PDF Operator's Manual Case 821F 921F Tier 2 Wheel Loader - 6 MB
This operator's manual is your guide to the safe and efficient operation of the Case 821F and 921F Tier 2 Wheel Loaders.
It covers all controls, instruments, and recommended operating techniques.
The manual also outlines daily service checks to ensure your machine is always ready to work.
Every operator must be familiar with this content to promote a safe and productive job site.
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--- Page 1 ---
821F
921F
Tier 2
Wheel Loader
OPERATOR’S MANUAL
Part number 84548518
2nd edition English
February 2012
Replaces part number 84377185
--- Page 3 ---
1 - GENERAL INFORMATION
Machine components
RCPH10WHL094FAH 1
1. Cab door and hand holds 5. Bucket cylinder
2. Steps 6. Roll Over Protection System (ROPS) cab
3. Bucket 7. Loader lift arms
4. Electric disconnect and optional battery jump post 8. Battery access
1-5
--- Page 4 ---
2 - SAFETY INFORMATION
Safety rules
Getting on and off the machine
• Use the recommended hand holds and steps with at
least three points of support when getting on and off
the machine. The door must be latched and secured
in the open position before using the door hand hold.
Keep steps and platform clean. Face the machine
and use the hand holds and steps adhering to a
three-point access system when climbing up and
down.
• Do not jump off the machine.
• Do not dismount while the machine is in motion.
• Foreign material or grease on the steps and hand
rails can cause an accident. Keep the steps and
hand rails clean.
RCPH10WHL436AAH 1
2-5
--- Page 5 ---
2 - SAFETY INFORMATION
Transport service link
WARNING
Crushing hazard!
Engage the safety lock link before service or transport.
Failure to comply could result in death or serious injury.
W1154A
Prior to any maintenance, service work or transportation, lock the articulation transport service link.
1. Remove the safety security pin to change positions
of the service link.
RCPH10WHL062BAL 3
2. Move the service link into the locked position to pre-
vent articulation. Insert the safety security pin.
RCPH10WHL063BAL 4
2 - 15
--- Page 6 ---
2 - SAFETY INFORMATION
WARNING — Entanglement hazard
RCPH10WHL153AAH 35
This WARNING safety sign is located at the rear of the
engine compartment on the fan guard.
WARNING — Entanglement Hazard. Keep clear or
stop engine before servicing. Failure to comply with this
warning could result in death or serious injury.
ISO decal number: 388113A1 388113A1 36
Maintenance decal
84397761A 38
RCPH10WHL153AAH 37
This information safety sign is located in the rear of the
engine compartment on the fan guard.
Informational decal - maintenance intervals
Informational sign decal number: 84397761
2 - 25
--- Page 7 ---
2 - SAFETY INFORMATION
Lower the boom
RCPH10WHL016BAD 72
Retract arm
RCPH10WHL014BAD 73
Extend arm
RCPH10WHL011BAD 74
Fill tool
RCPH10WHL015BAD 75
2 - 35
--- Page 8 ---
3 - CONTROLS/INSTRUMENTS
Steering column
Ignition switch
The ignition switch has four positions:
Accessory position
This position will energize the optional radio only. It will
not energize the instruments or start the engine.
OFF position
In this position, all switch controlled current is OFF. Turn
the key to OFF to stop the engine. Remove the key and
turn the Master Disconnect Switch to OFF.
START position RCPH10WHL114BAL 1
Turn the key to this position to engage the starter motor
to start the engine. The switch is spring loaded and will
return to the ON position when released.
ON position
This position will energize all electrical systems. The key
will return to this position after you release the key from
the start position.
Horn and turn signal
WARNING
Hazard to bystanders!
Always sound the horn before starting the ma-
chine. Make sure the work area is clear of
other persons, domestic animals, tools, etc.
before you operate the machine. Never allow
anyone in the work area during machine oper-
ation.
Failure to comply could result in death or se-
rious injury.
W0304A
1. Horn - Push the horn lever in to actuate RCPH10WHL115BAL 2
the horn.
2. Turn signal lever - Push the control lever
up to signal a left turn. Pull the lever down
to signal a right turn. The lever must be
moved manually to the center position to
stop the signals.
3-9
--- Page 9 ---
3 - CONTROLS/INSTRUMENTS
Shuttle shifting - direction change manual or
automatic
It is not necessary to bring the machine to a complete
stop when changing directions from forward to reverse or
reverse to forward. For smooth operation and operator
comfort, reduce engine speed before direction changes.
RCPH10WHL110BAL 3
3 - 19
--- Page 10 ---
3 - CONTROLS/INSTRUMENTS
4. TRANSMISSION DOWNSHIFT
BUTTON - Drops the transmission down
one gear at a time.
5. F-N-R Switch. This switch will allow the
operator to put the transmission in forward,
neutral, or reverse. To activate this auxiliary
F-N-R switch, the proper sequence must
be followed. The primary shift lever must
be in the neutral position before using the
auxiliary F-N-R switch. Push the switch
forward to place the transmission in forward,
place the switch in the middle position to RCPH10WHL120BAL 3
place the transmission in neutral, and pull
the switch rearward to put the transmission
in reverse.
A. Forward (Transmission)
B. Neutral (Transmission)
C. Reverse (Transmission)
3 - 29
--- Page 11 ---
3 - CONTROLS/INSTRUMENTS
8. Transmission oil temperature gauge
The transmission oil temperature gauge
indicates the oil temperature of the
transmission.
The Caution Master Indicator is a non-critical warning dis-
play. See Non-Critical Warning Displays.
The normal operating temperature is in the green zone.
When the transmission oil temperature increases, the
gauge will move into the yellow zone, the warning alarm RCPH10WHL008AAD 3
sounds, and the caution master indicator turns yellow.
When the temperature continues to increase the gauge
moves into the red zone, the warning alarm will sound
continuously, and the stop master indicator turns red. Do
not operate the machine when the temperature is in the
red zone.
Transmission oil temperature gauge
Gauge indication Condition Master Gauge status Alarm status
indicator
20 °C (68 °F) and below Oil temperature is very low Caution (yellow) Flashes 3 Seconds
20 - 120 °C (68 - 248 Oil temperature is normal
°F)
120 - 125 °C (248 - 257 Oil temperature is high Caution (yellow) Flashes 3 Seconds
°F)
(See the note below.)
125 °C (257 °F) and Oil temperature is very high Stop (red) Flashes Continuous
above
NOTE: To prevent damage to the transmission, stop the machine, shift the transmission to neutral, and run the engine
at partial throttle (approximately 1700 RPM) until the transmission cools. If the transmission oil temperature does not
return to normal operating temperature, run the engine at idle speed, and check the transmission oil level. Correct
the problem before continuing to operate the machine.
3 - 39
--- Page 12 ---
3 - CONTROLS/INSTRUMENTS
Entering the service screens
After the machine has been started or the key switch has been turned to ON, the operator or service technician may
use the main menu to adjust machine configurations to working conditions, to test components, view faults that may
have occurred, or to select preferences. Languages can be set at the beginning of the menu configuration to allow
the operator to work in the language of choice.
Main menu
Press and hold the confirm key for two seconds to arrive
at the main menu. The arrow keys can be used to scroll
through menu selections.
Items and selections in this menu are:
Settings
Display
Diagnostics
Service
RCPH10WHL804AAH 12
Settings
Selections at the setting menu include:
Engine
Transmission
Joystick steering (Option - will display only if machine is
joystick steering equipped)
RCPH10WHL803BAH 13
3 - 49
--- Page 13 ---
3 - CONTROLS/INSTRUMENTS
Switch operations
1. Rear wiper switch
A. Push switch to the center position for ON.
B. Push on the front of switch for washer
fluid.
2. Front wiper/washer switch
A. OFF - Toggle switch is in the OFF
position.
B. INTERMITTENT - Push toggle to the
first position. There are six settings for
intermittent wiper speeds.
C. LOW - Push toggle ahead until the wiper
runs continuously for low wiper speed. RCIL10WHL192BAL 1
D. HIGH - Push toggle ahead for high wiper
speed.
E. WASH - Push down on the front of the
switch for washer fluid.
3. Driving light switch
Push on the top of the switch for roading
machine. Pushing on the bottom of the
switch will turn the lights OFF. The middle
position is for marker/position lights.
4. Work light switch
Push on the top of the switch for front and
rear working lights. The middle position is
for front work lights only. Pushing on the
bottom of the switch will turn the lights OFF.
RCPH10WHL194AAH 2
5. Rotating beacon (optional)
Push on the top of the rotating beacon
switch for the ON position. Push the switch
bottom for the OFF position.
3 - 59
--- Page 14 ---
4 - OPERATING INSTRUCTIONS
4 - OPERATING INSTRUCTIONS
COMMISSIONING THE UNIT
Before starting the engine
WARNING
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY.
MAKE SURE THAT EVERY OPERATOR:
-is instructed in the safe and proper use of this machine.
-reads and understands the operator's manual for this machine.
-reads and understands ALL safety signs on the machine.
Failure to comply could result in death or serious injury.
W0188A
WARNING
Avoid injury!
Do not operate the machine while under the influence of alcohol or drugs.
Failure to comply could result in death or serious injury.
W0160A
Before starting the engine
1. Perform a daily walk around and visual inspection 2. See the quick reference Maintenance Chart in this
of the machine. Check for loose connections, faulty manual and complete the items in the daily - 10 hour
hoses, oil leaks, debris or trash buildup, loose bolts, section of the chart.
damaged, or missing parts that could effect the 3. Check that the machine fuel tank is filled with clean
normal and safe operation of the machine. Make fuel that matches the specifications given in this
any necessary corrections before operating the manual.
machine.
4-1
--- Page 15 ---
4 - OPERATING INSTRUCTIONS
STOPPING THE UNIT
Stopping the engine
WARNING
Unexpected movement!
Always engage the parking brake and switch off the engine before exiting the machine.
Failure to comply could result in death or serious injury.
W0209A
1. Stop the machine on hard, level ground and place
the gearshift selector in NEUTRAL.
NOTICE: If you must temporarily park the machine
on a hillside, put the front of the machine toward the
bottom of the hill. Make sure the machine is behind
an object that will not move.
RCIL10WHL193BAL 1
2. Slowly move the equipment control levers forward
to rest the equipment on the ground.
3. Push the parking brake switch to the ON position.
Turn the engine off.
RCPH10WHL028BAL 2
4. Slowly move the equipment levers through all ro-
tations to insure that residual pressures in the hy-
draulic system are released.
RCPH10WHL119BAL 3
4 - 11
--- Page 16 ---
4 - OPERATING INSTRUCTIONS
When steps 1 through 5 have been completed the trans-
mission enable switch may be enabled by pushing down
on the top of the switch (4). The indicator light on the bot-
tom of the switch will illuminate.
The transmission enable switch will be DEACTIVATED
and F-N-R control will default back to the Standard
Transmission Control Lever if:
1. The engine is stopped.
2. The parking brake is applied.
3. The transmission control lever is taken out of the
neutral position.
RCPH10WHL008BAL 4
4 - 21
--- Page 17 ---
4 - OPERATING INSTRUCTIONS
Auxiliary hydraulic connection (if equipped)
WARNING
Escaping fluid!
Do not disconnect hydraulic quick coupler under pressurized conditions. Make sure all hydraulic
pressure is removed from the system before disconnecting hydraulic quick coupler.
Failure to comply could result in death or serious injury.
W0095A
Your Wheel Loader may be equipped with an Auxiliary Hy-
draulic System. A control lever on the console controls
flow to the auxiliary hydraulic connection points on the lift
arms. The auxiliary control lever (1) used with a joystick
(2) is equipped with mechanical detents to lock it into full
forward, full rearward and neutral positions. Auxiliary con-
trol levers on non-joystick machines DO NOT have me-
chanical detents.
RCIL10WHL280BAL 11
RCPH10WHL118BAL 12
4 - 31
--- Page 19 ---
6 - WORKING OPERATIONS
Operating the machine in water
WARNING
Driving hazard!
Do not operate the machine in a fast flowing
stream. Fast flowing water can cause you to
lose control of the machine.
Failure to comply could result in death or se-
rious injury.
W0151A
• Make sure that the bottom of the stream, or water
in which you will work, can support the weight of the
machine.
• Do not allow the water level to reach the wheel rim.
• Before using the machine in water, inject large quan-
tities of fresh grease into the appropriate grease fit-
tings.
• After completing the operation make sure to inject
fresh quantities of grease into any fitting that was in
water.
6-3
--- Page 20 ---
6 - WORKING OPERATIONS
Joystick operation
WARNING
Driving hazard!
Check all controls and safety devices in a safe, open area before starting work.
Failure to comply could result in death or serious injury.
W0248A
WARNING
Driving hazard!
Always use the primary steering when traveling on a public road or highway. The left armrest must be
raised and in a locked position during travel. Do not use joystick steering when traveling on a public
road or highway.
Failure to comply could result in death or serious injury.
W0451A
Joystick steering control lever (optional)
The joystick steering control lever allows the loader to be
operated using hand controls located on the left opera-
tor seat armrest. It allows for steering capabilities at the
operator’s fingertips. Moving the lever right or left steers
the machine in the right or left direction. When the Joy-
stick is released, the lever will return to the neutral po-
sition automatically. The machine will remain in the last
direction chosen. Forward and reverse are accomplished
with the F-N-R switch. Use the joystick steering controls
for short cycle, repetitive high production load and carry
operations to reduce operator fatigue and increase oper-
ating efficiency.
RCIL10WHL188BAL 1
1. Joystick steering control lever
2. Forward-neutral-reverse switch
3. Kick-down switch
6 - 13
--- Page 21 ---
7 - MAINTENANCE
Support strut for loader lift arm
Loader lift arm support
DANGER
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
Failure to comply will result in death or serious injury.
D0084A
1. Empty the loader bucket, raise the loader lift arms
to approximately 2.1 m (7 ft) and stop engine.
2. Remove the support strut from the storage position
by removing the retaining bolt (1).
3. Place the support strut on to the cylinder rod with the
guide lock tab on top of cylinder and pointing toward
the bucket (2).
4. Install the retaining bolt entirely into the support strut
using all threads (3).
5. Slowly lower the lift arms onto the support strut.
If you do not follow this procedure, you can cause death
or serious injury if the loader lift arms are lowered unex- RCPH10WHL059BAL 1
pectedly.
NOTE: Support strut in transport position.
RCPH10WHL061BAL 2
NOTE: Support strut in service position.
7-3
--- Page 22 ---
7 - MAINTENANCE
MAINTENANCE CHART
Maintenance Chart
Cleaning
Adjust
Drain fluid
Replace
Change fluid
Grease
Check
Interval Page Maintenance Action Nb.
Nb. of
pts
Daily inspection 7-15 General X
Every 10 hours 7-19 Engine oil X
Every 50 hours 7-20 Bucket/attachment grease fittings X
7-21 Grease machine and attachments X
7-22 Hydraulic oil level X
7-23 Transmission oil level X
7-24 Engine coolant X
Initial 100 hours 7-25 Wheel torque X
7-27 Change engine oil and filter (Initial) X
7-30 Replace hydraulic oil filter (Initial) X
7-31 Fuel prefilter (Initial) X
7-32 Replace fuel filter (Initial) X
Every 100 hours 7-33 Grease fittings X
Every 250 hours 7-35 Grease drive shaft slip joints X
7-36 Cab air filter X
7-38 Wheels and tires X
Every 500 hours 7-40 Change engine oil and filter X
7-43 Replace fuel prefilter X
7-44 Fuel filter X
7-45 Fuel tank sediment X
7-46 Axle oil level X
7-47 Roll over protective structure X
7-50 Battery fluid level X
Every 1000 hours 7-51 Pivot points X
7-52 Articulation fittings X
7-53 Hydraulic oil filter X
7-54 Drive belt X
7-56 Cab air filter X
7-58 Replacing the engine breather filter X
Every 1500 hours 7-59 Change front and rear axle oil X
7-61 Calibrating the gear box X
7-62 Transmission declutch pressure adjustment X
7-63 Transmission fluid and filter X
Every 2000 hours 7-65 Hydraulic oil and filters X
7-67 Engine coolant X
7-69 Engine air filters X
7-71 Frame and cab - lubricate X
7-71 Engine valve clearance X
7 - 13
--- Page 23 ---
7 - MAINTENANCE
Transmission oil level
Check the transmission oil level every 50 hours of operation.
Prior operation:
Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking
brake applied and the attachment lowered to the ground. The transmission oil level sight gauge is on the left side of
the machine.
Service specifications
Type of oil CASE AKCELA NEXPLORE™ FLUID
821F Capacity 34.1 l (36.0 US qt)
921F Capacity 34.1 l (36.0 US qt)
Cold oil level check
Before you start the engine, check the transmission oil level
in the sight gauge. If the oil level is below the arrow, add
oil to raise the oil level up to the arrow.
RCPH10WHL141AAH 1
Engine running check
WARNING
Hazard to bystanders!
Make sure the area surrounding the machine is clear of all persons before starting the engine.
Failure to comply could result in death or serious injury.
W0090A
1. Keep all non-authorized personnel clear of the
area. Park the machine on level ground, in
neutral with the parking brake applied and the
attachment lowered to the ground. The pilot
lock out should be engaged to neutralize hy-
draulic flow.
2. The transportation/service link must be in place
to prevent unexpected articulation.
3. Locate the transmission oil level sight gauge on
the left side of the machine.
4. If this check is to be performed in an enclosed
area, ventilate properly to reduce the deadly
exhaust fumes.
5. Check the transmission oil level at idle speed
with the oil temperature of 65 - 70 °C (149.0 -
158.0 °F). The oil level should rise to the top
of the gauge. Oil level should be between the
bottom and top of the cross hatch region.
6. Add oil if necessary. Do not overfill.
7 - 23
--- Page 24 ---
7 - MAINTENANCE
Every 100 hours
Grease fittings
WARNING
Improper operation or service of this machine can result in an accident.
Read and understand the SAFETY INFORMATION Section before you perform any maintenance, ser-
vice, or repairs. Read and understand the specific service procedures for the components you plan
to work with before you start servicing the machine.
Failure to comply could result in death or serious injury.
W0138A
WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
support strut from the storage position and place the strut onto the cylinder rod. Install the retaining
bolt entirely into the strut. Lower lift arms onto the support strut.
Failure to comply could result in death or serious injury.
W0140A
WARNING
Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine.
1. Disengage all drives.
2. Engage parking brake.
3. Lower all attachments to the ground, or raise and engage all safety locks.
4. Shut off engine.
5. Remove key from key switch.
6. Switch off battery key, if installed.
7. Wait for all machine movement to stop.
Failure to comply could result in death or serious injury.
W0047A
Machine grease fittings
RCPH10WHL096AAH 1 RCPH10WHL094AAH 2
7 - 33
--- Page 25 ---
7 - MAINTENANCE
Replace fuel prefilter
WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
Failure to comply could result in death or serious injury.
W0904A
Prior operation:
Park the machine on a firm, level surface. Lower the attachment to the ground. apply the parking brake, and install
the transport service link to prevent unexpected articulation.
Drain fuel prefilter condensation
1. Change the fuel prefilter when the machine hourme-
ter registers 500 hours. Change filter every 500
hours thereafter or more often if conditions so require
or if fuel quality is poor. The prefilter is located on the
right side of the machine.
2. Remove connector. Open the drain valve on the
fuel prefilter by turning counterclockwise two or three
turns. Drain the water and/or contaminants from the
prefilter into a suitable container until clean fuel flows.
Do not allow fuel to spill on engine or ground.
3. Turn the filter counterclockwise to remove.
4. Replace with a new filter cartridge, turning clockwise RCPH10WHL114AAH 1
until the cartridge meets the filter head. Hand tighten
firmly in place. Do not use a wrench to tighten. Re-
place connector at bottom of filter.
7 - 43
--- Page 26 ---
7 - MAINTENANCE
Hydraulic oil filter
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
Failure to comply could result in death or serious injury.
W0161A
WARNING
Pressurized fluid can penetrate the skin and cause severe injuries.
Keep hands and body away from any pressurized leak. DO NOT use your hand to check for leaks. Use
a piece of cardboard or paper. If fluid penetrates the skin, seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0158A
Replace the hydraulic oil filter when the hourmeter registers 1000 hours The filter should be changed every 1000
hours thereafter or more frequently when operating conditions are severe.
Prior operation:
Keep all non-authorized personnel clear of the area. Park the machine on level ground in neutral with the parking
brake applied and the attachment lowered to the ground.
1. Release pressure in the hydraulic system. Install the
transport/service link into the lock position.
2. Slowly loosen the filler cap on the hydraulic reser-
voir to release any residual pressure in the reservoir.
Leave it loose during the procedure.
3. Turn the filter counterclockwise to remove. Lubricate
the gasket and threads of the new filter with clean oil
and install. After the filter makes contact with the filter
head tighten 1/2 to 3/4 turns.
4. Tighten the cap on the hydraulic reservoir.
RCPH10WHL099BAL 1
5. Start the engine and run at 1000 RPM. Have an as-
sistant check for leaks around the filter area. Stop
the engine and check and hydraulic level. Top off if
necessary.
RCPH10WHL127AAH 2
NOTICE: Never use a filter wrench to tighten a new filter on install.
7 - 53
--- Page 27 ---
7 - MAINTENANCE
Transmission fluid and filter
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
Change the transmission fluid and filter every 1500 hours or more frequently when operating conditions are severe.
Shorten service intervals in severe applications which involve running the torque converter under high load for more
than 25% of operation time. Applications include basement digging or land clearing. Reduce intervals as well if using
low viscosity oil.
Prior operation:
Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking
brake applied and the attachment lowered to the ground.
Oil Type
Non-Case Nexplore (other brands) CASE AKCELA NEXPLORE™ FLUID