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Case CONSTRUCTION 3 Series Service Manual
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Case CONSTRUCTION 3 Series Service Manual

Case CONSTRUCTION 3 Series Service Manual

Compact wheel loaders
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21E
121E
221E
321E
Series 3
Compact Wheel Loaders
Service Manual
Print No. 87734636C

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Summary of Contents for Case CONSTRUCTION 3 Series

  • Page 1 121E 221E 321E Series 3 Compact Wheel Loaders Service Manual Print No. 87734636C...
  • Page 2 10135 TORINO - Italy 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: REFERENCES...
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.............................
  • Page 6 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 .........................
  • Page 7 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.
  • Page 8 SECTION 00 - INTRODUCTION 1. SAFETY INSTRUCTIONS ..........................1 2. GENERAL SAFETY INSTRUCTIONS......................2 3. TECHNICAL SPECIFICATIONS......................... 12 Find manuals at https://best-manuals.com...
  • Page 9 SECTION 00 - INTRODUCTION Find manuals at https://best-manuals.com...
  • Page 10 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.
  • Page 11 SECTION 00 - INTRODUCTION GENERAL SAFETY INSTRUCTIONS Carefully read this Manual before proceeding with maintenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and instructed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy hammers.
  • Page 12 SECTION 00 - INTRODUCTION EMERGENCY Be prepared for emergencies. Always keep at dis- posal on the machine a first aid kit and a fire extin- guisher. Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s in- structions.
  • Page 13 SECTION 00 - INTRODUCTION PLACING THE MACHINE IN SAFE CONDITIONS Before carrying out any repair operation on this ma- chine, place it in safe conditions. Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.
  • Page 14 Keep the exhaust manifold and tube free from combustion materials. Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spill- age. Never attempt to check or adjust the fan belts when the engine is running.
  • Page 15 SECTION 00 - INTRODUCTION HYDRAULIC SYSTEMS Splashes of fluids under pressure can penetrate the skin causing serious injuries. Avoid this hazard by relieving pressure before dis- connecting hydraulic or other lines. Relieve the residual pressure by moving the hydrau- lic control levers several times. Tighten all connections before applying pressure.
  • Page 16 SECTION 00 - INTRODUCTION HOSES AND TUBES Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connections.
  • Page 17 SECTION 00 - INTRODUCTION BATTERY Batteries give off explosive gases. Never handle naked flames and unshielded light sources near batteries, never smoke. To prevent any risk of explosion, observe the follow- ing instructions:  when disconnecting the battery cables, always dis- connect the negative (-) cable first;...
  • Page 18 SECTION 00 - INTRODUCTION FLAMMABLE LIQUIDS When handling flammable liquids:  do not smoke;  keep away from unshielded light sources and na- ked flames. Fuels often have a low flash point and are readily ig- nited. Never attempt to extinguish burning liquids with wa- ter.
  • Page 19 SECTION 00 - INTRODUCTION TYRES Before inflating the tyres, always check the condition of rims and the outer condition of tyres to find out the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tyre, make sure that there are no nearby persons, then position yourself at tread side.
  • Page 20 SECTION 00 - INTRODUCTION 2.10 WASTE DISPOSAL Improperly disposing of waste can threaten the envi- ronment. Each country has its own Regulations on this sub- ject. It is therefore advisable to prepare suitable con- tainers to collect and store momentarily all solid and fluid materials that must not be scattered in the envi- ronment to avoid pollution.
  • Page 21 SECTION 00 - INTRODUCTION TECHNICAL SPECIFICATIONS MAIN COMPONENTS 1. Wheel loader bucket 9. Hydraulic pumps 2. Tilt dumping cylinder 10. Battery 3. Lifting cylinder 11. Rear axle 4. Fuel tank 12. Transmission 5. Cab 13. Steering cylinder 6. Hydraulic oil tank 14.
  • Page 22 SECTION 00 - INTRODUCTION DIMENSIONS AND PERFORMANCE WITH BUCKET BUCKET - DIMENSIONS 121E 221E 321E Total length mm (in) 5360 (211.02) 5490 (216.14) 5590 (220.07) 5650 (222.44) Cab height mm (in) 2710 (107.70) 2790 (109.84) 2790 (109.84) 2790 (109.84) Bucket width mm (in) 1900 (74.80) 2050 (80.70) 2100 (88.70)
  • Page 23 SECTION 00 - INTRODUCTION DIMENSIONS AND PERFORMANCE WITH FORKS BUCKET WITH FORKS - DIMENSIONS 121E 221E 321E Total length with forks mm (in) 1200 (47.24) 1200 (47.24) 1200 (47.24) 1200 (47.24) Width of fork support mm (in) 1450 (57.08) 1450 (57.08) 1450 (57.08) 1450 (57.08) Fork weight kg (lb) 336 (741)
  • Page 24 SECTION 00 - INTRODUCTION WEIGHTS 121E 221E 321E Engine kg (lb) 300 (660) Front axle kg (lb) 230 (506) 318 (700) Rear axle (gearbox included) kg (lb) 312 (686) 251 (552) 315 (693) and travel motor kg (lb) 470 (1034) Variable-displacement pump kg (lb) 30 (66)
  • Page 25 40 (29.50) Inspection covers 25 (18.43) Timing gearbox cover 25 (18.43) Timing gearbox 25 (18.43) Flywheel case (M8) 35 (25.81) Flywheel case (M12) 120 (88.50) Cylinder head - 1st phase (M12) 65 (47.94) Cylinder head - 2nd phase (M12) 90 (66.38) Cylinder head - 3rd phase (M12) 60 (44.25)
  • Page 26 SECTION 00 - INTRODUCTION BRAKES SYSTEM BRAKE PEDAL VALVE Allowable service pressure ....................175 bar (2538 psi) Adjusted pressure ........................55 bar (797 psi) Pressure of brake on disc ......................55 bar (797 psi) Accumulator charging valve Preloading pressure....................... 175 bar (2537 psi) “Cut-in”...
  • Page 27 SECTION 00 - INTRODUCTION STEERING SYSTEM System pressure ........................175 bar (2537 psi) POWER STEERING 21E - 121E - 221E 321E Model OSPC200LS OSPC315LS Displacement 200 (12.20) 315 (19.22) /rev (in /rev) Rated oil flow l/min (gal/min) 20 (5.30) 32 (8.40) Weight kg (lb) 5.8 (13)
  • Page 28 SECTION 00 - INTRODUCTION VARIABLE-DISPLACEMENT PUMP 121E 221E 321E System Pump with adjustment depending on engine rpm AV4VG40DA1D2 A4VG56DA1D2 A4VG56DA1D2 A4VG71DA1D2 Model / 32R / 32R / 32R / 32R /rev 56.0 56.0 71.0 Displacement (2.44) (3.41) (3.41) (4.33) /rev) Power kW (hp) 35.7 (46.1)
  • Page 29 SECTION 00 - INTRODUCTION HYDRAULIC CYLINDERS 121E 221E 321E Lifting cylinder Quantity Ø rod mm (in) 50 (1.96) 55 (2.16) 55 (2.16) 60 (2.36) Ø piston mm (in) 90 (3.54) 100 (3.93) 100 (3.93) 110 (4.33) Stroke mm (in) 721 (28.38) 728 (28.66) 718 (28.26) 730 (28.74)
  • Page 30 SECTION 00 - INTRODUCTION TRAVEL MOTOR 121E 221E 321E Type A6VM80HA1U1 / 63W A6VM107HA1U1 / 63W Displacement Q 80 / 18.8 80 / 23.7 80 / 24.8 107 / 34.5 (4.88 / 1.51) (6.52 / 2.10) (4.88 / 1.14) (4.88 / 1.44) Maximum speed 4352 5289...
  • Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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Construction 21eConstruction 121eConstruction 221eConstruction 321e