Case 521G Service Manual

Wheel loader

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521G

Stage IV

Wheel Loader

SERVICE MANUAL

Part number 48082189

English

February 2017

Table of Contents

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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 Find manuals at https://best-manuals.com...
Page 3 Link Product / Engine Product Market Product Engine 521G ZBAR-EH, NEW CAB Europe F4HFE413N*B001 TIER4B 48082189_EN 14/02/2017 Find manuals at https://best-manuals.com...
Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
Page 5 Brakes and controls ..............33 [33.202] Hydraulic service brakes ............33.1 [33.110] Parking brake or parking lock .
Page 6 [55.201] Engine starting system ............. 55.3 [55.301] Alternator .
Page 7 48082189_EN 14/02/2017 Find manuals at https://best-manuals.com...
Page 8 INTRODUCTION 48082189_EN 14/02/2017 Find manuals at https://best-manuals.com...
Page 9: Table Of Contents
Contents INTRODUCTION Safety rules ..................3 Personal safety .
Page 10 INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.
Page 11 INTRODUCTION Personal safety Carefully read this Manual before proceeding with main- tenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and in- structed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy ham- mers.
Page 12 Keep the exhaust manifold and tube free from combustible materials. Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage. Never attempt to check or adjust the belts when the en- gine is running.
Page 13 INTRODUCTION Pay attention to rotating components and do not allow anyone to approach these areas to avoid becoming en- tangled. Hands, clothing or tools getting caught in the fan blades or engine belts, can cause amputations, violent hemorrages and generate conditions of grave danger. For this reason avoid touching or approaching all rotating or moving parts.
Page 14 INTRODUCTION When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital. If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid penetrating the skin must be removed within a few hours to avoid serious infections.
Page 15 INTRODUCTION Hoses and tubes Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the correct position be- fore tightening the connections.
Page 16 INTRODUCTION Battery Batteries give off explosive gases. Never handle open flames and unshielded light sources near batteries. (No smoking is addressed in the next in- struction). To prevent any risk of explosion, observe the following instructions: • When disconnecting the battery cables, always discon- nect the negative (-) cable first.
Page 17 INTRODUCTION Flammable liquids When handling flammable liquids: • Do not smoke. • Keep away from unshielded light sources and open flames. Fuels often have a low flash point and are readily ignited. Never attempt to extinguish burning liquids with water. Use: •...
Page 18: Personal Safety
INTRODUCTION Tires Before inflating the tires, always check the condition of rims and the outer condition of tires for the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tire, make sure that there are no nearby persons, then position yourself at tread side.
Page 19 INTRODUCTION Waste disposal Improperly disposing of waste can threaten the environ- ment. Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.
Page 20: Basic Instructions - Important Notice Regarding Equipment Servicing
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.
Page 21: Basic Instructions - How To Use The Maintenance Standard And Precautions
INTRODUCTION Basic instructions - How to use the maintenance standard and precautions Application WHEN THE MACHINE IS NEW Confirm that the performances are in accordance with standard specifications as compared to the performance stan- dards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY) Use the data for the criterion, for the purpose of correction, adjustment and replacement.
Page 22 INTRODUCTION PARTS REQUIRING REGULAR REPLACEMENT Critical hoses that are necessary to secure safety, we designate as Very Important Parts (V.I.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.
Page 23: Basic Instructions - Precaution For Disassembly And Assembly
• Confirm ready access to a first-aid kit and fire extinguisher, as well as appropriate emergency personnel contacts in the case of a medical accident or fire. • Before performing any work on the machine, follow lockout/tagout procedures by attaching a “maintenance in progress tag”.
Page 24 INTRODUCTION Reassembling hydraulic equipment • Clean parts in a well ventilated room. • Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly. • Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling. •...
Page 25: Basic Instructions - Electrical Equipment Precautions
INTRODUCTION Basic instructions - Electrical equipment precautions WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. An- tidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk.
Page 26: Consumables - Biodiesel Fuel
INTRODUCTION Consumables - Biodiesel Fuel Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters. NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751.
Page 27: Consumables
Capacity (with filter change) 10.9 L (11.5 US qt) Total capacity in system 11.8 L (12.5 US qt) Cooling system Type of coolant CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT CASE CONSTRUCTION specifications MAT3624 System capacity 23 L (24.3 US qt)
Page 28: Hydraulic Contamination
INTRODUCTION Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: • When you drain the oil or disconnect any line •...
Page 29: Product Identification
INTRODUCTION Product identification 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 48082189_EN 14/02/2017...
Page 30: Product Identification - Identification Of Machine Components
INTRODUCTION Product identification - Identification of machine components LEIL16WHL1254FB 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...
Page 31 INTRODUCTION LEIL16WHL1255FB 1. Cab side window 5. Cab air filter door 2. Driving lights 6. Windshield washer reservoir 3. Bucket (Z-bar version) 7. D (DEF)/A ® fill tank IESEL XHAUST LUID 4. Drive shaft 48082189_EN 14/02/2017...
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...
Page 33 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.216] Fuel tanks .
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 .
Page 36 Engine - Engine and crankcase Engine - General specification Engine with 4 Speed Transmission A. Low idle 1020 – 1080 RPM Alternate low idle 870 – 930 RPM Alternate Accelerated Idle 1270 – 1330 RPM B. Maximum No Load RPM 2074 –...
Page 37 Engine - Engine and crankcase Engine - Remove 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.
Page 38 Engine - Engine and crankcase 4. Slowly loosen the hydraulic reservoir filler cap to re- lease air pressure in the hydraulic reservoir. RCPH10WHL099BAL 5. Raise the engine hood using the handle hood under the rear grill. LEIL16WHL2016AB 6. Remove the retaining bolts of the inner fender panels. NOTE: right-hand side of the machine is shown.
Page 39 Engine - Engine and crankcase 8. Remove the two battery covers. Disconnect the batter- ies from the machine. LEIL16WHL1225AA 9. Loosen the screw (1) and open the access cover (2) under the battery. RAPH12WEL1494AA 10. Place a suitable container below the radiator drain. Remove the drain plug (1) and radiator cap to drain the engine coolant into the container.
Page 40 Engine - Engine and crankcase 12. Double up a nylon lifting strap and slide the strap through the exhaust stack (1), located on the engine hood. LEIL14WHL0400AB 13. Place a solid steel bar through the nylon strap. Raise the engine hood and release the tension on the lifting motor.
Page 41 Engine - Engine and crankcase 16. Disconnect the hood wiring harness connector from the rear chassis wiring harness connector. Identify and tag the connectors to aid in reassembly. LEIL15WHL0142AB 17. Tag and disconnect the backup alarm connector (1). Remove the two straps cable tie (2). LEIL15WHL0143AB 18.
Page 42 Engine - Engine and crankcase 20. With the assistance of another technician, balance the engine hood and remove the hood hinge mounting bolts (1) near the cab (2) from the cooler frame. Re- peat the procedure for the other side. RAPH12WEL1461AA 21.
Page 43 Engine - Engine and crankcase 24. Tag and disconnect the engine wiring harness con- nector from the air inlet humidity sensor (1). LEIL15WHL0197AB 25. Loosen the clamps (2) on the turbocharger. 26. Loosen the clamps (3) on the air filter housing. 27.
Page 44 Engine - Engine and crankcase 30. Remove the two securing bolts (3), the four washers (4), and two nuts (5). Remove the bracket (2) with the air filter (1) as an assembly. LEIL15WHL0171BB 31. Remove the four mounting bolts and the four washers from the belt cover.
Page 45 Engine - Engine and crankcase 32. After removing the belt cover, remove the cover mounting bracket from the right rear side of machine frame. LEIL16WHL1343AB 33. If machine is equipped with the air conditioning sys- tem, identify, tag, and disconnect the engine wiring harness connectors from the air compressor clutch connector (1).
Page 46 Engine - Engine and crankcase 36. Loosen the clamp. Remove and discard the O-ring and the air intake tube of the turbocharger. LEIL16WHL1346AB 37. Loosen the clamp of the hose of the after cooler inlet and remove the hose. LEIL15WHL0263AB 38.
Page 47 Engine - Engine and crankcase 40. Loosen the bolts (1) and remove the two clamps to separate the SCR sensor wiring harness from the rear chassis. LEIL15WHL0272AB 41. Tag and disconnect the SCR sensor connector from the rear chassis harness connector. LEIL16WHL1347AB 42.
Page 48 Engine - Engine and crankcase 45. Remove the two bolts (1), the four washers (2), and the two nuts (3) to separate the clamps (4) and (6) from the bracket (8). Remove the clamp (4) from the DEF bundle (5). Re- move the clamp (6) from the hose coolant assembly (7).
Page 49 Engine - Engine and crankcase 48. Drain the engine coolant. Disconnect the hoses (1) from the Dosing Module (2). LEIL15WHL0323AB 49. Disconnect the electrical connector (3) from the Dos- ing Module (2). LEIL15WHL0176AA 50. Loosen the bolt to remove the P-clamps (1). Discon- nect the return coolant hose (2) and remove it from the machine.
Page 50 Engine - Engine and crankcase 52. Remove the bolts (2) to remove the DEF/A ® tank vent filter (1) from the rear plate of the cooling system frame. LEIL15WHL0268AB 53. Remove the bolts (2) and washers to remove the bracket (1) from the engine. LEIL15WHL0191AB 54.
Page 51 Engine - Engine and crankcase 55. Attach a suitable lifting straps to support the muffler support (1) with the Diesel Oxidation Catalyst (DOC) (6) and the Selective Catalytic Reduction muffler (SCR) (7). 56. Remove the bolts (4) and (5) with their related wash- ers to separate the muffler support (1) from the sup- port structures (2) and (3).
Page 52 Engine - Engine and crankcase 60. Tag and disconnect the fuel filter heater wire (1) and the water sensor (2). Drain the fuel filter and discon- nect the inlet fuel line (3) and outlet fuel line (4) from the fuel filter head. Plug the lines and cap the fittings. LEIL16WHL1374AB 61.
Page 53 Engine - Engine and crankcase 64. Tag and disconnect the wire harness and DEF/ ® supply return lines from DEF/A ® storage tank. Cap the supply lines. LEIL15WHL0304AA 65. Remove the bolts (1), the washers, and the nuts to remove the supply module support (2). LEIL15WHL0276AB 66.
Page 54 Engine - Engine and crankcase 67. Loosen the clamp on the intake manifold that secures the after cooler output hose. RAPH12WEL1464AA 68. Loosen the clamp (2) on the after cooler and remove the output hose (1) of the after cooler from the inter- cooler.
Page 55 Engine - Engine and crankcase 71. Cut the tie straps (1) and remove the clamp (4). Sep- arate the breather hose (3) from the radiator hose (2). Loosen clamp (6) from the hose (5). Loosen clamp on the engine then remove the hose (5). LEIL15WHL0279AB 72.
Page 56 Engine - Engine and crankcase 75. Remove the bolts (1), the washers, and the nuts. Re- move the bracket (2) and the intercooler from the rear plate of the cooling system frame as an assembly. LEIL15WHL0294AB 76. Disconnect and plug the hoses (1) and (2) from the air conditioning condenser (3).
Page 57 Engine - Engine and crankcase 80. Remove the clamp (1) and extract the upper radiator hose (2). LEIL15WHL0297AB 81. Remove the coolant hose. Plug the line and cap the fitting. LEIL15WHL0306AB 82. Tag and remove the grid heater cable. NOTE: hold the rear nut with a second wrench to prevent grid heater damage.
Page 58 Engine - Engine and crankcase 84. Disconnect the wiring harnesses from the EDC17 con- troller. NOTE: lifting up on the lever will release the connector from the controller. LEIL15WHL0302AA 85. Mark and tag the positive cables (1) to aid in reassem- bly.
Page 59 Engine - Engine and crankcase 89. Remove the lower cover of the drive shaft. RAPH12WEL1481AA 90. Remove the drive shaft bolts from the flywheel. Move the drive shaft clear of the flywheel. RAPH12WEL1421AA 91. Connect a suitable lifting equipment to the engine lift- ing brackets (2).
Page 60 Engine - Engine and crankcase Engine - Install WARNING Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap.
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