CASE 1221E TIER 3 Wheel Loader Service Repair Manual

87728465 NA 1221E Tier 3 Wheel Loader 01Mar 08 First Edition REVISION HISTORY Remarks Issue Issue Date Applicable Machines This unit first became available 03-2008 Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A.. CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold. All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition.For exact information about any particular product, please consult your Dealer NOT FOR PRINT

WHEEL LOADER REPAIR MANUAL TABLE OF CONTENTS Section 1 - General Safety Hints ................................................................................................................. 1-1 Specification ................................................................................................................ 1-8 Operational Checkout Record Sheet ........................................................................... 1-20 Section 2 - Engine Structure And Function ................................................................................................ 2-1 Section 3 - Power Train System Structure And Function ................................................................................................ 3-1 Operational Checks And Troubleshooting ................................................................... 3-67 Tests And Adjustments ................................................................................................ 3-79 Disassembly And Assembly ........................................................................................ 3-82 Section 4 - Brake System Structure And Function ................................................................................................ 4-1 Operational Checks And Troubleshooting ................................................................... 4-19 Tests And Adjustments ................................................................................................ 4-25 Section 5 - Steering System Structure And Function ................................................................................................ 5-1 Operational Checks And Troubleshooting ................................................................... 5-19 Tests And Adjustments ................................................................................................ 5-26 Disassembly And Assembly ........................................................................................ 5-32 Section 6 - Work Equipment Structure And Function ................................................................................................ 6-1 Operational Checks And Troubleshooting ................................................................... 6-31 Tests And Adjustments ................................................................................................ 6-40 Disassembly And Assembly ........................................................................................ 6-54 Section 7 - Electrical System Component Location ................................................................................................... 7-1 Electronic Monitor System ........................................................................................... 7-23 Switches ...................................................................................................................... 7-36 Electrical Component Specification ............................................................................. 7-43 Connectors .................................................................................................................. 7-49 Troubleshooting ........................................................................................................... 7-69 NOT FOR PRINT

WHEEL LOADER REPAIR MANUAL NOTES NOT FOR PRINT

0-1 87728465 NA Issued 03-2008 Bur SECTION 0 - FOREWORD 1. STRUCTURE This service manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This service manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. Structure and function This group explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. Operational checks and troubleshooting This group explains the system operational checks and troubleshooting charts correlating problem to remedy. Tests and adjustments This group explains checks to be amide before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Disassembly and assembly This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your CASE distributor for the latest information. NOT FOR PRINT

0-2 Issued 03-2008 Bur 87728465 NA SECTION 0 - FOREWORD 2. HOW TO READ THE SERVICE MANUAL Distribution and updating Any additions, amendments or other changes will be sent to CASE distributors. Get the most up-to-date information before you start any work. Filing method 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 3. Additional pages : Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Revised edition mark (---------------) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. Revisions Revised pages are shown at the list of revised pages on the between the contents page and section 1 page. Symbols So that the service manual can be of ample practical use, important places for safety and quality are marked with the following symbols. 3 - 3 Section number (3. Power train system) Consecutive page number for each section 10 - 4 10 - 4 - 1 10 - 4 - 2 10 - 5 Added pages Symbol Item Remarks Safety Special safety precautions are necessary when performing the work. Extra special safety precautions are necessary when performing the work because it is under internal pressure. Caution Special technical precautions or other precautions for preserving standards are necessary when performing the work. ①②③… NOT FOR PRINT

0-3 87728465 NA Issued 03-2008 Bur SECTION 0 - FOREWORD 3. CONVERSION TABLE Method of using the Conversion Table. The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example 1. Method of using the Conversion Table to convert from millimeters to inches. Convert 55mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as ’a’, then draw a horizontal line from ’a’. (2) Locate the number 5 in the row across the top, take this as ’b’, then draw a perpendicular line down from ’b’. (3) Take the point where the two lines cross as ’c’. This point ’c’ gives the value when converting from millimeters to inches. Therefore, 55mm = 2.165 inches. 2. Convert 550mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (Move the decimal point one place to the left) to convert it to 55mm. (2) Carry out the same procedure as above to convert 55mm to 2.165 inches. (3) The original value (550mm) was divided by 10, so multiply 2.165 inches by 10 (Move the decimal point one place to the right) to return to the original value. This gives 550mm = 21.65 inches. Millimeters to inches 1mm = 0.03937 in 0 1 2 3 4 5 6 7 8 9 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536 40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323 60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 b c a NOT FOR PRINT

0-4 Issued 03-2008 Bur 87728465 NA SECTION 0 - FOREWORD Millimeters to Inches 1mm = 0.03937in Kilogram to Pound 1kg = 2.2046lb 0 1 2 3 4 5 6 7 8 9 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536 40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323 60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 0 1 2 3 4 5 6 7 8 9 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84 10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89 20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93 30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98 40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03 50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07 60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12 70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17 80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21 90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26 NOT FOR PRINT

0-5 87728465 NA Issued 03-2008 Bur SECTION 0 - FOREWORD Liter to U.S. Gallon 1 l = 0.2642 U.S.Gal Liter to U.K. Gallon 1 l = 0.21997 U.K.Gal 0 1 2 3 4 5 6 7 8 9 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303 40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944 50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586 60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228 70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870 80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511 90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153 0 1 2 3 4 5 6 7 8 9 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379 30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579 40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778 50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978 60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178 70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378 80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577 90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777 NOT FOR PRINT

0-6 Issued 03-2008 Bur 87728465 NA SECTION 0 - FOREWORD kg · m to lb · ft 1kg · m = 7.233lb · ft 0 1 2 3 4 5 6 7 8 9 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1 40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4 50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8 60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1 70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4 80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7 90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1 100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4 140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7 150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0 160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4 170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7 180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0 190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4 NOT FOR PRINT

CASE 1221E TIER 3 Wheel Loader Service Repair Manual

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