PDF Operator's Manual Case 521G Stage IV Wheel Loader - 8 MB
This is the complete operator's manual for the Case 521G Stage IV wheel loader.
This guide is an essential read for anyone operating the machine, covering topics from daily checks and controls to safe operating practices.
By following the manufacturer's recommendations, you can maximize productivity while ensuring safety and equipment longevity.
It is a critical resource for every operator.
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--- Page 1 ---
ORIGINAL INSTRUCTIONS - according to Directive 2006/42/EC, Annex I, 1.7.4.1
521G
Stage IV
Wheel Loader
OPERATOR’S MANUAL
Part number 51418663
1st edition English
November 2017
--- Page 3 ---
1 - GENERAL INFORMATION
Electro-Magnetic Compatibility (EMC)
This machine complies strictly with the European Regulations on the electro-magnetic emissions. However, interfer-
ence may arise as a result of add-on equipment which may not necessarily meet the required standards. As such
interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the follow-
ing:
• Ensure that each piece of non- CASE CONSTRUCTION equipment fitted to the machine bears the CE mark.
• The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the
national authorities of the country where you use the machine.
• The electromagnetic field generated by the add on system should not exceed 100 V/m at any time and at any
location in the proximity of electronic components.
Failure to comply with these rules will render the CASE CONSTRUCTION warranty null and void.
1-5
--- Page 4 ---
1 - GENERAL INFORMATION
EC Declaration of Conformity
The following page provides a facsimile copy of the “EC” Declaration of Conformity. The EC Declaration of Conformity
is the manufacturer’s declaration about machine compliance to relevant EU provisions. Please keep the original
document in a safe place. Local authorities may require you to show this document in order to assure compliance of
your machine.
Translation of this declaration in your own country language is provided on the reverse page of the original document.
For your better and easier understanding of the document
hereafter you’ll find some explanatory notes.
1. QR code
2. Under section 1.2 are listed those options or variants which have safety related functions. Some of them are
standard provided, like FOPS or ROPS.
3. Under section 2 are listed all information required by EU "Outdoor Noise" Directive 2000/14/EC. Please refer your
own original EC Declaration of Conformity for specific machine information.
4. Generic serial number for this machine type. Sequence of letters and numbers may vary depending on machine
configuration.
5. EC Declaration of Conformity serial number. Please make reference to this number when requiring information or
support about declaration.
6. Signature of a person authorized to sign the document on behalf of the company.
1-15
--- Page 5 ---
2 - SAFETY INFORMATION
Burn prevention
WARNING • When the battery electrolyte is frozen, the battery can
explode if you try to charge the battery or if you try to
Battery acid causes burns. Batteries contain boost start and run the engine. To prevent the battery
sulfuric acid. electrolyte from freezing, try to keep the battery at full
Battery electrolyte contains sulfuric acid. charge. If you do not follow these instructions, you or
Contact with skin and eyes could result in others in the area can be injured.
severe irritation and burns. Always wear
splash-proof goggles and protective clothing • Hot coolant can spray out if the cooling system cap is
(gloves and aprons). Wash hands after han- removed. To remove the cap, let the cooling system
dling. cool, turn to the first notch, wait until the pressure is
Failure to comply could result in death or se- released, then remove the cooling system tank cap.
rious injury. • Hot surfaces within the engine compartment can cause
W0120A
burns: the engine and the exhaust system will be very
hot. To prevent burns, open the engine compartment
CAUTION and allow components to cool to comfortable touch
Burn hazard! temperature before working inside the engine com-
Hot coolant can spray out if you remove the partment.
filler cap while the system is hot. After the
system has cooled, turn the filler cap to the
first notch and wait for all pressure to release
before proceeding.
Failure to comply could result in minor or
moderate injury.
C0043A
CAUTION
Burn hazard!
The engine and exhaust system become hot
during operation. To prevent burns, open
the engine compartment and allow the com-
ponents to cool to a comfortable touch tem-
perature before you work inside the engine
compartment.
Failure to comply could result in minor or
moderate injury.
C0178A
2-9
--- Page 6 ---
2 - SAFETY INFORMATION
Lower load or tool slowly
LEEN11T0016AA 12
Turn machine left swing load left
To stop movement, stop moving hand and make a fist.
LEEN11T0017AA 13
Turn machine right swing load right
To stop movement, stop moving hand and make a fist
LEEN11T0018AA 14
Raise boom
LEEN11T0019AA 15
2-19
--- Page 7 ---
2 - SAFETY INFORMATION
LEIL16WHL2272AA 19
Location: left-hand side of the machine, near the
articulation area.
WARNING
Run-over hazard!
Block the wheels to prevent movement before
disengaging the parking brake. 329050A1_ 20
Failure to comply with this warning could result in death
or serious injury.
ISO decal number: 329050A1
LEIL16WHL2272AA 21
Only installed if machine is equipped with Ride Control.
Location: left-hand side of the machine, near the
articulation area (both sides of the frame plate).
DANGER
Crush hazard! 87453136 22
Servicing the valve will cause the lift arms to fall.
Failure to comply will result in death or serious injury.
ISO decal number: 87453136
2-29
--- Page 8 ---
2 - SAFETY INFORMATION
LEIL16WHL2273AA 59
Location: access compartment on the top of the
machine, behind the cab.
Informational decal: hydraulic oil
ISO decal number: 395895A1
395895A1 60
LEIL17WHL2063AB 61
Location: access compartment on the top of the
machine, behind the cab.
NOTE: only with optional use of biodegradable hydraulic
oil, the P/N 47482423 replaces the P/N 395895A1 decal.
Informational decal: biodegradable hydraulic oil
47482423_A 62
ISO decal number: 47482423
2-39
--- Page 9 ---
3 - CONTROLS AND INSTRUMENTS
3 - CONTROLS AND INSTRUMENTS###_3_###
Access to operator's platform
Proper entry and exit
WARNING
Fall hazard!
Clean the steps and access handles to remove all traces of grease, oil, mud, and ice (in winter).
Failure to comply could result in death or serious injury.
W0139A
Steps and hand holds
Use the steps and hand holds to get down from or get
onto the machine. Use at least three points of support to
get on and off the machine. Lock the cab door into the full
open or full closed position.
LEIL15WHL1811AA 1
WARNING
Fall hazard!
Always lock the cab doors in the full open or full closed position before using the handrails on the
doors.
Failure to comply could result in death or serious injury.
W0133A
Cab door
Use the key to lock or unlock the cab door from outside
the machine. Use the cab door handle to open the cab
door from the outside.
To lock in place, open the cab door completely until the
cab door latches in place against the cab.
NOTICE: lock the cab door into the full open or full closed
position before using the door hand hold.
NOTE: the key provided with the machine can be used
to lock and unlock the various panels and to activate the
engine starter switch functions. LEIL15WHL0502AA 2
3-1
--- Page 10 ---
3 - CONTROLS AND INSTRUMENTS
Lumbar adjustment
Turn the knob to adjust both the height and curvature of
the backrest cushion.
LEIL16WHL1401AB 26
Seat heating
Use the rocker switch to activate the seat heating for cold
weather comfort.
LEIL16WHL1402AB 27
Headrest (Optional)
The seat is equipped at the top with provisions for optional
headrest.
LEIL16WHL1392AB 28
3-11
--- Page 11 ---
3 - CONTROLS AND INSTRUMENTS
1. Multifunction keypad
Refer to page ”Multifunction keypad” – Chapter 3 in this
manual to the multifunction keypad operations.
2. Ignition switch
The ignition switch has four positions:
A. OFF position
In this position, all switch controlled current is OFF.
Turn the key to OFF to stop the engine. Remove the
key and turn the timed disconnect switch to OFF.
B. ACCESSORY position
This position will energize the optional radio only. It
will not energize the instruments or start the engine.
C. ON position
This position will energize all electrical systems. The
key will return to this position after you release the key
from the start position. LEIL17WHL1588AB 2
D. START position
Turn the key to this position to engage the starter mo-
tor to start the engine. The switch is spring loaded and
will return to the ON position when released.
LEIL17WHL1446AA 3
3. Control lever (joystick)
Refer to page “Control lever operation” – Chapter 3 in this
manual for the joystick/control lever operation.
4. Arm pad
LEIL16WHL1304AB 4
3-21
--- Page 12 ---
3 - CONTROLS AND INSTRUMENTS
Four function valve - one control lever (joy-
stick) with two auxiliary functions
Lift arm and bucket control (1)
A. DUMP
B. ROLLBACK
C. HOLD (central position) - The loader arms and bucket
will not move when the control lever is in the HOLD
position. When released, the control lever will auto-
matically return to the HOLD position.
D. FLOAT - When in the FLOAT position, the loader
LEIL16WHL1290AA 9
bucket floats across the rough ground.
E. LOWER
F. RAISE
Auxiliary control (2)
G. AUXILIARY FUNCTION
H. AUXILIARY FUNCTION
Auxiliary control (3)
I. AUXILIARY FUNCTION (WITH DETENT)
J. AUXILIARY FUNCTION (WITH DETENT)
48185668_C 10
NOTE: since the decal is applied on the right-hand side
window, the directions are to be intended as follows:
D, E, G, I: Forward
F, H, J: Backward
A: Right-hand
B: Left-hand
3-31
--- Page 13 ---
3 - CONTROLS AND INSTRUMENTS
Battery isolator
1. The vehicle is equipped with a battery isolator that sup-
plies battery power to the vehicle. The battery isola-
tor is controlled by the vehicle controller and the timed
disconnect switch located at the rear of the machine
in the battery box.
LEIL16WHL1166AA 6
2. The vehicle controller will turn ON the battery isolator
with the following inputs:
• Timed disconnect switch
• Key switch
• Door switch
3. Under normal operation when the timed disconnect
switch is in ON position (switch closed) and the oper-
ator either opens the door or turns the key switch from
OFF to ACC or ON position, the vehicle controller will
turn ON the battery isolator.
4. The vehicle controller will turn OFF the isolator when
the key switch has been in the OFF position for a pe-
riod of time (about 5 min) to allow vehicle functions to
complete prior to turning OFF the battery isolator.
5. If the timed disconnect switch is in OFF position
(switch open), the vehicle will not turn ON the battery
isolator.
6. If the timed disconnect switch is in ON position (with
the key in OFF position), but for 5 min none of the
actions before described is carried out or the machine
is not used, the power supply is excluded through the
UCM and the relays.
To restore the power supply, switch to OFF position
first and then switch back to ON position or turn the
key to ON position.
7. The operator can hear an audible “click” when the bat-
tery isolator opens and closes.
3-41
--- Page 14 ---
3 - CONTROLS AND INSTRUMENTS
→ Display selections
Units
Day Brightness
Night Brightness
LEIL15WHL0529AA 21
Language
Date
LEIL15WHL0530AA 22
Digital clock
LEIL15WHL0531AA 23
Fan
Use the keypad on the right-hand of the display to select
the key to switch to the “Fan” settings.
LEIL15WHL0635AA 24
3-51
--- Page 15 ---
3 - CONTROLS AND INSTRUMENTS
→ Joystick Steering
JSS Flow Command
Steering Wheel Speed
JSS Activation Switch
JSS Armrest Switch
JSS Joystick Position
LEIL16WHL0895AA 57
Calibration Settings
Use the keypad on the right-hand of the display to select
the key to switch to the “Calibration Settings” screens.
LEIL16WHL0874AA 58
→ Tire Size
Tire Size
Special (cm)
NOTICE: only for special Tire.
LEIL17WHL0951AA 59
→ Transmission Clutch Calibration
Conditions to be satisfied to start the transmission clutch
calibration:
• Transmission Oil Temperature within range of 75 –
90 °C
• Place Transmission in Neutral
• Turn on Parking Brake
Select “Start” to proceed with the transmission clutch cal-
ibration.
LEIL17WHL0952AA 60
3-61
--- Page 16 ---
3 - CONTROLS AND INSTRUMENTS
Access level summary
Features Basic User Advanced User Administrator
Start Lockout x x x
Trip computer x x x
Machine Status Information x x x
Machine Settings - Engine x x
Machine Settings - Transmission x x x
Machine Settings - Display x x
Machine Settings - Fan x x
Machine Settings - Joystick Steering x x x
Machine Settings - Aux Hydraulics x x
Machine Service - Maintenance x
Machine Service -Sensor Status Info x x x
Machine Service - Calibration Settings x
Machine Service - Controller Information x x x
Machine Service - Diagnostics x x x
Machine Service -Security Code x
Machine Service - Keypad Test x x x
Camera View and Settings x x x
Factory Setup menu x
3-71
--- Page 17 ---
3 - CONTROLS AND INSTRUMENTS
17. Engine coolant temperature gauge
The engine coolant temperature gauge
indicates the coolant temperature of
the engine. When the engine coolant
temperature continues to increase and
the gauge moves into the red zone, the
warning alarm sounds continuously. The
stop master indicator turns red. Do not
operate the machine when the temperature
is in the red zone.
LEIL15WHL0576AA 5
18. Transmission oil temperature gauge
The transmission oil temperature gauge
indicates the oil temperature of the
transmission.
When the transmission oil temperature continues to in-
crease and the gauge moves into the red zone, the warn-
ing alarm sounds continuously. The stop master indicator
turns red. Do not operate the machine when the temper-
ature is in the red zone.
LEIL15WHL0577AA 6
NOTE: to prevent damage to the transmission, stop the machine, shift the transmission to NEUTRAL and run the
engine at partial throttle (approximately 1700 RPM) until the transmission cools. If the transmission oil temperature
does not return to normal operating temperature, run the engine at idle speed and check the transmission oil level.
Correct the problem before continuing to operate the machine.
19. Fuel level gauge
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
If the machine runs out of fuel, do not attempt to work on pressurized hydraulic lines. Lines are under
high pressure.
Failure to comply could result in death or serious injury.
W0372A
The fuel level gauge indicates the fuel level.
When the tank is almost empty, the gauge
moves into the red zone, the fuel indicator
turns on and the warning alarm sounds.
NOTICE: do not allow the machine to run completely out
of fuel.
LEIL15WHL0578AA 7
3-81
--- Page 18 ---
4 - OPERATING INSTRUCTIONS
Starting the unit
Starting the engine
WARNING
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY.
MAKE SURE THAT EVERY OPERATOR:
-is instructed in the safe and proper use of this machine.
-reads and understands the operator's manual for this machine.
-reads and understands ALL safety signs on the machine.
Failure to comply could result in death or serious injury.
W0188A
Before operating the machine 10. Remove any obstructions which hinder visibility.
Clean the windshield, the windows and the rear view
Before operating this machine, complete the following mirrors.
procedures:
11. Check that no tools or other items have been left on
1. Check the level of all fluids (engine oil, fuel, transmis- the machine or in the operator's compartment.
sion oil, DEF/ADBLUE®, hydraulic fluid, and coolant)
and make sure that the fluids and lubricants are suit- 12. Make sure no one is on or under the machine. The
able for prevailing conditions. operator must be alone on the machine.
2. Carry out the daily maintenance operations. 13. Make sure no one is standing in the machine working
area.
3. Inspect the machine, look for any signs of possible
leakage and check the hoses. Tighten or replace as 14. Find out about current safety measures in use on the
necessary. work site.
4. See “Run-in period of a new machine” - Chapter 4 15. Work out a convenient means of escape from the
in this manual, if the machine is new or if the engine machine (emergency exit via the windshield, the rear
has been reconditioned. or side window glass) in the event of the cab door
being jammed or the machine turning over.
5. Check the tires for any visible damage. Replace or
repair as necessary. Check for correct tire air pres- 16. Before undertaking any travel or working operations
sure and adjust the pressure if necessary. during hours of darkness, make sure the lighting and
signaling equipment are fully operative.
6. Clean the steps and hand holds. Grease, oil, mud,
or ice in winter on the steps and access handles can 17. Adjust the seat so that you can apply the foot brakes
cause accidents. Keep the steps and the access when your back is against the seat backrest.
handles clean at all times. 18. Fasten and adjust the seat belt.
7. Clean or replace any decals which are illegible. See 19. With the engine running and at operating tempera-
“Safety signs” - Chapter 2 in this manual for further ture, check the instrument panel for correct indica-
information. tions.
8. Make sure that the engine access panels and all 20. Check the loader controls for correct operation.
doors are properly closed and latched.
9. Secure the cab door in either fully closed or fully
opened position.
4-3
--- Page 19 ---
4 - OPERATING INSTRUCTIONS
Ride control
Ride control is an optional feature that increases the ride comfort of the wheel loader over
all types of terrain with either an empty or loaded bucket. Ride control allows faster speeds
during operation, resulting in increased productivity and operator comfort. Ride control will
also reduce shock loads to the wheel loader for reduced tire flex, structural fatigue and
vibration, resulting in longer component life and reduced costs. Ride control will reduce fore
and aft pitching motion during travel to allow faster speeds in load and carry applications.
The machine is equipped with a ride control switch (auto and off). Most commonly, the operator will choose to leave
this switch in the automatic position. With ride control active, the green indicator light will illuminate. Anytime the
machine is traveling faster than 5 km/h (3.1 mph) ride control is functioning. Ride control will disengage automatically
at slower speeds for loading and unloading.
To turn ride control OFF, press the ride control button until the LED light turns off.
NOTE: turn ride control OFF when you operate the bucket in fine grading operations or when precision placement of
a load suspended from the bucket or other attachment is required.
4-13
--- Page 20 ---
4 - OPERATING INSTRUCTIONS
Loader functions
Loader function buttons
1. Return-to-dig
2. Height control
3. Return-to-travel
4. Float
The green LED indicator lights up when the corresponding
loader function is ON.
Press the button to disengage all detents.
LEIL16WHL1128AB 1
Return-to-dig
Use the return-to-dig function to automatically return the
loader bucket to the dig position after you have dumped
the loader bucket. To enable the return-to-dig function
press the button (1).
The green LED indicator lights up to indicate that the func-
tion is active.
To set the return-to-dig function proceed as follows:
1. Press the corresponding button (1) on the multifunc-
tion keypad to activate the function; the green LED in-
dicator lights up to indicate that the function is active. LEIL16WHL1129AB 2
2. Set the attachment or the bucket to the desired loca-
tion.
3. Press and hold the corresponding button (1) on the
multifunction keypad until the green LED indicator light
flashes (approximately 2 s).
4. The return-to-dig function is now set. Display will
prompt that the detent position is saved.
To actuate the return-to-dig function, move the joystick
into the ROLLBACK position until the function activation
point is reached. When the function activation point is
reached, the operator will notice more resistance from the
joystick. If released, the joystick will automatically return
to the HOLD (central) position and the bucket will con-
tinue to rollback until it reaches the desired return-to-dig
position. If you move the joystick when the return-to-dig
function is activated, the bucket will stop.
LEIL17WHL1454AB 3
4-23
--- Page 21 ---
5 - TRANSPORT OPERATIONS
5 - TRANSPORT OPERATIONS###_5_###
Road transport
Safety rules
WARNING
Crushing hazard!
Engage the safety lock link before service or transport.
Failure to comply could result in death or serious injury.
W1154A
WARNING
Driving hazard!
Know all rules, regulations, laws, and required safety equipment for transporting or operating this ma-
chine on a road or highway. See your dealer to obtain a rotating beacon, backup alarm, Slow Moving
Vehicle (SMV) emblem, and other safety equipment.
Failure to comply could result in death or serious injury.
W0154A
WARNING
Transport hazard!
The machine can slip or fall from a ramp or trailer. Make sure the ramp and trailer are not slippery.
Remove all oil, grease, ice, etc. Move the machine on or off the trailer with machine centered on the
trailer or ramp.
Failure to comply could result in death or serious injury.
W0152A
WARNING
Transport hazard!
Always use the primary steering when loading or unloading the machine for transport. Do not use
joystick steering when loading or unloading the machine from a truck or trailer.
Failure to comply could result in death or serious injury.
W0448A
Make sure you know the safety rules and regulations be- area that you will be in. Make sure that the truck and ma-
fore transporting the machine. You must know the rules chine are equipped with the correct safety equipment.
or laws for transportation and safety that are used in each
5-1
--- Page 22 ---
5 - TRANSPORT OPERATIONS
Moving a disabled machine
WARNING
Misuse hazard!
Towing is a delicate maneuver that is always carried out at the risk of the user. The manufacturer's
warranty does not apply to incidents or accidents that occur during towing. Where possible, carry out
the repairs at the site.
Failure to comply could result in death or serious injury.
W0286A
DANGER
Loss of control hazard!
Make sure you use a towing vehicle with adequate weight. Towing with an underweight vehicle could
cause a loss of control during transport or braking. Calculate the minimum towing vehicle weight
required as instructed in this manual.
Failure to comply will result in death or serious injury.
D0049A
Engine stalls while traveling
The operator can apply the brakes by pressing the pedal
for four or five applications until the accumulator is dis-
charged. The operator must limit the use of the brakes
in this situation. If the brakes cannot be applied by the
pedal, apply the parking brake.
The steering effort increases when the hydraulic system
loses power. If the engine stalls while traveling, park the
loader in a safe position and find the problem.
Engine or hydraulic failure
If your machine is disabled, you must judge if the machine
can be moved without further damage. If possible, repair
the machine at the job location.
If you cannot repair the machine at the job location and
if you have a transport trailer, park the trailer as close as
possible to the machine.
Never tow the machine from the front
Attach a rigid draw-bar to the machine.
NOTICE: make certain the towing machine has adequate
brake capacity to safely stop both machines.
LEIL16WHL2271AA 1
5-11
--- Page 24 ---
6 - WORKING OPERATIONS
4. After visually inspecting the locking pins to ensure
they are fully retracted, rest the attachment firmly and
safely on the ground.
LEIL15WHL1832AA 4
5. Roll the coupler forward and down, while slowly back-
ing away from the attachment, to remove the upper
male portion of coupler from upper female portion of
attachment.
LEIL16WHL0038AA 5
6-9
--- Page 25 ---
7 - MAINTENANCE
Releasing pressure in the hydraulic system
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
Failure to comply could result in death or serious injury.
W0161A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
Failure to comply could result in death or serious injury.
W0178A
WARNING
Escaping fluid!
Do not disconnect hydraulic quick coupler under pressurized conditions. Make sure all hydraulic
pressure is removed from the system before disconnecting hydraulic quick coupler.
Failure to comply could result in death or serious injury.
W0095A