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SERVICE MANUAL

Engine

521G WHEEL LOADER XR-EH, NEW CAB TIER4B

521G WHEEL LOADER XT-EH, NEW CAB TIER4B

521G ZBAR-EH, NEW CAB TIER4B

48082189_EN 14/02/2017

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Summary of Contents for 521G

Page 1: ...1 2 521G Wheel Loader SERVICE MANUAL Wheel Loader 521G Stage IV Part number 48082189 English February 2017 2017 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL Part number 48082189 ...

Page 2: ...SERVICE MANUAL 521G WHEEL LOADER XR EH NEW CAB TIER4B 521G WHEEL LOADER XT EH NEW CAB TIER4B 521G ZBAR EH NEW CAB TIER4B 48082189_EN 14 02 2017 EN Find manuals at https best manuals com ...

Page 3: ...Link Product Engine Product Market Product Engine 521G ZBAR EH NEW CAB TIER4B Europe F4HFE413N B001 48082189_EN 14 02 2017 Find manuals at https best manuals com ...

Page 4: ...nsmission external controls 21 2 21 155 Powershift transmission internal components 21 3 Four Wheel Drive 4WD system 23 23 314 Drive shaft 23 1 Front axle system 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 108 Final drive hub steering knuckles and shafts 25 3 25 310 Final drives 25 4 Rear axle system 27 27 100 Powered rear axle 27 1 27 106 Rear bevel gear...

Page 5: ...tem 35 7 35 701 Front loader arm hydraulic system 35 8 35 723 Front loader bucket hydraulic system 35 9 35 734 Tool quick coupler hydraulic system 35 10 Frames and ballasting 39 39 100 Frame 39 1 Steering 41 41 200 Hydraulic control components 41 1 41 216 Cylinders 41 2 41 910 Auxiliary steering 41 3 Wheels 44 44 511 Front wheels 44 1 44 520 Rear wheels 44 2 Cab climate control 50 50 200 Air condi...

Page 6: ...l system 55 6 55 989 Exhaust Gas Recirculation EGR electrical system 55 7 55 530 Camera 55 8 55 DTC FAULT CODES 55 9 Front loader and bucket 82 82 100 Arm 82 1 82 300 Bucket 82 2 Platform cab bodywork and decals 90 90 150 Cab 90 1 90 105 Machine shields and guards 90 2 48082189_EN 14 02 2017 Find manuals at https best manuals com ...

Page 7: ...48082189_EN 14 02 2017 Find manuals at https best manuals com ...

Page 8: ...INTRODUCTION 48082189_EN 14 02 2017 1 Find manuals at https best manuals com ...

Page 9: ... standard and precautions 14 Basic instructions Precaution for disassembly and assembly 16 Basic instructions Electrical equipment precautions 18 Consumables Biodiesel Fuel 19 Consumables 20 Hydraulic contamination 21 Product identification 22 Product identification Identification of machine components 23 48082189_EN 14 02 2017 2 Find manuals at https best manuals com ...

Page 10: ...CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Machine safety NOTICE Notice indicates a situation that if not avoided could result in machine or property damage Throughout this manual you will find the signal word Notice followed by special instruction...

Page 11: ...rom any other position than the operator s seat TULI12WEX2004AA 1 Never carry out any operation on the machine when the engine is running except when specifically indicated Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps covers valves etc All repair and maintenance operations should be carried out with the greatest care and attention Service st...

Page 12: ...otections Goggles with lateral shield or masks for eye protection Do not wear rings wristwatches jewelry unbuttoned or flapping clothing such as ties torn clothes scarves open jackets or shirts with open zips which could get caught into moving parts TULI12WEX2008AA 4 Engine Radiator Never leave the engine running in enclosed spaces with out proper ventilation which is able to evacuate toxic ex hau...

Page 13: ...e cap while engine is hot wear safety clothes and equipment then loosen the cap slowly to relieve the pressure gradually When checking the fuel oil and coolant levels use lights and lamps explicitly designated as explosion proof If these types of lamps are not used fires or explosions may occur TULI12WEX2011AA 7 Hydraulic systems Jets of fluids under pressure can penetrate the skin caus ing seriou...

Page 14: ...entally be pierced when the heat expands beyond the area immediately heated Arrange for temporary fire resistant shields to protect hoses or other components during welding or torch use Have any visible leakage repaired immediately Discharged oil pollutes the environment Soak up any oil that has spilled with a proper binding agent Sweep up binding agent and dispose of it separately from other wast...

Page 15: ...d outer sheath will allow water penetra tion Concealed corrosion of the wire reinforcement could subsequently occur along the hose length with resultant hose failure Ballooning of the hose indicates an internal leakage due to structural failure This condition rapidly deteriorates and total hose failure soon occurs Kinked crushed stretched or deformed hoses generally suffer internal structural dama...

Page 16: ...id vomiting Drink water to rinse your mouth Consult a doctor EYES Rinse abundantly with water for 15 min and con sult a doctor When the electrolyte of a battery is frozen it can ex plode if you attempt to charge the battery or if you try to start the engine using a booster battery Always keep the battery charged to prevent the electrolyte freezing Provide good ventilation when changing a battery o...

Page 17: ...il or fuel Fuel or oil spills can cause slipping hazards thoroughly contain and clean affected areas Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly Never use fuel to clean machine parts that will be exposed to dirt or debris Use a non flammable product for cleaning parts Always perform fuel or oil refilling in well aired and venti lated areas TULI12WEX2018AA 15 During r...

Page 18: ...y means of an inflation pistol complete with extension and pressure control valve Use an inflation cage TULI12WEX2020AA 17 Cleaning Clean the exterior of all components before carrying out any form of repair Dirt and dust can reduce the efficient working life of a component and lead to costly replace ment Solvents should be checked that they are suitable for the cleaning of components and also tha...

Page 19: ...nd pure an tifreeze Fuel Filter elements oil and fuel filters Filter elements air filters Battery Also polluted rags paper sawdust and gloves must be disposed in compliance with the same procedures Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping int...

Page 20: ...nsibility for damages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and or components not approved by the manufacturer The info...

Page 21: ...e at which reconditioning is impossible without replacement of parts If the value is expected to exceed the service limit before next inspection and correction are performed replace the parts immediately The operation over the specified values causes increase of damage and requires the down time of machine and also causes safety problems Cautions to be exercised at judgment EVALUATION OF MEASURED ...

Page 22: ... P and recommend that they should be replaced regularly INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance it is necessary for the user to familiarize themselves with the machine and handle safely Use caution when inspecting and replacing oils and grease Refer to the Operators Manuals as well 48082189_EN 14 02 2017 15 ...

Page 23: ...sassembling and assembling hydraulic equipment Before removing lines release the pressure of hydraulic oil tank or open the cover on the return side to tank and take out the filter Drain the oil in removed lines into an appropriate container to prevent oil contamination Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system Thoroughly clean...

Page 24: ...emoved o rings back up rings and oil seals with new ones Apply gear oil on them before reassembling Thoroughly clean and dry surfaces on which liquid sealant must be reapplied Before assembling remove rust preventives on new parts Use special tools to fit bearings bushing and oil seal Assemble parts matching to the marks After completion check that there is no omission of parts 48082189_EN 14 02 2...

Page 25: ...e equipment with care so as not to drop it or bump it Connector should be removed by unlocking while hold ing the connector Never disconnect electrical plugs by pulling on the wires Always use only the electrical connectors to make the disconnection Check that connector is connected and locked com pletely Engine key off before removing and connecting connec tor Engine key off before touching termi...

Page 26: ... and may cause shortened filter life or filter blockages Blockages are more common in cold weather conditions Consult your dealer for information on cold weather operation and proper maintenance intervals when using any biodiesel fuel blend Biodiesel fuel may degrade natural rubber gaskets and hoses as it is more solvent than petro diesel Frequently inspect hoses and other engine components when u...

Page 27: ...f oil CASE AKCELA NEXPLORE FLUID Technical specifications SAE 10W 30 API GL 4 ISO VG 32 46 CASE CONSTRUCTION specifications MAT 3525 Service capacity with filter change 18 9 L 20 0 US qt Axles Type of oil CASE AKCELA TRANSAXLE FLUID 80W 140 Technical specifications SAE 80W 140 API GL 4 CASE CONSTRUCTION specifications MAT 3510 Front axle Standard and Heavy Duty 22 L 23 2 US qt Rear axle Standard a...

Page 28: ...ear rapidly Relief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times or a lack of power If your machine has any of these problems check the hydraulic oil for contamination There are two types of contamination microscopic and visible Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydrauli...

Page 29: ...ification The terms right hand left hand front and rear are used in this manual to indicate the sides as they are seen from the operator s seat 1 Front 2 Right hand 3 Rear 4 Left hand RCPH10WHL003BAH 1 48082189_EN 14 02 2017 22 ...

Page 30: ...omponents LEIL16WHL1254FB 1 1 Cab door and hand holds 5 Roll Over Protection System ROPS cab 2 Steps 6 Loader lift arm 3 Bucket Z bar version 7 Battery compartment 4 Bucket cylinder 8 Timed disconnect switch and optional battery jump post 48082189_EN 14 02 2017 23 ...

Page 31: ...N LEIL16WHL1255FB 2 1 Cab side window 5 Cab air filter door 2 Driving lights 6 Windshield washer reservoir 3 Bucket Z bar version 7 DIESEL EXHAUST FLUID DEF ADBLUE fill tank 4 Drive shaft 48082189_EN 14 02 2017 24 ...

Page 32: ...SERVICE MANUAL Engine 521G WHEEL LOADER XR EH NEW CAB TIER4B 521G WHEEL LOADER XT EH NEW CAB TIER4B 521G ZBAR EH NEW CAB TIER4B 48082189_EN 14 02 2017 10 ...

Page 33: ...uel tanks 10 2 10 202 Air cleaners and lines 10 3 10 500 Selective Catalytic Reduction SCR exhaust treatment 10 4 10 400 Engine cooling system 10 5 10 414 Fan and drive 10 6 10 310 Aftercooler 10 7 10 304 Engine lubrication system 10 8 48082189_EN 14 02 2017 10 ...

Page 34: ...Engine 10 Engine and crankcase 001 521G WHEEL LOADER XR EH NEW CAB TIER4B 521G WHEEL LOADER XT EH NEW CAB TIER4B 521G ZBAR EH NEW CAB TIER4B 48082189_EN 14 02 2017 10 1 10 001 1 ...

Page 35: ...Contents Engine 10 Engine and crankcase 001 TECHNICAL DATA Engine General specification 3 SERVICE Engine Remove 4 Install 27 Test 50 48082189_EN 14 02 2017 10 1 10 001 2 ...

Page 36: ...tall 2020 2220 RPM E Converter and Hydraulic Stall 1400 1600 RPM Temperature of the torque converter oil 82 104 C 180 219 F Temperature of the hydraulic oil 54 57 C 129 135 F NOTE hydraulic stall and converter and hydraulic stall RPM values are read with the lift arms raised the bucket held in rolled back position and the engine at Wide Open Throttle WOT in maximum power mode with the transmission...

Page 37: ...avoided remove the sensors using extreme caution prior to performing any service procedure 1 Park the machine on a level surface and lower the bucket to the ground Put the articulation lock in the LOCKED position RAPH12WEL1412AA 1 2 Turn the engine OFF Actuate the brake pedal several times to discharge the brake accumulators LEIL15WHL0564AA 2 3 Turn the key switch to the ON position Move the contr...

Page 38: ...he rear grill LEIL16WHL2016AB 5 6 Remove the retaining bolts of the inner fender panels NOTE right hand side of the machine is shown The op eration is similar for the left hand side LEIL16WHL1378AB 6 7 Locate the timed disconnect switch under the engine hood on the left hand side of the machine Turn the timed disconnect switch to the OFF position LEIL16WHL1382AB 7 48082189_EN 14 02 2017 10 1 10 00...

Page 39: ...hen reinstall the radiator cap after the coolant has drained NOTE see machine specifications for cooling system vol ume RAPH12WEL1411AA 10 11 Place a suitable container below the engine oil drain Remove the engine oil cap 2 to drain the engine oil into the container Then reinstall the engine oil cap after the engine oil has drained NOTE see machine specifications for cooling system vol ume NOTE af...

Page 40: ...h the nylon strap Raise the engine hood and release the tension on the lifting motor RAPH12WEL1458AA 13 14 Remove the right hand gas strut from the engine hood Remove the left hand gas strut from the engine hood RAPH12WEL1489AA 14 15 Remove the gas spring to separate the engine hood from the rear chassis NOTE engine hood is NOT shown LEIL16WHL1432AB 15 48082189_EN 14 02 2017 10 1 10 001 7 ...

Page 41: ...g and disconnect the backup alarm connector 1 Remove the two straps cable tie 2 LEIL15WHL0143AB 17 18 Remove the connector 1 from the battery isolator LEIL16WHL1381AB 18 19 Tag and disconnect the battery to isolator cable 1 and the isolator to starter cable 2 from the battery isolator Disconnect the connector 3 from the timed discon nect switch LEIL16WHL1342AB 19 48082189_EN 14 02 2017 10 1 10 001...

Page 42: ...ine hood from the machine Lower the engine hood onto a suitable plat form Disconnect the lifting equipment from the ex haust stack 1 LEIL14WHL0400AB 21 22 Loosen the two bolts 2 and the related washers to remove the bracket 1 of the relay decal LEIL15WHL0195AB 22 23 Tag and disconnect the engine wiring harness con nector from the air filter sensor 1 Loosen the clamp 2 on the air intake hose 3 and ...

Page 43: ...rbocharger 26 Loosen the clamps 3 on the air filter housing 27 Loosen the clamp 4 on the crankcase vent hose 5 28 Remove the intake air hose 1 Cover the tur bocharger inlet to prevent debris entry LEIL15WHL0198AB 25 29 Loosen the bolt to separate the P clamp of the alter nate hose on the engine side of the heat shield LEIL15WHL0148AA 26 48082189_EN 14 02 2017 10 1 10 001 10 ...

Page 44: ...r washers 4 and two nuts 5 Remove the bracket 2 with the air filter 1 as an assembly LEIL15WHL0171BB 27 31 Remove the four mounting bolts and the four washers from the belt cover Remove the cover LEIL16WHL1311AB 28 LEIL16WHL1362AB 29 48082189_EN 14 02 2017 10 1 10 001 11 ...

Page 45: ...igerant as indicated in Air condi tioning Service instruction 50 200 Disconnect the low pressure line 2 from the suction port and the high pressure line 3 from the discharge port lo cated on the compressor Immediately install protec tive caps on the open ports and lines LEIL16WHL1349AB 31 34 Remove the belt 4 Remove the three mounting bolts 2 Remove the bolt 3 and carefully remove the compressor 1...

Page 46: ... and remove the hose LEIL15WHL0263AB 35 38 Remove the clamp 2 and the clamp 3 Separate the clamp 4 from the bracket of the coolant overflow tank Loosen the bolts 1 to remove the coolant tank LEIL15WHL0264AB 36 39 Remove the bolts and the washers 2 to separate the bracket 1 of the overflow tank from the rear plate of the cooling system frame LEIL15WHL0265AB 37 48082189_EN 14 02 2017 10 1 10 001 13 ...

Page 47: ...42 Loosen the hexagonal nut of the temperature sensor 1 Disconnect the temperature sensor 1 on the exhaust pipe DOC to SCR 43 Tag and disconnect the wire harness 3 of the rear chassis wiring harness of the temperature sensor 1 Cut the straps 2 that hold the sensor lead LEIL16WHL1348AB 40 44 Remove the bolts the washers and the nuts 3 to separate the bracket 2 of the tube radiator from the muffler ...

Page 48: ...m the hose coolant assembly 7 LEIL15WHL0193BB 42 46 Remove the two bolts 4 the washers 5 the spacer 10 and the nut 6 to separate the clamp 3 from the bracket 11 Remove the clamp 3 from the hose coolant assembly 1 47 Remove the two bolts 8 the washers 9 and the nut 6 to separate the clamp 7 from the bracket 11 Remove the clamp 7 from the DEF bundle 2 LEIL15WHL0261BB 43 48082189_EN 14 02 2017 10 1 1...

Page 49: ...Module 2 LEIL15WHL0176AA 45 50 Loosen the bolt to remove the P clamps 1 Discon nect the return coolant hose 2 and remove it from the machine LEIL15WHL0270AB 46 51 Loosen the bolt 1 and remove the P clamp 3 from the supply module support 4 Remove the P clamp 2 Tag and disconnect the hose 5 from the DEF ADBLUE tank vent filter LEIL15WHL0269AB 47 48082189_EN 14 02 2017 10 1 10 001 16 ...

Page 50: ...1 from the rear plate of the cooling system frame LEIL15WHL0268AB 48 53 Remove the bolts 2 and washers to remove the bracket 1 from the engine LEIL15WHL0191AB 49 54 Loosen the clamp 1 to separate the exhaust flap from the inlet DOC pipe LEIL15WHL0172AB 50 48082189_EN 14 02 2017 10 1 10 001 17 ...

Page 51: ...not damage the muffler support during removal LEIL16WHL1345BB 51 58 Tag and disconnect the DEF ADBLUE supply and re turn lines 1 from the supply module Tag and discon nect the coolant water supply and return lines 2 from the supply module Tag and disconnect the wiring har ness 3 from the supply module LEIL16WHL1497AB 52 59 Push inward on the fitting retaining clip and discon nect the coolant outle...

Page 52: ... the washers and the nuts to separate the bracket 2 of the supply module from the support 3 Remove the two bolts 4 the washers and the nuts to separate the bracket 2 of the supply module from the rear chassis Remove the bracket 2 of the supply module with the supply module the DEF ADBLUE Heater Control valve and the fuel pre filter as an assembly NOTE pay attention to supply module and heater valv...

Page 53: ...E storage tank Cap the supply lines LEIL15WHL0304AA 58 65 Remove the bolts 1 the washers and the nuts to remove the supply module support 2 LEIL15WHL0276AB 59 66 Remove the four bolts 3 and the four washers 4 to remove the support structures 1 from the rear chas sis 2 LEIL16WHL1344BB 60 48082189_EN 14 02 2017 10 1 10 001 20 ...

Page 54: ...ose 1 of the after cooler from the inter cooler LEIL15WHL0277AB 62 69 Remove the cooling fan screen 3 and the bottom cooling fan screen 2 removing the four bolts 1 and the related nuts LEIL15WHL0301AB 63 70 Loosen the clamps 1 and 2 to remove the bottom hose coolant 3 from the engine NOTE the battery cover plate has been hidden for clarify LEIL15WHL0278AB 64 48082189_EN 14 02 2017 10 1 10 001 21 ...

Page 55: ...ose 5 LEIL15WHL0279AB 65 72 Remove the nuts 2 from the U bolt clamp to sepa rate the radiator hose 3 from the bracket 1 LEIL15WHL0280AB 66 73 Remove the clamp 1 to disconnect the breather hose 2 from the engine LEIL15WHL0291AB 67 74 Remove the bolts 1 the washers and the nuts to re move the bracket 2 from the rear plate of the cooling system frame LEIL15WHL0292AB 68 48082189_EN 14 02 2017 10 1 10 ...

Page 56: ...n to drain the refrigerant R134A LEIL15WHL0296AB 70 77 Unlatch the air conditioning condenser clamp 1 78 Rotate the air conditioning condenser up Remove the two retaining bolts 2 the washers and the nuts lo cated on each side Move the air conditioning con denser 3 back from the cooling system frame LEIL15WHL0295AB 71 79 Loosen the flange nuts 1 to remove the upper radi ator hose 2 Remove the brack...

Page 57: ...p the fitting LEIL15WHL0306AB 74 82 Tag and remove the grid heater cable NOTE hold the rear nut with a second wrench to prevent grid heater damage RAPH12WEL1478AA 75 83 Disconnect the wiring from the alternator Identify and tag the wires to aid in reassembly NOTE move the wires away from the engine RAPH12WEL1468AA 76 48082189_EN 14 02 2017 10 1 10 001 24 ...

Page 58: ... from the starter NOTE move the starter cables away from the engine RAPH12WEL1474AA 78 86 Tag and disconnect wire harness 2 from the primary fuel filter 1 87 Remove the fuel line 3 from the top of the primary fuel filter 1 Plug the line and cap the fitting NOTE make note on how fuel lines are routed LEIL15WHL0298AB 79 88 Connect a vacuum pump to the hydraulic reservoir Turn the vacuum on Tag and r...

Page 59: ...uipment to the engine lift ing brackets 2 Take up all slack in lifting equipment Remove the engine mounting bolts 1 92 Slowly raise engine from rear chassis Be sure that all the wire harness connections and the hoses have been disconnected and are clear of the engine Guide the oil drain hose from the frame as the engine is lifted Remove the engine from machine LEIL15WHL0299AB 83 LEIL15WHL0300AB 84...

Page 60: ...pressure to escape Failure to comply could result in death or serious injury W0296A NOTE emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations Use of tools that gen erate extreme vibrations such as impact wrenches and hammers will result in damage to emission sensors Avoid using these tools during any service procedure in close proximity of emission sensors If the use...

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