Case 521E User manual

SERVICE MANUAL
WHEEL LOADER
521E
TIER 3
84243970
(Replaces 87728450)
Revised June 2009
Issued February 2008

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84243971 Copyright © 2009 CNH America LLC.
All rights reserved.
Printed in U.S.A.
Issued February, 2008 Revised December 2009
CNH America LLC.
700 State Street
Racine, WI 53404 U.S.A. (Replaces 5-10820)
521E Wheel Loader
Service Manual
84243970 (Replaces 87728450)
Table of Contents
Description Section No. Form No.
General Tab 1
Section Index - General 5-10830
Standard Torque Specifications 1001 8-71603
Fluids and Lubricants 1002 5-10840
Metric Conversion Chart 1003 7-52950
Engines Tab 2
Section Index - Engines 5-10850
Engine and Radiator Removal and Installation 2000 5-10860
Stall Tests 2002 5-10870
After Cooler 2003 6-49850
For Engine Repair, See the Engine Service Manual 87630273
Fuel System Tab 3
Section Index - Fuel System 5-11830
For Fuel System Repair, See the Engine Service Manual 87630273
Electrical Tab 4
Section Index - Electrical 5-10880
Removal and Installation of Starter and Alternator 4001 5-10890
Electrical Specifications and Troubleshooting 4002 5-11190
Batteries 4003 6-42331
Instrument Cluster 4005 5-10900
Steering Tab 5
Section Index - Steering 5-10911
Removal and Installation of Steering Components 5001 5-10920
Steering Specifications, Pressure Checks, and Troubleshooting 5002 5-7410
Steering Cylinders 5005 5-10930
Center Pivot 5006 5-10940
Auxiliary Steering Motor and Pump 5008 5-10950
Joystick Steering 5009 5-17000
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84243971 Copyright © 2009 CNH America LLC.
All rights reserved.
Printed in U.S.A.
Issued February, 2008 Revised December 2009
CNH America LLC.
700 State Street
Racine, WI 53404 U.S.A. (Replaces 5-10820)
Power Train Tab 6
Section Index - Power Train 5-10960
Removal and Installation of Power Train Components 6001 5-10970
Transmission Specifications, Pressure Checks, and Troubleshooting 6002 5-11840
Transmission 6003 5-11820
Front Axle 6004 5-10980
Rear Axle 6004 84243973
Replaces 5-10990
Drive Shafts, Center Bearing, and Universal Joints 6005 5-11000
Wheels and Tires 6006 5-11010
Transmission Control Valve 6007 6-81450
Brakes Tab 7
Section Index - Brakes 5-11020
Removal and Installation of Brake Components 7001 5-11030
Hydraulic Brake Troubleshooting 7002 5-11040
Brake Pump 7003 5-11050
Brake Accumulators 7004 5-11060
Parking Brake 7008 5-11070
Hydraulics Tab 8
Section Index - Hydraulics 5-11080
How to Read Hydraulic Schematics 8000 5-5670
Removal and Installation of Hydraulic Components 8001 5-11090
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 5-11100
Cleaning the Hydraulic System 8003 7-49641
Loader Control Valve 8005 5-11110
Cylinders 8006 5-11610
Coupler Solenoid Locking Valve 8007 6-42600
Ride Control Accumulator 8013 5-11120
Ride Control Valve 8014 5-3010
521E Wheel Loader
Service Manual
84243970 (Replaces 87728450)
Table of Contents
Description Section No. Form No.
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84243971 Copyright © 2009 CNH America LLC.
All rights reserved.
Printed in U.S.A.
Issued February, 2008 Revised December 2009
CNH America LLC.
700 State Street
Racine, WI 53404 U.S.A. (Replaces 5-10820)
NOTE: 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.
Mounted Equipment Tab 9
Section Index - Mounted Equipment 5-11130
Air Conditioning Troubleshooting and System Checks 9002 5-4030
Air Conditioner System Service 9003 5-11140
Removal And Installation Of Air Conditioning And Heater Components 9004 5-11150
Loader 9006 5-11160
Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF) 9007 5-11170
Cab Glass Installation 9010 6-42710
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 5-11180
521E Wheel Loader
Service Manual
84243970 (Replaces 87728450)
Table of Contents
Description Section No. Form No.
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Copyright © 2008 CNH America LLC.
All rights reserved.
Printed in U.S.A.
Issued February, 2008
CNH America LLC.
700 State Street
Racine, WI 53404 U.S.A. Bur 5-10830
SECTION INDEX
GENERAL
Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Section Title Section Number
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Section
1002
1002
Copyright © 2008 CNH America LLC.
All rights reserved.
Printed in U.S.A.
Issued February, 2008
CNH America LLC.
700 State Street
Racine, WI 53404 U.S.A. Bur 5-10840
FLUIDS AND LUBRICANTS

1002-2
Bur 5-10840 Issued 2-08 Printed in U.S.A.
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANMISSION Temperature CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC/BRAKE SYSTEM Temperature CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 521E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Model 521E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1002-3
Bur 5-10840 Issued 2-08 Printed in U.S.A.
CAPACITIES AND LUBRICANTS
Engine Oil
Capacity .................................................................................................................. 10.9 liters (11.5 U.S. Quarts)
Capacity with Filter Change ..................................................................................... 11.8 liters (12.5 U.S. Quarts)
Type of oil ........................................................................................................Case AKCELA (SAE 15W-40)
Engine Cooling System
Capacity....................................................................................................................... 22 liters (23.2 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ................................................................................................................... 189.3 liters (50 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 6
Hydraulic System
Hydraulic Reservoir Refill Capacity..........................................................................56.8 liters (15.0 U.S. Gallons)
Total System Capacity............................................................................................ 113.6 liters (30.0 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 18.9 liters (20 U.S. Quarts)
Total System Capacity.................................................................................................. 26 liters (27.5 U.S. Quarts)
Type of Oil .......................................................................................................Case AKCELA (SAE 15W-40)
Axles
Capacity
Front...................................................................................................................... 22.0 liters (23.2 U.S. Quarts)
Rear ...................................................................................................................... 22.0 liters (23.2 U.S. Quarts)
Type of Lubricant.......................................................................... Case AKCELA Transaxle Fluid (SAE 80W-140)
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System)................................................................Case AKCELA Hy-Tran Ultra®
Fittings
Grease as required ................................................................................................... Case AKCELA Molydisulfide

1002-4
Bur 5-10840 Issued 2-08 Printed in U.S.A.
ENGINE OIL RECOMMENDATIONS
Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CI-4.
See the chart below for recommended viscosity at
ambient air temperature ranges.
NOTE: Do not put performance additives or other oil
additive products in the engine crankcase. The oil
change intervals given in this manual are according
to tests with Case AKCELA lubricants.
BD03A102
BC02N250

1002-5
Bur 5-10840 Issued 2-08 Printed in U.S.A.
TRANMISSION TEMPERATURE CHART
BC04F193
HYDRAULIC/BRAKE SYSTEM TEMPERATURE CHART
BC04F192

1002-6
Bur 5-10840 Issued 2-08 Printed in U.S.A.
DIESEL FUEL SYSTEM
Use No. 2 diesel fuel in the engine of this machine.
The use of other fuels can cause the loss of engine
power and high fuel consumption.
In very cold temperatures, a mixture of No. 1 and No.
2 diesel fuels is temporarily permitted. See the
following Note.
NOTE: See your fuel dealer for winter fuel
requirements in your area. If the temperature of the
fuel lowers below the cloud point (wax appearance
point), wax crystals in the fuel will restrict the fuel
filter and cause the engine to lose power or not start.
The diesel fuel used in this machine must meet the
specifications as shown below in, “Specifications for
Acceptable No. 2 Diesel Fuel”, or Specification
(ASTM-D-975) of the American Society for Testing
and Materials.
Fuel Storage
If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
tank. Many engine problems are caused by water in
the fuel.
Keep the fuel storage tank outside and keep the fuel
as cool as possible. Remove water from the storage
container at regular periods of time.
Fill the fuel tank at the end of the daily operating
period to prevent condensation in the fuel tank.
Specifications for Acceptable No. 2 Diesel Fuel
API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%

1002-7
Bur 5-10840 Issued 2-08 Printed in U.S.A.
MAINTENANCE SCHEDULE
Model 521E
SERVICE
INTERVAL
ITEM NUMBER
SERVICE POINTS
Initial Service
FREQUENCY IN HOURS
CHECK CLEAN CHANGE DRAIN LUBRICATE REPLACE ADJUST
Variable
Periodic
(*)
29 Air cleaner **
18 Bleed Fuel Filter of Condensation *
19 Hydraulic Filter *
22 Alternator, AC, Drive Belt *
13 Radiator Coolant Level *
XX Fire extinguisher *
14 Tires *
Every 10 Hours 1 Check Engine Oil Level 10
Every 50 Hours
2 Check Engine Coolant Level 50
3 Check Transmission Oil Level 50
4 Check Hydraulic Oil Level 50
5 & 6 Grease Bucket Mounting Fittings 50
Every 100 Hours
7 Grease Front Drive Shaft Support Bearing 100
8 & 9 Lubricate The Steering Cylinder Pivots - Rod And
Closed End (4 Fittings) 100
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
11 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
Every 250
Hours
12 Check Cab Air Filter 250
13 Check Tire Pressure & Wheel Torque 100 250
14 Check Drive Belt 250
Every 500
Hours
15 Check Battery Electrolyte Level 500
16 Check Axle Oil Level 500
17 Drain Fuel Tank Condensation & Water Separator 500
18 Change Engine Oil and Filter 100 500
18 Change Crankcase Filter 500
19 & 27 Replace Fuel Filter 100 500
XX ROPS/CSF and seat belt torques 500
Every 1000
Hours
20 Change Front & Rear Axle Oil 100 1000
21 Replace Hydraulic Oil filter 100 1000
22 Replace Cab Air Filter 1000
23 Replace Drive Belt 1000
24 Change Transmission Oil and Filter 100 1000
25 Grease Articulation Fittings 1000
26 Check Injector Calibration 1000
27 Fuel Pre-Filter 1000
XX Drive Shaft Slip Joint 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 250 1000
Every 2000
Hours
28 Change Hydraulic Oil 2000
29 Change Coolant 2000
30 Replace Engine Air Cleaner 2000
Every 4000
Hours XX Valve Clearance (Engine Manual) 4000