Case 521D Wheel Loader Complete Workshop Service Repair Manual

CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 South Service Road Hamilton, ON L7N 3M6 CANADA Bur 6-42722 Copyright © 2003 Case Corporation Printed in U.S.A. August, 2001 (Revised February, 2003) 521D Loader Service Manual 6-40742 Table of Contents Description Section No. Form No. General Tab 1 Section Index - General 6-42730 Standard Torque Specifications 1001 8-71602 Fluids and Lubricants 1002 6-40762 Metric Conversion Chart 1003 7-52950 Loctite Product Chart 8-98902 Engines Tab 2 Section Index - Engines 6-42281 Engine and Radiator Removal and Installation 2000 6-42290 Engine and Radiator Removal and Installation P.I.N. JEE0135501 and Above 2000 6-48920 Stall Tests 2002 6-40770 For Engine Repair, See the Engine Service Manual Fuel System Tab 3 Section Index - Fuel System 6-42300 For Fuel System Repair, See the Engine Service Manual Electrical Tab 4 Section Index - Electrical 6-42311 Removal and Installation of Starter and Alternator 4001 6-42321 Electrical Specifications and Troubleshooting 4002 6-40782 Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above 4002 6-48930 Batteries 4003 6-42330 Information and Diagnostic Center 4005 6-42351 Alternator - 65 Ampere 4007 7-12260 Alternator - 45 Ampere 4008 6-42360 Steering Tab 5 Section Index - Steering 6-42370 Removal and Installation of Steering Components 5001 6-42380 Steering Specifications, Pressure Checks, and Troubleshooting 5002 6-40790 Steering Control Valve 5003 6-42390 Steering Priority Valve 5004 6-42400 Steering Cylinders 5005 6-42410 Center Pivot 5006 6-42420 Auxiliary Steering Motor and Pump 5008 6-42430

Bur 6-42722 Revised 2-03 Printed in U.S.A. Power Train Tab 6 Section Index - Power Train 6-42442 Removal and Installation of Power Train Components 6001 6-42451 Transmission Specifications, Pressure Checks, and Troubleshooting 6002 6-40800 Transmission 6003 6-42460 Front and Rear Axle 6004 6-42470 Front and Rear Axle P.I.N. JEE0135501 and Above 6004 6-48970 Drive Shafts, Center Bearing, and Universal Joints 6005 6-42480 Wheels and Tires 6006 6-42490 Transmission Control Valve 6007 6-42500 Brakes Tab 7 Section Index - Brakes 6-42510 Removal and Installation of Brake Components 7001 6-42521 Hydraulic Brake Troubleshooting 7002 6-40811 Brake Accumulators 7004 6-42531 Parking Brake 7008 6-42540 NOTE: For parking brake and brake pedal adjustments, see Section 9001. Hydraulics Tab 8 Section Index - Hydraulics 6-42550 Removal and Installation of Hydraulic Components 8001 6-42560 Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 6-40820 Cleaning the Hydraulic System 8003 7-49640 Cylinders 8006 6-42590 Coupler Solenoid Locking Valve 8007 6-42600 Pilot Pressure Accumulator and Ride Control Accumulator 8013 6-42621 Mounted Equipment Tab 9 Section Index - Mounted Equipment 6-42640 Pedals and Levers 9001 6-40830 Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant 9002 6-42650 Air Conditioner System Service 9003 6-42660 Removal and Installation of Air Conditioning Components For Systems with HFC-134a Refrigerant 9004 6-42671 Loader 9006 6-42690 ROPS Cab and ROPS Canopy 9007 6-42700 Cab Glass Installation 9010 6-42710 521D Loader Service Manual 6-40742 Table of Contents Description Section No. Form No.

CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 South Service Road Hamilton, ON L7N 3M6 CANADA Bur 6-42722 Copyright © 2003 Case Corporation Printed in U.S.A. August, 2001 (Revised February, 2003) NOTE: Case Corporation reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold. Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket 6-40841 Electrical Schematic Foldouts and Hydraulic Schematic Foldout P.I.N JEE0135501 and Above In Rear Pocket 6-49280 521D Loader Service Manual 6-40742 Table of Contents Description Section No. Form No.

CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION 3350 South Service Road Hamilton, ON L7N 3M6 CANADA Bur 6-42730 Copyright © 2001 Case Corporation Printed in U.S.A. August, 2001 SECTION INDEX GENERAL Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003 Loctite Product Chart Section Title Section Number

Section 1001 1001 CASE CORPORATION 700 State Street Racine, WI 53404 U.S.A. CASE CANADA CORPORATION 450 Sherman Avenue Hamilton, ON L8N 4C4 CANADA Rac 8-71602 © 1999 Case Corporation Printed in U.S.A. Revised May, 1999 STANDARD TORQUE SPECIFICATIONS

1001-2 Rac 8-71602 Revised 5-99 Printed in U.S.A 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 NOTE: Case Corporation reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

1001-3 Rac 8-71602 Revised 5-99 Printed in U.S.A 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 Rac 8-71602 Revised 5-99 Printed in U.S.A 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

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Case 521D Wheel Loader Complete Workshop Service Repair Manual

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