Part of the Case Repair Manuals.
The 521D is Case's compact wheel loader, and when the hydraulics quit or it will not start after a wet day the machine sits idle. This is the real factory service manual, part 6-40745, 1,018 pages covering the diesel engine, fuel, electrical, steering, power train, brakes, hydraulics and mounted equipment, plus full electrical and hydraulic schematic foldouts. Whether you are chasing a total loss of bucket control, a no start after water, or an articulation lock that will not work, it is here in factory order with the capacities and torque values to work to.
What's Inside This Case 521D Manual
| System | Pages | Key Topics |
|---|---|---|
| General | Machine Specifications, Fluid and Fuel Capacities, Standard Torque Values, General Service | |
| Engines | Diesel Engine Repair, Cylinder Head, Block, Timing, Lubrication, Cooling | |
| Fuel System | Injection Pump, Injectors, Fuel Supply, Filters, Governor, Speed Settings | |
| Electrical | Wiring Diagrams, Charging and Starting, Lighting, Gauges, Sensors | |
| Steering | Hydrostatic Steering, Steering Pump and Valve, Cylinders, Articulation | |
| Power Train | Transmission, Torque Converter, Axles, Differentials, Final Drives | |
| Brakes | Service and Park Brakes, Brake Valves, Accumulator, Bleeding and Adjustment | |
| Hydraulics | Loader Hydraulic Circuits, Pump, Control Valves, Lift and Tilt Cylinders, Reservoir | |
| Mounted Equipment | Loader Linkage, Boom, Bucket, Quick Coupler, Counterweight | |
| Electrical and Hydraulic Schematic Foldouts | Full Electrical and Hydraulic Circuit Schematic Foldouts for the 521D |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Oil Capacity (with filter) | 11.3 L (12 US qt) | |
| Cooling System Capacity | 34.1 L (36 US qt) | |
| Fuel Tank Capacity | 189 L (50 US gal) | |
| Hydraulic Reservoir Refill (with filter) | 68.5 L (72 US qt) | |
| Hydraulic System Total Capacity | 113.6 L (30 US gal) | |
| Transmission Refill (with filter) | 18.9 L (20 US qt) | |
| Transmission Total Capacity | 26 L (27.5 US qt) | |
| Front Axle Capacity | 21.8 L (23 US qt) | |
| Rear Axle Capacity | 20.8 L (22 US qt) | |
| Production Years | 2005 to 2008 |
Case 521D Common Problems This Manual Covers
Complete hydraulic system failure with loss of bucket control
A total loss of bucket control points to the hydraulic pump, a failed control valve or a loss of fluid. Check the system pressure and flow against spec, inspect the reservoir level and the pump, and check the control valve and relief before condemning a part. The hydraulics section gives the test points, the capacities and the pump service.
Manual Section: HydraulicsEngine fails to start or runs erratically after water exposure
After a wet day, water can foul the electrical connections, the intake or the fuel. Dry and clean the connections, drain the water separator and change the fuel filter, and inspect the air intake. The engine and electrical sections cover the starting circuit, the fuel service and the tests to isolate it.
Manual Section: EnginesArticulation lock will not engage or release
An articulation lock that will not work is usually the lock linkage, pin or the hydraulic or mechanical actuation. Inspect the lock and its linkage, check for bent or seized pins, and confirm the actuation. The steering and mounted equipment sections cover the articulation and the lock service.
Manual Section: SteeringFrequently Asked Questions
What does Case part number 6-40745 cover?
It is the full factory service manual for the Case 521D wheel loader, 1,018 pages covering the diesel engine, fuel, electrical, steering, power train, brakes, hydraulics and mounted equipment, plus full electrical and hydraulic schematic foldouts.
My 521D lost bucket control, where do I start?
A loss of bucket control points to the loader hydraulics, the pump, a control valve or the fluid. The hydraulics section covers the pump, the pressure and flow checks and the reservoir capacity so you can isolate a total hydraulic failure.
My loader will not start or runs rough after a wet day, what should I check?
Water exposure can foul the intake, the electrical connections or the fuel. Check and dry the connections, change the fuel filter and water separator, and inspect the intake. The engine and electrical sections cover the starting circuit and the fuel service.
Does it include the wiring and hydraulic schematics?
Yes. It has full electrical and hydraulic schematic foldout sections for the 521D, covering both the electrical and the hydraulic circuits.
Is this the same manual a Case dealer uses?
It is the factory service manual (part number 6-40745), the same step by step repair, specification and torque data the 521D was built and serviced to.
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