Case Construction 3 series User manual

Print No. 87734636C

Service Manual

21E

121E

221E

321E

Series 3

Compact Wheel Loaders

TO THE READER

This manual has been printed for a skilful engineer

to supply necessary technical information to carry

out service operations on this machine.

Read carefully this manual to collect correct infor-

mation relevant to repair procedures.

For any question or remark, or in case of any error

relevant the contents of this manual, please con-

tact:

CNH ITALIA S.p.A.

Via Plava, 80

10135 TORINO - Italy

REFERENCES

Beyond this Repair Manual, also refer to docu-

ments listed hereunder:

Operator’s Manual

Parts Catalogue

COMPLETE REPAIR MANUAL

The complete Repair Manual consists of two vol-

umes:

21E - 121E - 221E - 321E

Repair Manual for “Wheel loaders”

21E - 121E - 221E - 321E

Repair Manual for “Engine”

The Repair Manuals for “Wheel loaders” and “En-

gine” contain the necessary technical information

to carry out service and repair on machine and on

engine, necessary tools to carry out those opera-

tions and information on service standard, on pro-

cedures for connection, disconnection,

disassembly and assembly of parts.

The complete Repair Manual which covers the

loader models 21E - 121E - 221E - 321E consists

of the following volumes, which can be identified

through their print number as stated below:

VOLUME MACHINE TYPE PRINT NUMBER

Repair Manual - “Wheel loaders” 21E - 121E - 221E - 321E 87734636C

Repair Manual - “Engine” 21E - 121E - 221E - 321E 87736548A

Find manuals at https://best-manuals.com

TO PREVENT ACCIDENTS

The majority of accidents and injuries which occur in industry, on the farm, at home or on the

road, are caused by the failure of some individual to follow simple and fundamental safety rules

or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the

real cause and taking the necessary precautions, before the accident occurs.

Regardless of the care used in design and construction of any type of equipment, there may be

conditions that cannot be completely safeguarded against, without interfering with reasonable

accessibility and efficient operation.

A careful operator and / or technician is the best insurance against accidents. The complete ob-

servance of one simple rule would prevent many thousands of serious injuries each year.

This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.

SWARNING

Before carrying out any maintenance operation, adjustment and or repair on machines equipped

with attachments, controlled hydraulically or mechanically, make sure that the attachment is low-

ered and safely set on the ground. If it is necessary to have the equipment partially or fully raised

to gain access to certain items, be sure the equipment is suitably supported by means other than

the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.

NOTE: in this manual, the abbreviations of the models are the same as in the following table.

CNH S.p.A.

Via Plava, 80

10135 TORINO - Italy

prohibited.

21E Series 3 21E

121E Series 3 121E

221E Series 3 221E

321E Series 3 321E

Find manuals at https://best-manuals.com

INDEX

SECTION 00 - INTRODUCTION

1. SAFETY INSTRUCTIONS ............................................................................................................................ 1

1. GENERAL SAFETY INSTRUCTIONS .......................................................................................................... 2

1. TECHNICAL SPECIFICATIONS................................................................................................................. 12

SECTION 10 - ENGINE

1. DIESEL ENGINE .......................................................................................................................................... 1

2. FUEL SYSTEM ............................................................................................................................................. 2

3. COLD START DEVICE (NORTH AMERICA) ............................................................................................... 5

SECTION 25 - FRONT AXLES

1. REMOVAL AND INSTALLATION ................................................................................................................. 1

2. DIMENSIONS ............................................................................................................................................... 4

3. TECHNICAL SPECIFICATIONS................................................................................................................... 5

4. OIL CHANGE.............................................................................................................................................. 10

5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 13

5.1 DISC BRAKE ASSY (21E)................................................................................................................... 13

5.2 BRAKE CALIPER ................................................................................................................................ 20

5.3 REDUCTION GEAR (21E)................................................................................................................... 25

5.4 REDUCTION GEAR (121E, 221E, 321E)............................................................................................ 28

5.5 WHEEL HUB (21E).............................................................................................................................. 31

5.6 WHEEL HUB (121E, 221E, 321E)....................................................................................................... 40

5.7 WHEEL SHAFT (121E, 221E, 321E)................................................................................................... 46

5.8 BRAKE AND WHEEL SHAFT (121E, 221E, 321E “STANDARD” and “HIGH SPEED”) ..................... 50

5.9 DIFFERENTIAL SUPPORT ................................................................................................................. 58

5.10 DIFFERENTIAL ASSY....................................................................................................................... 66

5.11 PINION............................................................................................................................................... 73

6. TROUBLESHOOTING................................................................................................................................ 79

7. SPECIAL TOOLS........................................................................................................................................ 82

SECTION 27 - REAR AXLES

1. REMOVAL AND INSTALLATION ................................................................................................................. 1

2. DIMENSIONS ............................................................................................................................................... 3

3. TECHNICAL SPECIFICATIONS................................................................................................................... 7

4. OIL CHANGE.............................................................................................................................................. 14

5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 18

5.1 MOTOR TB150 .................................................................................................................................... 18

5.2 MOTOR TB138.5 “HIGH SPEED” ....................................................................................................... 21

5.3 TRANSMISSION BOX TB150 ............................................................................................................. 25

5.4 TRANSMISSION TB138.5 “HIGH SPEED” ......................................................................................... 34

5.5 REDUCTION GEAR (21E)................................................................................................................... 54

5.6 REDUCTION UNIT (121E, 221E, 321E).............................................................................................. 57

Find manuals at https://best-manuals.com

INDEX

5.7 WHEEL HUB (21E) .............................................................................................................................. 61

5.8 WHEEL HUB (121E, 221E, 321E) ....................................................................................................... 70

5.9 WHEEL SHAFT (121E, 221E, 321E) ................................................................................................... 76

5.10 DIFFERENTIAL SUPPORT ............................................................................................................... 80

5.11 DIFFERENTIAL ASSY....................................................................................................................... 88

5.12 LIMITED SLIP DIFFERENTIAL ASSY ............................................................................................... 94

5.13 PINION............................................................................................................................................. 101

6. TROUBLESHOOTING .............................................................................................................................. 107

7. SPECIAL TOOLS...................................................................................................................................... 110

SECTION 33 - BRAKE SYSTEM

1. BRAKE SYSTEM DIAGRAM ........................................................................................................................ 1

1.1 STANDARD DIAGRAM (21E)................................................................................................................ 1

1.2 “HIGH SPEED” DIAGRAM (121E, 221E, 321E) .................................................................................... 2

2. TECHNICAL SPECIFICATIONS................................................................................................................... 3

2.1 BRAKE PEDAL VALVE.......................................................................................................................... 3

2.2 PRESSURE SWITCHES ....................................................................................................................... 3

3. OPERATION ................................................................................................................................................. 4

3.1 SERVICE BRAKE OPERATION ............................................................................................................ 6

3.2 PARKING BRAKE OPERATION............................................................................................................ 8

4. BRAKE PEDAL VALVE................................................................................................................................. 9

5. PRESSURE SWITCHES ............................................................................................................................ 11

6. BRAKE ACCUMULATOR ........................................................................................................................... 12

6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 12

7. CHECKS AND ADJUSTMENTS ................................................................................................................. 13

7.1 SERVICE BRAKE SYSTEM PRESSURE CHECK .............................................................................. 13

7.2 ACCUMULATOR PRESSURE CHECK ............................................................................................... 14

7.3 PEDAL ANGLE ADJUSTMENT ........................................................................................................... 15

7.4 “INCHING” VALVE ADJUSTMENT...................................................................................................... 16

8. TROUBLESHOOTING ................................................................................................................................ 17

SECTION 35 - HYDRAULIC SYSTEM

1. HYDRAULIC DIAGRAMS ............................................................................................................................. 1

1.1 HYDRAULIC DIAGRAM FOR 21E......................................................................................................... 1

1.2 HYDRAULIC DIAGRAM FOR 21E WITH OPTIONAL OUTFITS........................................................... 3

1.3 HYDRAULIC DIAGRAM FOR 121E....................................................................................................... 5

1.4 HYDRAULIC DIAGRAM FOR 121E WITH OPTIONAL OUTFITS......................................................... 7

1.5 HYDRAULIC DIAGRAM FOR 221E....................................................................................................... 9

1.6 HYDRAULIC DIAGRAM FOR 221E WITH OPTIONAL OUTFITS....................................................... 11

1.7 HYDRAULIC DIAGRAM FOR 321E..................................................................................................... 13

1.8 HYDRAULIC DIAGRAM FOR 321E WITH OPTIONAL OUTFITS....................................................... 15

2. TRANSMISSION......................................................................................................................................... 17

2.1 HYDRAULIC DIAGRAM....................................................................................................................... 17

2.2 OPERATION ........................................................................................................................................ 18

2.3 ADJUSTMENTS................................................................................................................................... 20

3. VARIABLE-DISPLACEMENT PISTON PUMP............................................................................................22

3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 23

3.2 MAIN VALVES ..................................................................................................................................... 24

Find manuals at https://best-manuals.com

INDEX

3.3 DISASSEMBLY.................................................................................................................................... 32

3.4 ASSEMBLY.......................................................................................................................................... 51

4. GEAR PUMP .............................................................................................................................................. 58

4.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 58

4.2 COMPONENTS ................................................................................................................................... 59

4.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 60

5. PRIORITY VALVE ...................................................................................................................................... 63

5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 63

6. TRAVEL MOTOR........................................................................................................................................ 64

6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 64

6.2 MAIN COMPONENTS ......................................................................................................................... 66

6.3 OPERATION........................................................................................................................................ 67

6.4 REMOVAL ........................................................................................................................................... 70

6.5 DISASSEMBLY AND ASSEMBLY....................................................................................................... 71

7. ONE-WAY DISTRIBUTOR VALVE............................................................................................................. 85

8. HYDRAULIC OIL TANK.............................................................................................................................. 86

8.1 OIL FILTER.......................................................................................................................................... 87

9. TROUBLESHOOTING................................................................................................................................ 88

SECTION 39 - FRAME

1. ARTICULATED JOINT.................................................................................................................................. 1

1.1 COMPONENTS ..................................................................................................................................... 1

1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 2

SECTION 41 - STEERING SYSTEM

1. OPERATION................................................................................................................................................. 1

1.1 EMERGENCY STEERING .................................................................................................................... 3

1.2 PRESSURE ADJUSTMENT.................................................................................................................. 4

2. POWER STEERING ..................................................................................................................................... 5

2.1 TECHNICAL SPECIFICATIONS............................................................................................................ 6

2.2 COMPONENTS ..................................................................................................................................... 7

2.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8

2.4 TROUBLESHOOTING......................................................................................................................... 24

2.5 SPECIAL TOOLS................................................................................................................................. 25

3. STEERING CYLINDER .............................................................................................................................. 26

3.1 REMOVAL AND INSTALLATION ........................................................................................................ 27

3.2 DISASSEMBLY.................................................................................................................................... 29

4. TROUBLESHOOTING................................................................................................................................ 34

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM

1. HEATING ...................................................................................................................................................... 1

2. AIR CONDITIONING .................................................................................................................................... 3

3. TROUBLESHOOTING................................................................................................................................ 29

Find manuals at https://best-manuals.com

INDEX

SECTION 55 - ELECTRICAL SYSTEM

1. ELECTRICAL DIAGRAMS............................................................................................................................ 1

2. FUSES AND RELAYS ................................................................................................................................ 17

3. VOLTAGE AND CONTINUITY CHECK ...................................................................................................... 20

4. BATTERY.................................................................................................................................................... 21

4.1 REPLACEMENT .................................................................................................................................. 24

5. BULBS ........................................................................................................................................................ 25

6. TROUBLESHOOTING ................................................................................................................................ 29

SECTION 82 - WORKING EQUIPMENT

1. HYDRAULIC DIAGRAM................................................................................................................................ 2

2. OPERATION ................................................................................................................................................. 3

3. REMOVAL AND INSTALLATION ................................................................................................................. 4

4. QUICK TOOL COUPLER.............................................................................................................................. 6

4.1 COMPONENTS ..................................................................................................................................... 7

4.2 QUICK TOOL COUPLER CYLINDERS ................................................................................................. 8

5. BUCKET........................................................................................................................................................ 9

5.1 ASSEMBLY............................................................................................................................................ 9

5.2 DISASSEMBLY.................................................................................................................................... 10

5.3 BUCKET TEETH - REPLACEMENT.................................................................................................... 11

6. FORKS........................................................................................................................................................ 12

6.1 DISASSEMBLY AND ASSEMBLY....................................................................................................... 13

6.2 CHECKS .............................................................................................................................................. 14

7. CYLINDERS................................................................................................................................................ 16

7.1 BOOM CYLINDER ............................................................................................................................... 16

7.2 DUMPING CYLINDER ......................................................................................................................... 20

8. CONTROL VALVE ...................................................................................................................................... 24

9. LOAD HOLDING VALVE ............................................................................................................................ 27

9.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 27

10. TROUBLESHOOTING .............................................................................................................................. 28

Find manuals at https://best-manuals.com

1. SAFETY INSTRUCTIONS ............................................................................................................................ 1

2. GENERAL SAFETY INSTRUCTIONS .......................................................................................................... 2

3. TECHNICAL SPECIFICATIONS................................................................................................................. 12

SECTION 00 - INTRODUCTION

Find manuals at https://best-manuals.com

SECTION 00 - INTRODUCTION

Find manuals at https://best-manuals.com

SECTION 00 - INTRODUCTION 1

1. SAFETY INSTRUCTIONS

Carefully read the safety rules contained herein and

follow advised precautions to avoid potential haz-

ards and to safeguard your safety and personal in-

tegrity.

In this manual you will find the following indications:

SWARNING

This symbol warns about the possibility of potential

damages to the machine that can involve the opera-

tor’s safety.

SDANGER

With specific warnings about potential dangers for

the operator’s or other persons integrity directly or

indirectly involved.

The non compliance with the warning preceded by

the above mentioned key-words (WARNING and

DANGER) can cause serious accidents or even the

death of the persons involved.

Moreover in the present Manual have been given

some instructions with texts in italics, preceded by

the words NOTE and CAUTION, with following

meanings for machine protection:

NOTES: it emphasizes and underlines to the opera-

tor the correct technique or correct procedure to fol-

low.

SWARNING

It warns the operator of a possible hazard of machine

damage in case he does not follow a determined pro-

cedure.

Your safety and that of people around you depends

on you. It is essential that you understand this man-

ual for the correct operation, inspection, lubrication

and maintenance of this machine.

Find manuals at https://best-manuals.com

Other manuals for CONSTRUCTION 3 Series

This manual suits for next models

Popular Construction Equipment manuals by other brands

Ammann

Ammann AV23-2 manual

stellar labs

stellar labs Model 7628 owner's manual

Hailo

Hailo H-50 manual

Graco

Graco LineLazer ES 1000 Operation - repair - parts

Greenlee

Greenlee 555RSC instruction manual

Manitowoc

Manitowoc Grove CD3340B Service manual

Lux Tools

Lux Tools A-FMR-20 Set manual

SIP

SIP 03683 manual

Volvo

Volvo L30G Operator's manual

Grizzly

Grizzly G8712 instruction sheet

Wacker Neuson

Wacker Neuson DT05 Operator's manual

HYVA

HYVA AMCO VEBA 81 Series WARNING, OPERATING AND MAINTENANCE MANUAL

Atlas Copco

Atlas Copco Dynapac V5100TV manual

Manitowoc

Manitowoc National Crane 1400A Operator's manual

SGS

SGS EC1500 owner's manual

Turbosol

Turbosol BM 30 Use and maintenance manual

Fayat

Fayat CC424CHF instruction manual

Altrad

Altrad BELLE TDX 650A Operator's manual

Case CONSTRUCTION 3 Series User manual

Popular Construction Equipment manuals by other brands