CASE CONSTRUCTION 521F User manual

Part number 47955970
1st edition English
February 2016
SERVICE MANUAL
521F
Tier 4B (final)
Wheel Loader
Printedin U.S.A.
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
Case is a trademark registered in the United States and many
other countries, owned by or licensed to CNH Industrial N.V.,
its subsidiaries or affiliates.

SERVICEMANUAL
521F
4795597002/02/2016
EN

LinkProduct/Engine
ProductMarketProductEngine
521FTIER4BZ-BARNorthAmericaF4HFE413N*B001
521FTIER4BXTNorthAmericaF4HFE413N*B001
521FTIER4BXRNorthAmericaF4HFE413N*B001
4795597002/02/2016

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.202]Aircleanersandlines..............................................................10.2
[10.500]SelectiveCatalyticReduction(SCR)exhausttreatment...........................10.3
[10.400]Enginecoolingsystem.............................................................10.4
[10.414]Fananddrive......................................................................10.5
[10.310]Aftercooler..........................................................................10.6
[10.304]Enginelubricationsystem..........................................................10.7
Transmission..............................................................................21
[21.113]Powershifttransmission............................................................21.1
[21.135]Powershifttransmissionexternalcontrols..........................................21.2
[21.155]Powershifttransmissioninternalcomponents......................................21.3
Four-WheelDrive(4WD)system..................................................23
[23.314]Driveshaft..........................................................................23.1
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
[25.310]Finaldrives.........................................................................25.4
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
[27.124]Finaldrivehub,steeringknuckles,andshafts.....................................27.4
Brakesandcontrols....................................................................33
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[33.202]Hydraulicservicebrakes...........................................................33.1
[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.106]Variabledisplacementpump.......................................................35.3
[35.359]Maincontrolvalve..................................................................35.4
[35.357]Pilotsystem........................................................................35.5
[35.752]Hydraulicfandrivecoolingsystem.................................................35.6
[35.355]Hydraulichandcontrol.............................................................35.7
[35.701]Frontloaderarmhydraulicsystem.................................................35.8
[35.723]Frontloaderbuckethydraulicsystem..............................................35.9
[35.734]Toolquickcouplerhydraulicsystem.............................................35.10
Framesandballasting.................................................................39
[39.100]Frame..............................................................................39.1
Steering.....................................................................................41
[41.200]Hydrauliccontrolcomponents......................................................41.1
[41.216]Cylinders...........................................................................41.2
[41.910]Auxiliarysteering...................................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
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[55.100]Harnessesandconnectors.........................................................55.2
[55.015]Enginecontrolsystem..............................................................55.3
[55.201]Enginestartingsystem.............................................................55.4
[55.301]Alternator...........................................................................55.5
[55.302]Battery..............................................................................55.6
[55.202]Coldstartaid.......................................................................55.7
[55.011]Fueltanksystem...................................................................55.8
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem............................55.9
[55.989]ExhaustGasRecirculation(EGR)electricalsystem.............................55.10
[55.012]Enginecoolingsystem...........................................................55.11
[55.024]Transmissioncontrolsystem.....................................................55.12
[55.519]Cabbrakecontrols...............................................................55.13
[55.030]Servicebrakeelectricalsystem..................................................55.14
[55.031]Parkingbrakeelectricalsystem..................................................55.15
[55.512]Cabcontrols......................................................................55.16
[55.036]Hydraulicsystemcontrol.........................................................55.17
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.18
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem...............55.19
[55.047]Steeringcontrolsystem..........................................................55.20
[55.524]Cabcontrols(Liftarm,Boom,Dipper,Bucket)...................................55.21
[55.415]Loaderarmandbucketcontrolsystem..........................................55.22
[55.518]Wiperandwashersystem........................................................55.23
[55.404]Externallighting..................................................................55.24
[55.405]Externallightingswitchesandrelays............................................55.25
[55.514]Cablighting......................................................................55.26
[55.510]Caborplatformharnessesandconnectors......................................55.27
[55.408]Warningindicators,alarms,andinstruments....................................55.28
[55.DTC]FAULTCODES..................................................................55.29
Frontloaderandbucket...............................................................82
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[82.100]Arm.................................................................................82.1
[82.300]Bucket..............................................................................82.2
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.156]Cabglazing........................................................................90.2
[90.105]Machineshieldsandguards.......................................................90.3
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INTRODUCTION
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1

Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Personalsafety.................................................................................5
Basicinstructions-Importantnoticeregardingequipmentservicing.........................14
Basicinstructions-Howtousethemaintenancestandardandprecautions.................15
Basicinstructions-Precautionfordisassemblyandassembly...............................17
Basicinstructions-Electricalequipmentprecautions........................................19
Consumables.................................................................................20
Consumables-BiodieselFuel................................................................21
Hydrauliccontamination......................................................................22
Productidentication..........................................................................23
Productidentication..........................................................................24
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Personalsafety
CarefullyreadthisManualbeforeproceedingwithmain-
tenance,repairs,refuellingorothermachineoperations.
Repairshavetobecarriedoutonlybyauthorizedandin-
structedstaff;specicprecautionshavetobetakenwhen
grinding,weldingorwhenusingmalletsorheavyham-
mers.
Non-authorizedpersonsarenotallowedtorepairorcarry
outmaintenanceonthismachine.Donotcarryoutany
workontheequipmentwithoutpriorauthorization.
Askyouremployeraboutthesafetyinstructionsinforce
andsafetyequipment.
Nobodyshouldbeallowedinthecabduringmachine
maintenanceunlessheisaqualiedoperatorhelping
withthemaintenancework.
Ifitisnecessarytomovetheequipmenttocarryoutre-
pairsormaintenance,donotliftorlowertheequipment
fromanyotherpositionthantheoperator’sseat.
TULI12WEX2004AA1
Nevercarryoutanyoperationonthemachinewhenthe
engineisrunning,exceptwhenspecicallyindicated.
Stoptheengineandensurethatallpressureisrelieved
fromhydrauliccircuitsbeforeremovingcaps,covers,
valves,etc.
Allrepairandmaintenanceoperationsshouldbecarried
outwiththegreatestcareandattention.
Servicestairsandplatformsusedinaworkshoporinthe
eldshouldbebuiltincompliancewiththesafetyrulesin
force.
Anyfunctionaldisorders,especiallythoseaffectingthe
safetyofthemachine,shouldthereforeberectiedim-
mediately.
DANGER
Unexpectedmovement!
Makesureparkingbrakeisapplied.Secure
machinewithwheelchocks.
Failuretocomplywillresultindeathorserious
injury.D0013A
TULI12WEX2005AA2
Beforeperforminganyworkonthemachine,attacha
maintenanceinprogresstag.Thistagcanbeappliedon
theleft-handcontrollever,safetyleverorcabdoor.
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INTRODUCTION
Emergency
Bepreparedforemergencies.Alwayskeepareextin-
guisherandrstaidkitreadilyavailable.Ensurethatthe
reextinguisherisservicedinaccordancewiththeman-
ufacturer’sinstructions.
SMIL12WEX0174AA3
Equipment
Wearclosettingclothingandsafetyequipmentappropri-
ateforthejob:
•Safetyhelmet
•Safetyshoes
•Heavygloves
•Reectiveclothing
•Wetweatherclothing
Ifworkingconditionsrequire,thefollowingpersonalsafety
equipmentshouldbeonhand:
•Respirators(ordustproofmasks)
•Earplugsoracousticearsprotections
•Goggleswithlateralshieldormasksforeyeprotection
Donotwearrings,wristwatches,jewelry,unbuttonedor
appingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtinto
movingparts.
TULI12WEX2008AA4
Engine-Radiator
Neverleavetheenginerunninginenclosedspaceswith-
outproperventilationwhichisabletoevacuatetoxicex-
haustgases-Keeptheexhaustmanifoldandtubefree
fromcombustiblematerials.
Donotrefuelwiththeenginerunning,especiallyifhot,as
thisincreasesrehazardincaseoffuelspillage.
Neverattempttocheckoradjustthebeltswhentheen-
gineisrunning.
Neverlubricatethemachinewiththeenginerunning.
TULI12WEX2009AA5
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INTRODUCTION
Payattentiontorotatingcomponentsanddonotallow
anyonetoapproachtheseareastoavoidbecomingen-
tangled.
Hands,clothingortoolsgettingcaughtinthefanbladesor
enginebelts,cancauseamputations,violenthemorrages
andgenerateconditionsofgravedanger.Forthisreason
avoidtouchingorapproachingallrotatingormovingparts.
Asurgingsprayofthecoolantfromtheradiatorcancause
seriousburnsandscalds.
Beforecheckingthecoolantlevel,shut-offtheengine
andallowmachinetocooldowntheradiatorandhoses.
Slowlyunscrewthecaptoreleaseanyresidualpressure.
TULI12WEX2010AA6
Ifitisnecessarytoremovethecapwhileengineishot,
wearsafetyclothesandequipment,thenloosenthecap
slowlytorelievethepressuregradually.
Whencheckingthefuel,oilandcoolantlevels,uselights
andlampsexplicitlydesignatedasexplosionproof.If
thesetypesoflampsarenotused,resorexplosionsmay
occur.
TULI12WEX2011AA7
Hydraulicsystems
Jetsofuidsunderpressurecanpenetratetheskincaus-
ingseriousinjuries.
Avoidthishazardbyrelievingpressurebeforedisconnect-
inghydraulicorotherlines.
Relievetheresidualpressurebymovingthehydraulic
controlleversseveraltimes.
Tightenallconnectionsbeforeapplyingpressure.
Toprotecttheeyeswearafacialshieldorsafetygoggles.
Protectyourhandsandbodyfrompossiblejetsofuids
underpressure.
Swallowinghydraulicoilisaseverehealthhazard.
TULI12WEX2012AA8
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INTRODUCTION
Whenhydraulicoilhasbeenswallowed,avoidvomiting,
butconsultadoctororgotoahospital.
Ifanaccidentoccurs,seeadoctorfamiliarwiththistype
ofinjuryimmediately.
Anyuidpenetratingtheskinmustberemovedwithina
fewhourstoavoidseriousinfections.
Flammablesplashesmayoriginatebecauseofheating
nearlineswithuidsunderpressure,resultinginserious
burns.Donotweldorusetorchesnearlinescontaining
uidsorotherammablematerials.
Linesunderpressurecanaccidentallybepiercedwhen
theheatexpandsbeyondtheareaimmediatelyheated.
Arrangefortemporaryreresistantshieldstoprotect
hosesorothercomponentsduringweldingortorchuse.
Haveanyvisibleleakagerepairedimmediately.
Dischargedoilpollutestheenvironment.Soakupany
oilthathasspilledwithaproperbindingagent.Sweep
upbindingagentanddisposeofitseparatelyfromother
waste.
Neversearchforleakageswithngers;instead,usea
pieceofcardboardandalwaysweargoggles.
Neverrepairadamagedline;alwaysreplaceit.Replace
hydraulichosesimmediatelyondetectinganydamaged
ormoistareas.
Alwaysstorehydraulicoilintheoriginalcontainers.
TULI12WEX2013AA9
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INTRODUCTION
Hosesandtubes
Alwaysreplacehosesandtubesiftheconeendorthe
endconnectionsonthehosearedamaged.
Wheninstallinganewhose,looselyconnecteachend
andmakesurethehosetakesupthecorrectpositionbe-
foretighteningtheconnections.Clampsshouldbetight-
enedsufcientlytoholdthehosewithoutcrushingandto
preventchang.
Afterreplacingahoseonamovingcomponent,checkthat
thehosedoesnotfallbymovingthecomponentthrough
thecompleterangeoftravel.Besureanyhosewhichhas
beeninstalledisnotkinkedortwisted.
Hoseconnectionswhicharedamaged,dented,crushed
orleaking,restrictoilowandtheproductivityofthecom-
ponentsbeingserved.Connectorswhichshowsignsof
movementfromtheoriginalpositionhavefailedandwill
ultimatelyseparatecompletely.
Ahosewithafrayedoutersheathwillallowwaterpenetra-
tion.Concealedcorrosionofthewirereinforcementcould
subsequentlyoccuralongthehoselengthwithresultant
hosefailure.
Ballooningofthehoseindicatesaninternalleakagedueto
structuralfailure.Thisconditionrapidlydeterioratesand
totalhosefailuresoonoccurs.
Kinked,crushed,stretchedordeformedhosesgenerally
sufferinternalstructuraldamagewhichcanresultinoil
restriction,areductioninthespeedofoperationandulti-
matehosefailure.
Free-moving,unsupportedhosesmustneverbeallowed
totoucheachotherorrelatedworkingsurfaces.This
causeschangwhichreduceshoselife.
TULI12WEX2014AA10
O-rings
ReplaceO-rings,sealringsandgasketswheneverthey
aredisassembled.
NevermixnewandoldsealsorO-rings,regardlessof
condition.AlwayslubricatenewsealringsandO-rings
withhydraulicoilbeforeinstallationtorelevantseats.
ThiswillpreventtheO-ringsfromrollingoverandtwisting
duringmountingwhichwilljeopardizesealing.
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INTRODUCTION
Battery
Batteriesgiveoffexplosivegases.
Neverhandleopenamesandunshieldedlightsources
nearbatteries.(Nosmokingisaddressedinthenextin-
struction).
Topreventanyriskofexplosion,observethefollowing
instructions:
•Whendisconnectingthebatterycables,alwaysdiscon-
nectthenegative(-)cablerst.
•T oreconnectthebatterycables,alwaysconnectthe
negative(-)cablelast.
•Nevershort-circuitthebatteryterminalswithmetalob-
jects.
•Donotweld,grindorsmokenearabattery.
Batteryelectrolytecausessevereburns.Thebatterycon-
tainssulphuricacid.Avoidanycontactwiththeskin,eyes
orclothing.
TULI12WEX2015AA11
Treatment:
•EXTERNAL:Rinsewellwithwater,removinganysoiled
clothing.
•INTERNAL:Avoidvomiting.Drinkwatertorinseyour
mouth.Consultadoctor.
•EYES:Rinseabundantlywithwaterfor15minandcon-
sultadoctor.
•Whentheelectrolyteofabatteryisfrozen,itcanex-
plodeifyouattempttochargethebatteryorifyoutryto
starttheengineusingaboosterbattery.Alwayskeep
thebatterychargedtopreventtheelectrolytefreezing.
Providegoodventilationwhenchangingabatteryorusing
abatteryinanenclosedspace.Alwaysprotectyoureyes
whenworkingnearabattery.
TULI12WEX2016AA12
Neversettoolsdownonthebattery.Theymayinduce
ashortcircuit,causingirreparabledamagetothebattery
andinjuringpersons.
Neverwearmetalnecklaces,braceletsorwatchstraps
whenworkingonthebattery.Themetalpartsmayinduce
ashortcircuitresultinginburns.
Disposeofusedbatteriesseparatelyfromotherwastein
theinterestsofenvironmentalprotection.
TULI12WEX2017AA13
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INTRODUCTION
Flammableliquids
Whenhandlingammableliquids:
•Donotsmoke.
•Keepawayfromunshieldedlightsourcesandopen
ames.
Fuelsoftenhavealowashpointandarereadilyignited.
Neverattempttoextinguishburningliquidswithwater.
Use:
•Drypowder
•Carbondioxide
•Foam
Waterusedforextinguishingpurposeswouldvaporizein-
stantaneouslyoncontactwithburningsubstancesand
spreadburningoil,forexample,overawidearea.Water
generatesshortcircuitsintheelectricalsystem,possibly
producingnewhazards.
TULI12WEX2016AA14
Stayawayfromopenamesduringrellingofhydraulic
oilorfuel.
Fueloroilspillscancauseslippinghazards;thoroughly
containandcleanaffectedareas.
Alwaystightenthesafetyplugsoffueltankandhydraulic
oiltankrmly.
Neverusefueltocleanmachinepartsthatwillbeexposed
todirtordebris.
Useanon-ammableproductforcleaningparts.
Alwaysperformfueloroilrellinginwellairedandventi-
latedareas.
TULI12WEX2018AA15
Duringrefuellingholdthepistolrmlyandalwayskeepit
incontactwiththellerneckuntiltheendoftherefuelling,
toavoidarcingduetostaticelectricity.
Donotoverllthetankbutleaveaspaceforfuelexpan-
sion.
Neverrefuelwhentheengineisrunning.
Takeallthenecessarysafetymeasureswhenwelding,
grindingorwhenworkingnearanakedame.
TULI12WEX2019AA16
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INTRODUCTION
Tires
Beforeinatingthetires,alwayschecktheconditionof
rimsandtheouterconditionoftiresforthepresenceof
dents,cuts,tearsofreinforcementpliesorotherfaults.
Beforeinatingatire,makesurethattherearenonearby
persons,thenpositionyourselfattreadside.
Wheninatingtires,ensuretirepressuredoesnotexceed
thatprescribedbythetiremanufacturer.Ensurethatthe
pressureoftherighttirecorrespondstothepressureof
thelefttire.
NOTE:Thefrontandreartirepressuresmaybedifferent.
Neverusereconditionedrimsbecausepossiblewelds,
heattreatmentsorbrazingsnotperformedcorrectlycan
weakenthewheelsandcausedamageorfailure.Deate
thetiresbeforetheirdisassembly.
Beforetakingoutpossiblejammedobjectsfromtherims,
itisnecessarytodeatethetires.Inatetiresbymeans
ofaninationpistolcompletewithextensionandpressure
controlvalve.
Needtomaintaininationcage
TULI12WEX2020AA17
Cleaning
Cleantheexteriorofallcomponentsbeforecarryingout
anyformofrepair.Dirtanddustcanreducetheefcient
workinglifeofacomponentandleadtocostlyreplace-
ment.
Solventsshouldbecheckedthattheyaresuitableforthe
cleaningofcomponentsandalsothattheydonotriskthe
personalsafetyoftheuser.
Dirt,oil,greaseandscatteredtoolsaredangerousforpeo-
ple,becausetheycancreateslippingortrippinghazards.
Formachinecleaning,useajetofwarmwaterorsteam
underpressureandcommercialdetergents.Neveruse
fuel,petroleumorsolvents,becausetheycanleavean
oilyresiduethatattractsdust,andsolvents(evenifweak)
damagethepaintandcanleadtotheformationofrust.
Neverusewaterjetsorsteamonsensors,connectorsor
otherelectriccomponents.
Avoiddirectsprayofsealsandseamstopreventwater
penetrationinsidethecab.
TULI12WEX2021AA18
4795597002/02/2016
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