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521F

TIER IV

Print No. 84581916A

Service Manual

Wheel Loader

Summary of Contents for 521F

Page 1: ...521F TIER IV Print No 84581916A Service Manual Wheel Loader ...

Page 2: ...521F Loader 84581916A Use for Repair Manual Find manuals at https best manuals com ...

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Page 4: ...talyst 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 F...

Page 5: ...ecks 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 Hy...

Page 6: ...d 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 84581...

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Page 8: ... 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 Find manuals at https best manuals com ...

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Page 10: ...01 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 Find manuals at https best manuals com ...

Page 11: ...sued 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 ...

Page 12: ... 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 54...

Page 13: ...s 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 ...

Page 14: ...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...

Page 15: ...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...

Page 16: ...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 ...

Page 17: ...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 ...

Page 18: ...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 Ure...

Page 19: ...erating 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 lubrica...

Page 20: ...1002 5 84581916A Issued 3 12 Printed in E C TRANMISSION TEMPERATURE CHART BC4F193 HYDRAULIC BRAKE SYSTEM TEMPERATURE CHART BC4F192 ...

Page 21: ...ation 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 t...

Page 22: ...es above 30 C 86 F greatly reduce the shelf life of DEF AdBlue DEF AdBlue has a typical shelf life of 6 12 months Refer to the SHELF LIFE table below In order for DEF AdBlue to remain in a usable condition storage requirements need to be met Store between 11 C 12 F and 30 C 86 F Use only an approved DEF AdBlue container Keep container tightly closed Keep container in a cool well ventilated area Ke...

Page 23: ...e the diesel emission control system to fail to conform to the emission control performance level it was verified to or to the requirements in the California Code of Regulations Title 13 Sections 2700 to 2706 and 2710 for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your diesel emission control system vehicle or equipment as specified in the ...

Page 24: ...e correct length and diameter triggered by the magnet in the tank filler neck and with overfill flow cut out This will ensure that The screen in the filler neck will not be damaged Impurities are not entering the DEF AdBlue tank The standardized DEF AdBlue nozzle matches the filler neck diameter The DEF AdBlue tank is not overfilled as the DEF AdBlue pump will stop when the DEF AdBlue tank is full...

Page 25: ...lter 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 21 Replace Hydraulic Oil fil...

Page 26: ...s and for detailed information of the service items on this chart Operators and service manuals are available for this machine from your dealer If you operate the machine in severe conditions lubricate and service the machine more frequently 19 27 12 22 10 11 11 26 18 14 5 2 4 5 10 1 18 13 20 16 21 23 24 8 20 16 6 15 6 7 25 9 3 17 18 29 28 30 32 31 ...

Page 27: ...1002 12 84581916A Issued 3 12 Printed in E C NOTES ...

Page 28: ...Section 1003 1003 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 METRIC CONVERSION CHART ...

Page 29: ...1003 2 84581916A Issued 3 12 Printed in E C TABLE OF CONTENTS CONVERSION FACTORS 3 Metric to U S 3 U S to Metric 4 ...

Page 30: ...ter 1 685 555 lb cubic yd Power kilowatt 1 341 02 horsepower Pressure kilopascal bar 0 145 038 14 50385 lb sq inch lb sq inch Temperature degree C 1 8 x C 32 degree F Torque newton meter newton meter 8 850 748 0 737 562 lb inch lb foot Velocity kilometer hr 0 621 371 miles hr Volume cubic centimeter cubic meter cubic meter milliliter litre litre litre litre 0 061 024 35 314 66 1 307 950 0 033 814 ...

Page 31: ... lb cubic yd 0 593 276 kg cubic meter Power horsepower 0 745 700 kilowatt Pressure lbs sq in lbs sq in lbs sq in 6 894 757 0 069 0 070 303 kilopascal bar kg sq cm Temperature degree F 1 8 F 32 degree C Torque pound inch pound foot 0 112 985 1 355 818 newton meter newton meter Velocity miles hr 1 609 344 kilometer hr Volume cubic inch cubic foot cubic yard ounce US fluid quart US liquid quart Imper...

Page 32: ...Issued March 2012 CNH Italia S p A Via Plava 80 10135 Torino Italia 84581916A SECTION INDEX ENGINES Engine and Radiator Removal and Installation 2000 Stall Tests 2002 After Cooler 2003 FOR ENGINE REPAIR SEE THE ENGINE REPAIR MANUAL 84392428 Section Title Section Number ...

Page 33: ......

Page 34: ...tion 2000 2000 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 ENGINE AND RADIATOR REMOVAL AND INSTALLATION ...

Page 35: ...2000 2 84581916A Issued 3 12 Printed in E C TABLE OF CONTENTS Engine 3 Removal 3 Installation 11 Radiator 20 Removal 20 Installation 23 ...

Page 36: ...th at least 30 times to release any pressure from hydraulic circuit Put key switch in OFF position STEP 3 Slowly loosen the filler cap for hydraulic reservoir to release air pressure in hydraulic reservoir STEP 4 W110R381 The master switch disconnect is located under the hood on the left read side of the machine Raise the hood put master disconnect switch in OFF position W110R381 STEP 5 W110R383 R...

Page 37: ...in Remove cap 3 and drain oil into container Install cap after oil has drained NOTE After draining oil disconnect drain hose from frame for removal with engine STEP 8 BD03A231 Double up a nylon lifting strap 1 and slide through the exhaust stack 2 on the hood STEP 9 BD07N564 01 Place a solid steel bar through the strap raise the hood and release tension on the lifting motor STEP 10 BD07N597 01 Rem...

Page 38: ...e hood by the cab 2 from the cooler frame Repeat procedure for the other side STEP 14 BD03A232 Carefully raise and remove hood from loader Lower hood onto suitable platform and disconnect lifting equipment STEP 15 W110R386 Tag and disconnect engine wiring harness connector from air filter restriction switch STEP 16 BD07N569 01 Loosen clamp on air cleaner intake hose and remove the crankcase ventil...

Page 39: ...inlet hose STEP 20 W110R390 Loosen the clamp on the after cooler and remove the after cooler inlet hose from the machine STEP 21 BD07N570 01 Loosen the clamp on the intake manifold for the after cooler output hose STEP 22 W110R391 Loosen the clamp on the after cooler and remove the after cooler outlet hose from the machine STEP 23 W110R392 Loosen the exhaust clamp from the turbocharger ...

Page 40: ...nnect the electrical connector 1 from exhaust temperature sensor 2 after the SCR catalist Tag and disconnect two hoses from Dosing Unit Injector 3 and disconnect electrical connector 4 STEP 26 W110R411 Disconnect NOx sensor module 1 from machine wiring harness Remove hex bolts 2 securing NOx sensor module to mounting support bracket and remove module 2 3 1 4 2 3 1 2 1 ...

Page 41: ...the support muffler left and right 1 2 W110R397 Muffler installation 1 Support Muffler RH 2 Support Muffler LH 3 Bracket Muffler RH 4 Bracket Muffler LH 5 Bracket 6 Clamp Muffler 7 Muffler SCR 8 Pipe exhaust system 9 Washer 10 5x18x1 6 mm 10 Bolt M10x20 11 Bolt M10x25 12 Nut M10 13 Bolt M10x30 14 Washer 13 5x24x2 5 mm 15 Bolt M12x50 16 Bolt M12x65 17 Bolt M12x45 18 Clamp 19 Strap Retaining 20 Brac...

Page 42: ... STEP 29 W230R423 Remove from the bottom on Electronic Control Unit DENOX Urea supply the electrical connections STEP 30 W230R424 Remove from the rear on Electronic Control Unit DENOX Urea supply the wiring harness 5 1 11 12 9 12 10 9 3 6 20 22 21 17 14 ...

Page 43: ...ackets from the machine frame STEP 32 BD07N576 01 Remove the drive belt from the engine STEP 33 BD07N577 01 Loosen clamps and remove lower cooler hose from the engine STEP 34 BD07N579 01 W110R395 If loader is equipped with air conditioning identify tag and disconnect the engine wiring harness connectors from air compressor clutch connector 1 Remove the two mounting bolts 2 for the compressor and s...

Page 44: ...move ground wires 2 from the engine STEP 37 BD07N581 01 Tag and remove the wires from the starter solenoid 2 remove the ground cable and ground strap 3 from the starter Then remove the two mounting bolts 1 NOTE Move the starter cables away from the engine move the wiring harness away from the engine STEP 38 BD07N599 01 Disconnect the engine coolant vent hose and route to the rear of the engine 2 2...

Page 45: ...gine 2 remove the clamp bolts and clamps 3 from the bell housing STEP 40 BD07N585 01 Tag and remove the grid heater cable STEP 41 BD07N586 01 Disconnect the wiring harness from the EDC 7 controller NOTE Lifting up on the lever will release the connector from the controller STEP 42 BD07N591 01 Remove the fuel line from the top of the EDC 7 controller plug the line and cap the fitting 1 2 3 ...

Page 46: ...5 BD07N589 01 Remove the lower cover for the drive shaft STEP 46 BD03A172 Remove the drive shaft bolts from the flywheel Move the drive shaft clear of the flywheel STEP 47 Connect suitable lifting equipment to engine lifting brackets Take up all slack in lifting equipment Remove the engine mounting bolts and lift the engine enough to gain access to the drain hose pull the engine oil drain hose wit...

Page 47: ...raise engine and move into position over rear chassis Be sure all harness connections and hoses are out of the way then lower engine Put washer 5 between front rubber isolator 4 and chassis Install washer 2 bolt 1 washer 6 and nut 7 in engine isolators Lower engine into position 1 ENGINE MOUNT BOLT 244 298 NM 182 220 LB FT 3 INSOLATOR UPPER 5 WASHER 7 NUT 9 OIL FILL TUBE 2 WASHER 4 INSOLATOR LOWER...

Page 48: ... bolts to a torque of 53 to 62 Nm 39 to 46 lb ft STEP 55 BD07N589 01 Install the lower cover for the drive shaft STEP 56 BD07N588 01 Connect and turn on vacuum pump to the hydraulic reservoir Remove caps from fittings and plugs from hoses Connect hoses to brake pump following tags installed during removal Remove and discard tags Turn off and disconnect vacuum pump from hydraulic reservoir STEP 57 ...

Page 49: ...r straight out from EDC 7 Use lever to pull connector into position STEP 60 BD07N585 01 Connect grid heater cable to grid heater Remove and discard tag STEP 61 BD07N596 01 BD07N583 01 BD07N584 01 Install the heater hose 2 to the rear of the engine mount the clamps 3 install the radiator hose 1 STEP 62 BD07N599 01 Connect the engine coolant vent hose 1 2 3 ...

Page 50: ...o studs and holes and apply Loctite 271 to each stud and hole and torque to 19 to 29 Nm 14 to 21 pound feet STEP 64 BD07N582 01 Install bolt securing wiring harness 1 clamp to the engine Install ground wires 2 to the engine STEP 65 BD07N575 01 Connect the wiring to the alternator Remove and discard tags STEP 66 BD07N579 01 W110R395 If loader is equipped with air conditioning mount the compressor u...

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