Case 521D Operators Manual

521D Loader Operator’s Manual Bur 6-26410

I TABLE OF CONTENTS TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE . . . . . . . . . . 4 IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 WHEEL AND TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 19 READ OPERATORS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INTERNATIONAL SYMBOL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-49 INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64 INFORMATION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-70 GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-77 TRANSMISSION DISPLAY CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-80 FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-95 MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 RUN - IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 STOPPING THE ENGINE AND PARKING THE MACHINE . . . . . . . . . . . . 111 BEFORE YOU OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 LOADER FUNCTION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 LOADER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

TABLE OF CONTENTS II BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 CLUTCH CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) . . . . . . . . . . . . 130 ROTATING BEACON (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 RIDE CONTROL(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 COUPLER PIN ENGAGEMENT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 133 LOADER OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 MACHINE DRAWBAR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 LUBRICATION/FILTERS/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . 151 SUPPORT STRUT FOR LOADER LIFT ARMS . . . . . . . . . . . . . . . . . . . . . 152 TRANSPORT/SERVICE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . 155 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 FLUIDS AND LUBRICANTS - 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 LUBRICATION/MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . 158-160 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 GREASE FITTINGS - 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 HYDRAULIC/BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

TABLE OF CONTENTS III AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 MAINTENANCE/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 TRANSMISSION CLUTCH CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 206 SECONDARY STEERING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 PARKING BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 LOADER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 217 TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS . . . . . . . . . . 220 ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT . 221 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . 222 SPARK ARRESTING MUFFLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 223 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 REPLACEMENT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 SERVICE ELECTRICAL CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION . 230 REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 ENGINE DATA - 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . 236-239 SPECIAL BOLT TORQUES (521D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

TABLE OF CONTENTS IV NOTES

1 TO THE OWNER BD00M077 521D Read this manual before you start the engine or operate the machine. If you need more information, see your dealer. Your dealer can give you help with Case Corporation approved service parts. Your dealer has specially trained technicians who know the best methods of repair and maintenance for your machine. Use this manual as a guide. Your Wheel Loader will remain a reliable working tool as long as it is kept in working condition and serviced properly CASE CORPORATION P.O. BOX 6006 FARGO, N.D. 58102 DEALERS STAMP

TO THE OWNER 2 BD00M082 DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely. This Wheel loader, with standard equipment and attachments, is intended to be used for above ground level digging and general earthmoving purpose such as land leveling, truck loading, and material rehandling. This machine is not intended to be used for lifting other objects or transporting loads at high speeds. DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in a application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer or the Case Corporation. Consult an authorized dealer or Case Corporation on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences. This Operators Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact you dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has Case Corporation approved service parts. Your dealer has technicians with special training that know best methods of repair and maintenance for your Wheel Loader. Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centers or from an approved organization.

TO THE OWNER 3 2. That the operator has read and understood the instructions given in this manual. Call your dealer if you need any assistance or information. Operator Manual Storage Compartment READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability and load characteristics of this machine before you start to operate. DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the inside of the rear cover of this manual. RD98K305 1. OPERATORS MANUAL STORAGE COMPARTMENT OFFICIAL JUSTIFING DOCUMENTS Special Test Certificate (Copy) ● Noise level (86/662/EEC with amendments 89/513/EEC and 95/27/EEC) ● Special safety equipment (86/295/EEC and 86/296/EEC) EEC Declaration of conformity for an earth-moving machine ● Safety (98/37/EC, was (89/392/EEC with amendments 91/368/EEC and 93/44/ EEC) 1

TO THE OWNER 4 AFTER DELIVERY CHECK Two copies of the After Delivery Check are in the back of this manual. One copy is for you and one copy is for the dealer. Make sure that your dealer does the After Delivery Check after the first 100 hours of machine operation. NOTE: Your cost for this check will be for filters, oil or other accessories. If the dealer comes to your machine, there can also be a cost for the time and distance. RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE Right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the operators seat. B891464J RIGHT SIDE LEFT SIDE REAR FRONT

TO THE OWNER 5 IDENTIFICATION NUMBERS Write your machine Product Identification Number (P.I.N.) and Serial numbers on the lines provided below. If needed, give these numbers to your dealer when you need parts or information for your machine. Make a record of the numbers. Keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency. MACHINE MODEL NUMBER PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER TRANSMISSION MODEL AND SERIAL NUMBER ROPS CAB OR CANOPY SERIAL NUMBER FRONT AXLE MODEL AND SERIAL NUMBER REAR AXLE MODEL AND SERIAL NUMBER BUCKET OR ATTACHMENT PART NUMBER Product Identification Number (P.I.N.) BD00N059 408373A1

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Case 521D Operators Manual

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