Case 521F User manual

521F
TIER IV
Print No. 84581916A
Service Manual
Wheel Loader

521F
Loader
84581916A
Use for Repair Manual
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Copyright © 2012 CNH Italia S.p.A.
All rights reserved.
Printed in E.C.
Issued March, 2012
CNH Italia S.p.A.
Via Plava, 80
10135 Torino
Italia 84581916A
521F Wheel Loader
Repair Manual
84581916A
Table of Contents
Description Section No.
General Tab 1
Section Index - General
Standard Torque Specifications 1001
Fluids and Lubricants 1002
Metric Conversion Chart 1003
Engines Tab 2
Section Index - Engines
Engine and Radiator Removal and Installation 2000
Stall Tests 2002
After Cooler 2003
SCR System Sensors 2020
SCR Catalyst 2030
Engine Intake Temperature/Humidity Sensor 2040
DEF/ADBLUE Heater Control Valve 2050
DEF/ADBLUE DNOx Supply Module 2060
DEF/ADBLUE Dosing Injector 2070
DEF/ADBLUE Supply Tank 2080
DEF/ADBLUE Supply Tank Level and Temperature Sensor/Pick-up and Heater 2090
DEF/ADBLUE Supply Filters 2100
For Engine Repair, See the Engine Service Manual 84392428
Fuel System Tab 3
Section Index - Fuel System
For Fuel System Repair, See the Engine Service Manual 84392428
Electrical Tab 4
Section Index - Electrical
Removal and Installation of Starter and Alternator 4001
Electrical Specifications and Troubleshooting - Electrical Schematic 4002
Batteries 4003
Instrument Cluster 4005
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Copyright © 2012 CNH Italia S.p.A.
All rights reserved.
Printed in E.C.
Issued March, 2012
CNH Italia S.p.A.
Via Plava, 80
10135 Torino
Italia 84581916A
Steering Tab 5
Section Index - Steering
Removal and Installation of Steering Components 5001
Steering Specifications, Pressure Checks, and Troubleshooting 5002
Steering Cylinders 5005
Center Pivot 5006
Auxiliary Steering Motor and Pump 5008
Power Train Tab 6
Section Index - Power Train
Removal and Installation of Power Train Components 6001
Transmission Specifications, Pressure Checks, and Troubleshooting 6002
Transmission 6003
Front Axle 6004
Rear Axle 6004
Drive Shafts, Center Bearing, and Universal Joints 6005
Wheels and Tires 6006
Transmission Control Valve 6007
Brakes Tab 7
Section Index - Brakes
Removal and Installation of Brake Components 7001
Hydraulic Brake Troubleshooting 7002
Brake Pump 7003
Brake Accumulators 7004
Parking Brake 7008
Hydraulics Tab 8
Section Index - Hydraulics
How to Read Hydraulic Schematics 8000
Removal and Installation of Hydraulic Components 8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002
Cleaning the Hydraulic System 8003
521F Wheel Loader
Repair Manual
84581916A
Table of Contents
Description Section No.
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Copyright © 2012 CNH Italia S.p.A.
All rights reserved.
Printed in E.C.
Issued March, 2012
CNH Italia S.p.A.
Via Plava, 80
10135 Torino
Italia 84581916A
Loader Control Valve 8005
Cylinders 8006
Coupler Solenoid Locking Valve 8007
Ride Control Accumulator 8013
Ride Control Valve 8014
Mounted Equipment Tab 9
Section Index - Mounted Equipment
Air Conditioning Troubleshooting and System Checks 9002
Air Conditioner System Service 9003
Removal And Installation Of Air Conditioning And Heater Components 9004
Loader 9006
Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF) 9007
Cab Glass Installation 9010
Hydraulic Schematic Foldout In Rear Pocket
521F Wheel Loader
Repair Manual
84581916A
Table of Contents
Description Section No.
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Copyright © 2012 CNH Italia S.p.A.
All rights reserved.
Printed in E.C.
Issued March, 2012
CNH Italia S.p.A.
Via Plava, 80
10135 Torino
Italia 84581916A
SECTION INDEX
GENERAL
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Section Title Section Number
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Section
1001
1001
Copyright © 2012 CNH Italia S.p.A.
All rights reserved.
Printed in E.C.
Issued March, 2012
CNH Italia S.p.A.
Via Plava, 80
10135 Torino
Italia 84581916A
GENERAL TORQUE SPECIFICATIONS
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1001-2
84581916A Issued 3-12 Printed in E.C.
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1001-3
84581916A Issued 3-12 Printed in E.C.
TORQUE SPECIFICATIONS - DECIMAL HARDWARE
Use the torques in this chart when special torques
are not given. These torques apply to fasteners with
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
used.
Grade 5 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
1/4 inch 108 to 132 12 to 15
5/16 inch 204 to 252 23 to 28
3/8 inch 420 to 504 48 to 57
Size
Pound-
Feet
Newton
metres
7/16 inch 54 to 64 73 to 87
1/2 inch 80 to 96 109 to 130
9/16 inch 110 to 132 149 to 179
5/8 inch 150 to 180 203 to 244
3/4 inch 270 to 324 366 to 439
7/8 inch 400 to 480 542 to 651
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983
Grade 8 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
1/4 inch 144 to 180 16 to 20
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Size
Pound-
Feet
Newton
metres
7/16 inch 70 to 84 95 to 114
1/2 inch 110 to 132 149 to 179
9/16 inch 160 to 192 217 to 260
5/8 inch 220 to 264 298 to 358
3/4 inch 380 to 456 515 to 618
7/8 inch 600 to 720 814 to 976
1.0 inch 900 to 1080 1220 to 1465
1-1/8 inch 1280 to 1440 1736 to 1953
1-1/4 inch 1820 to 2000 2468 to 2712
1-3/8 inch 2380 to 2720 3227 to 3688
1-1/2 inch 3160 to 3560 4285 to 4827
NOTE: Use thick nuts with Grade 8 bolts.

1001-4
84581916A Issued 3-12 Printed in E.C.
TORQUE SPECIFICATIONS - METRIC HARDWARE
Use the following torques when specifications are not
given.
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is
used.
Grade 12.9 Bolts, Nuts, and Studs
Usually the torque values specified for grade 10.9
fasteners can be used satisfactorily on grade 12.9
fasteners.
Grade 8.8 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
M4 24 to 36 3 to 4
M5 60 to 72 7 to 8
M6 96 to 108 11 to 12
M8 228 to 276 26 to 31
M10 456 to 540 52 to 61
Size
Pound-
Feet
Newton
metres
M12 66 to 79 90 to 107
M14 106 to 127 144 to 172
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
M36 1600 to 1950 2175 to 2600
8.8
Grade 10.9 Bolts, Nuts, and Studs
Size
Pound-
Inches
Newton
metres
M4 36 to 48 4 to 5
M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
M8 324 to 384 37 to 43
Size
Pound-
Feet
Newton
metres
M10 54 to 64 73 to 87
M12 93 to 112 125 to 150
M14 149 to 179 200 to 245
M16 230 to 280 310 to 380
M20 450 to 540 610 to 730
M24 780 to 940 1050 to 1275
M30 1470 to 1770 2000 to 2400
M36 2580 to 3090 3500 to 4200
10.9
12.9

1001-5
84581916A Issued 3-12 Printed in E.C.
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting
Tube OD
Hose ID
Thread
Size
Pound-
Inches
Newton
metres
1/4 inch
6.4 mm
7/16-20 72 to 144 8 to 16
5/16 inch
7.9 mm
1/2-20 96 to 192 11 to 22
3/8 inch
9.5 mm
9/16-18 120 to 300 14 to 34
1/2 inch
12.7 mm
3/4-16 180 to 504 20 to 57
5/8 inch
15.9 mm
7/8-14 300 to 696 34 to 79
Tube OD
Hose ID
Thread
Size
Pound-
Feet
Newton
metres
3/4 inch
19.0 mm
1-1/16-12 40 to 80 54 to 108
7/8 inch
22.2 mm
1-3/16-12 60 to 100 81 to 135
1.0 inch
25.4 mm
1-5/16-12 75 to 117 102 to 158
1-1/4 inch
31.8 mm
1-5/8-12 125 to 165 169 to 223
1-1/2 inch
38.1 mm
1-7/8-12 210 to 250 285 to 338
Split Flange Mounting Bolts
Size
Pound-
Inches
Newton
metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Size
Pound-
Feet
Newton
metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
Straight Threads with O-ring
Tube OD
Hose ID
Thread
Size
Pound-
Inches
Newton
metres
1/4 inch
6.4 mm
7/16-20 144 to 228 16 to 26
5/16 inch
7.9 mm
1/2-20 192 to 300 22 to 34
3/8 inch
9.5 mm
9/16-18 300 to 480 34 to 54
1/2 inch
12.7 mm
3/4-16 540 to 804 57 to 91
Tube OD
Hose ID
Thread
Size
Pound-
Feet
Newton
metres
5/8 inch
15.9 mm
7/8-14 58 to 92 79 to 124
3/4 inch
19.0 mm
1-1/16-12 80 to 128 108 to 174
7/8 inch
22.2 mm
1-3/16-12 100 to 160 136 to 216
1.0 inch
25.4 mm
1-5/16-12 117 to 187 159 to 253
1-1/4 inch
31.8 mm
1-5/8-12 165 to 264 224 to 357
1-1/2 inch
38.1 mm
1-7/8-12 250 to 400 339 to 542

1001-6
84581916A Issued 3-12 Printed in E.C.
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Face Seal End
O-ring Boss End
Fitting or Lock Nut
Nom.
SAE
Dash
Size Tube OD
Thread
Size
Pound-
Inches
Newton
metres
Thread
Size
Pound-
Inches
Newton
metres
-4 1/4 inch
6.4 mm
9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
-6 3/8 inch
9.5 mm
11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
-8 1/2 inch
12.7 mm
13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
Thread
Size
Pound-
Feet
Newton
metres
-10 5/8 inch
15.9 mm
1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
Nom.
SAE
Dash
Size Tube OD
Thread
Size
Pound-
Feet
Newton
metres
1-1/16-12 85 to 90 115 to 122
1-3/16-12 95 to 100 129 to 136
-12 3/4 inch
19.0 mm
1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
-14 7/8 inch
22.2 mm
1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
-16 1.0 inch
25.4 mm
1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
-20 1-1/4 inch
31.8 mm
1-11/16-12 125 to 140 170 to 190
-24 1-1/2 inch
38.1 mm
2-12 150 to 180 200 to 254

Section
1002
1002
Copyright © 2012 CNH Italia S.p.A.
All rights reserved.
Printed in E.C.
Issued March, 2012
CNH Italia S.p.A.
Via Plava, 80
10135 Torino
Italia 84581916A
FLUIDS AND LUBRICANTS

1002-2
84581916A Issued 3-12 Printed in E.C.
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANMISSION Temperature CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What is Selective Catalytic Reduction (SCR)?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Selective Catalytic Reduction (SCR) - Basic instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1002-3
84581916A Issued 3-12 Printed in E.C.
CAPACITIES AND LUBRICANTS
Engine Oil
Capacity with Filter Change ..................................................................................... 10.9 liters (11.5 U.S. Quarts)
Total system capacity............................................................................................... 11.8 liters (12.5 U.S. Quarts)
Type of oil................................ AMBRA Mastergold (SAE 15W-40) - see engine oil recommendations on page 4
Engine Cooling System
Capacity....................................................................................................................... 22 liters (23.2 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 189 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 (35.9 U.S. Quarts)
Type of Oil....................................................................................................................................... Case Nexplore
Axles
Capacity
Standard Front ......................................................................................................... 22 liters (23.2 U.S. Quarts)
Standard Rear.......................................................................................................... 22 liters (23.2 U.S. Quarts)
Optional Front .......................................................................................................... 22 liters (23.2 U.S. Quarts)
Optional Rear........................................................................................................... 22 liters (23.2 U.S. Quarts)
Type of Lubricant ............................................................................................................................ Case Nexplore
DEF (Diesel Exhaust Fluid)
Total Capacity Urea Tank ......................................................................................28.6 liters (10.20 U.S. Gallons)
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®
Grease Fittings
Grease fittings as required by maintenance schedule ...............................................Case AKCELA Molydisulfide

1002-4
84581916A Issued 3-12 Printed in E.C.
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
84581916A Issued 3-12 Printed in E.C.
TRANMISSION TEMPERATURE CHART
BC4F193
HYDRAULIC/BRAKE SYSTEM TEMPERATURE CHART
BC4F192