Quality Manual
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
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
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
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
Case 21E 121E 221E 321E Series 3 Compact Wheel Loader Service Manual
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Download Case 21E 121E 221E 321E Series 3 Compact Wheel Loader Service Manual
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This Factory Service Repair Manual offers all the service and repair information about Case 21E ,121E , 221E , 321E Series 3 Compact Wheel Loaders. The information on this manual covered everything you need to know when you want to repair or service Case 21E ,121E , 221E , 321E Series 3 Compact Wheel Loaders.
Models Covered:
21E
121E
221E
321E
Series 3
Compact Wheel Loaders
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Manual Contents:
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
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
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
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
This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
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