50: Air conditioning
• Electrical systems 55: Harnesses and connectors, engine starting system, alternator, battery, SCR electrical system, EGR electrical system, cab controls, loader arm and bucket control system, camera, fault codes (DTC)
• Front loader and bucket 82: Arm, bucket
• Platform, cab, bodywork, and decals 90: Cab, mechanically-adjusted operator seat, pneumatically-adjusted operator seat, machine shields and guards

This Case 821G 921G Tier 4B wheel loader service manual is a full workshop-level document that walks through every major system on the machine. The engine section alone covers removal and installation of the engine and crankcase, complete fuel tank servicing, air cleaner and line procedures, the full SCR exhaust treatment system including the SCR muffler, Diesel Oxidation Catalyst (DOC), DEF/AdBlue tank, coolant control valve, dosing module, and all associated sensors, plus engine cooling system radiator removal and installation, fan and drive service including the reverse fan control system, aftercooler removal, installation, and pressure testing, and the engine lubrication system including the crankcase ventilation system. The transmission section covers the powershift transmission removal and installation, complete disassembly and assembly of internal components including all clutch packs (KV, KR, K1, K2, K3, K4), and torque converter service including oil heating procedures and stall tests.

The axle sections for both front and rear cover powered axle removal and installation, bevel gear set and differential service including backlash measurement and adjustment for both MT-L 3095 II and MT-L 3105 II axle models, differential disassembly and assembly for D, DL, and DHL versions, and final drive hub, steering knuckle, and shaft service. The brake section covers hydraulic service brakes with complete test procedures, bleeding, modulation pressure checks, accumulator cut-in and cut-out pressure checks, brake pedal control valve removal and installation, brake pump service including disassembly, inspection, and assembly, accumulator removal, installation, discharging, checking, and charging, brake disc service for both axle model families, and brake line removal and installation. The parking brake section covers the Spring Applied Hydraulic Released (SAHR) sliding caliper FSG 88 with complete disassembly, inspection, assembly, service instructions, and testing.

The hydraulic systems section is particularly comprehensive, covering the complete hydraulic system with schematics for both 821G and 921G, the reservoir, cooler, and filter service including oil cooler and thermal bypass valve removal and installation, the variable displacement pump with testing and adjustment of the high pressure pump differential pressure and flow testing, the main control valve with circuit relief valve testing and adjustment, complete disassembly, inspection, assembly, and installation, the pilot system with pilot accumulator specifications and pilot solenoid valve block checking, the remote control valves including the electro-hydraulic control valve removal and installation, the hydraulic fan drive cooling system with the cooling fan reversing valve removal and installation, the front loader arm hydraulic system with lift arm cylinder removal, disassembly, inspection, assembly, and installation, ride control solenoid valve block service including bleeding, accumulator discharging, removal, installation, and charging, the front loader bucket hydraulic system with bucket cylinder removal, disassembly, inspection, assembly, and installation, and the tool quick coupler hydraulic system with solenoid valve removal and installation.

The steering section covers steering control with limit pressure testing and adjustment, hydraulic control components with component identification for standard steering, standard steering with JSS, steering system with auxiliary steering, and steering system with auxiliary steering and JSS, steering valve removal and installation, main priority valve removal, installation, testing, and adjustment, steering circuit relief valve removal, installation, and testing, auxiliary steering priority valve removal and installation, and steering cylinder removal, installation, leak testing, disassembly, inspection, and assembly. The electrical systems section is equally detailed, covering all harnesses and connectors with complete electrical schematics for every circuit, the engine starting system with starter removal and installation, the alternator removal and installation, battery visual inspection, testing, and charging procedures, the SCR electrical system with supply module, dosing module, humidity sensor, temperature sensors, NOx sensor, tank level and temperature sensor, and NH3 sensor removal and installation, the EGR electrical system, cab controls including joystick and electric hydraulic control removal and installation, the loader arm and bucket control system including EH lift sensor and EH tilt sensor removal, disassembly, assembly, installation, and checking, the camera removal and installation, and the complete fault codes (DTC) section covering hundreds of diagnostic trouble codes with context, cause, possible failure modes, and solution procedures.

This manual also includes complete torque specifications, special tool requirements, service limits, and adjustment values throughout every section. The fault codes section alone covers engine, transmission, brake, steering, hydraulic, and electrical diagnostic trouble codes with detailed diagnostic procedures for each code.

Why This Manual Matters

When you are servicing a Case 821G or 921G wheel loader, having the correct procedures, torque values, and diagnostic steps is critical. These machines are complex, with electronically controlled engines, powershift transmissions, hydraulic systems that operate at high pressures, and aftertreatment systems that require precise handling. Using incorrect procedures can lead to component damage, system failures, or safety hazards. This manual gives you the exact sequence of operations for every procedure, the torque values for every fastener, the specifications for every component, and the diagnostic logic for every fault code.

Whether you are a professional technician in a dealership or an owner-operator who does your own maintenance, this manual provides the information you need to complete repairs correctly the first time. The procedures are written for technicians who need to remove and install major components, disassemble and assemble assemblies, test and adjust systems, and diagnose faults. The level of detail is suitable for someone who has mechanical experience and the proper tools, and the manual references special tools where they are required.

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Instant PDF Delivery

This Case 821G 921G Tier 4B wheel loader service manual is delivered as an instant PDF download after purchase. There is no shipping, no waiting for a physical book, and no risk of a damaged or lost package. You can access the manual on any device that reads PDF files, whether that is a computer, tablet, or smartphone. You can print the pages you need for the job and keep them in the workshop, or use the search function to find specific sections quickly. The PDF format also means you can zoom in on diagrams and illustrations for a closer look at components and assemblies.

With 2935 pages covering every system on the machine, this is the most comprehensive service information available for the 821G and 921G wheel loaders. It is the same document that professional dealership technicians use when servicing these machines, and it provides the complete scope of service information in a single download.