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SERVICE MANUAL

WHEEL LOADER

521E

TIER 3

84243970

(Replaces 87728450)

Revised June 2009
Issued February 2008

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Summary of Contents for 521E

Page 1: ...SERVICE MANUAL WHEEL LOADER 521E TIER 3 84243970 Replaces 87728450 Revised June 2009 Issued February 2008 ...

Page 2: ...Find manuals at https best manuals com ...

Page 3: ...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 I...

Page 4: ...s 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 Specificat...

Page 5: ... 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 Hy...

Page 6: ...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 Find manuals at https best manuals com ...

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Page 14: ...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 ...

Page 15: ...S 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 ...

Page 16: ...al 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 ...

Page 17: ...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 lubri...

Page 18: ...1002 5 Bur 5 10840 Issued 2 08 Printed in U S A TRANMISSION TEMPERATURE CHART BC04F193 HYDRAULIC BRAKE SYSTEM TEMPERATURE CHART BC04F192 ...

Page 19: ...ication 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...

Page 20: ...linder 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 bel...

Page 21: ...items 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 ...

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Page 26: ...d February 2008 CNH America LLC 700 State Street Racine WI 53404 U S A Bur 5 10850 SECTION INDEX ENGINES Engine and Radiator Removal and Installation 2000 Stall Tests 2002 After Cooler 2003 FOR ENGINE REPAIR SEE THE ENGINE REPAIR MANUAL 87630273 Section Title Section Number ...

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Page 28: ...2000 2000 Copyright 2008 CNH Ameica 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 10860 ENGINE AND RADIATOR REMOVAL AND INSTALLATION ...

Page 29: ...2000 2 Bur 5 10860 Issued 2 08 Printed in U S A TABLE OF CONTENTS Engine 3 Removal 3 Installation 11 Radiator 20 Removal 20 Installation 23 ...

Page 30: ... reservoir STEP 4 BD07N563 01 The master disconnect is located under the hood on the left read side of the machine Raise the hood put master disconnect switch in OFF position Remove both battery covers and disconnect batteries from the machine STEP 5 BD02N160 Put a container capable of holding at least 22 7 liter 6 0 gallon below radiator drain Remove radiator cap Remove cap and drain coolant into...

Page 31: ...e right front lift cylinder from the hood Repeat the procedure for the left hand side STEP 10 BD07N565 01 Remove the rear lift cylinder from the machine STEP 11 BD07N566 01 Tag and disconnect hood wiring harness connector and backup alarm connector from rear chassis wiring harness connector STEP 12 BD07N567 01 Have another person balance the hood and remove the hood hinge mounting bolts 1 located ...

Page 32: ...engine wiring harness connector from air filter restriction switch STEP 15 BD07N569 01 Loosen clamp on air cleaner intake hose and remove the crankcase ventilation hose STEP 16 BD07N569 01 Loosen clamps on turbocharger and air cleaner remove the intake hose STEP 17 BD07N590 01 Remove the air cleaner by removing the four bolts STEP 18 BD07N569 01 Loosen the clamp on the turbocharger for the after c...

Page 33: ...from the machine STEP 20 BD07N570 01 Loosen the clamp on the intake manifold for the after cooler output hose STEP 21 BD07N571 01 Loosen the clamp on the after cooler and remove the after cooler outlet hose from the machine STEP 22 BD07N572 01 Loosen the exhaust clamp from the turbocharger STEP 23 BD07N592 01 Remove the muffler from the bracket ...

Page 34: ...hine frame STEP 25 BD07N576 01 Remove the drive belt from the engine STEP 26 BD07N577 01 Loosen clamps and remove lower cooler hose from the engine STEP 27 BD07N579 01 BD07N578 01 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 set the compresso...

Page 35: ...Remove ground wires 2 from the engine STEP 30 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 31 BD07N599 01 Disconnect the engine coolant vent hose and route to the rear of the engine 2...

Page 36: ...engine 2 remove the clamp bolts and clamps 3 from the bell housing STEP 33 BD07N585 01 Tag and remove the grid heater cable STEP 34 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 35 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 37: ... 38 BD07N589 01 Remove the lower cover for the drive shaft STEP 39 BD03A172 Remove the drive shaft bolts from the flywheel Move the drive shaft clear of the flywheel STEP 40 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 w...

Page 38: ...ly 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 3 INSOLATOR UPPER 5 WASHER 7 NUT 9 OIL FILL TUBE 2 WASHER 4 INSOLATOR LOWER 6 WASHER 8 REMOTE OIL...

Page 39: ...ix bolts to a torque of 53 to 62 Nm 39 to 46 lb ft STEP 48 BD07N589 01 Install the lower cover for the drive shaft STEP 49 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 5...

Page 40: ...ver straight out from EDC 7 Use lever to pull connector into position STEP 53 BD07N585 01 Connect grid heater cable to grid heater Remove and discard tag STEP 54 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 55 BD07N599 01 Connect the engine coolant vent hose 1 2 3 ...

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