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Home / Wheel Loaders / Case Wheel Loaders / Case 521D XT

Case 521D XT Troubleshooting

The Case 521D XT wheel loader is powered by Case 4TA-390 4-cylinder direct injection turbocharged diesel engine with a rated power of 110 hp (82 kW) at 2000 rpm. The Case 521D XT is equipped with a 4x3 powershift transmission, power steering system, hydraulic wet disc brakes, and 17.5x25 standard tires. The hydraulic system has a pump with fluid flow rate of 35.4 gpm (134 lpm). The hydraulic pressure is 2755 psi (190 bar). The wheel loader has a rated operating capacity of 5860 lbs (2655 kg) and tipping load of 11715 lbs (5313 kg). The maximum lift height is 148.4" (3770 mm) to hinge pin, and breakout force is 23190 lbs (10520 kg).

Engine Troubleshooting

Engine difficult to start or won't start
Air trapped in fuel system - Bleed air.
Fuel filter plugged - Clean or change the filter.
Damaged or dirty injection nozzles - Check injection nozzles and replace if required.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is out of adjustment - Check and adjust.
Fuel injection pump damage - Repair or install a new fuel pump.

Engine starts but then stops
Air filter is dirty - Change or service air filter element.
Clogged fuel filter - Service or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Fuel injection pump is not working correctly - Repair or replace injection pump.

Engine stalls while running
Engine not warmed up - Warm up the engine.
Fuel filter plugging - Clean or change the filter.
Air in the fuel pipes - Bleed the fuel pipes.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pump timing is wrong - Set up as recommended.

Engine stops while idling
Incorrect low idle speed adjustment - Adjust as required.
Damaged fuel injection pump - Repair or install new pump.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Incorrect valve clearance - Adjust valve clearance.

Engine lacks power
Air filter is clogged - Replace or clean air filter element.
Fuel injection nozzles are faulty or clogged - Check and replace nozzles if required.
Fuel injection pressure is wrong - Adjust to proper pressure.
Valve clearance is out of adjustment - Check and adjust as required.
Incorrectly set low idle speed - Adjust low idle speed.
Dirty fuel lines or hoses - Clean fuel system lines and hoses.
Worn cylinder head gasket - Install new cylinder head gasket.
Piston rings are worn or defective - Piston rings need to be replaced.

Engine overheated
Insufficient coolant fluid - Top up coolant fluid and check system for leaks.
Lack of engine oil - Fill the crankcase with engine oil.
Radiator fins are dirty or radiator cap is defective - Replace cap or clean radiator.
Loose or defective fan belt - Fan belt must be replaced.
Diesel engine is overloaded - Reduce load on the engine.

Insufficient oil pressure
Lack of oil - Add oil to the engine crankcase.
Engine oil filter is plugged - Replace or clean engine oil filter element.
Different type of engine oil - Drain crankcase and refill with correct oil.
Excessive crankshaft bearing oil clearance - Bearing replacement required.
Oil pump malfunction - Install a new pump.

Abnormal engine noise or knocking
Low engine oil level - Fill the crankcase with engine oil.
Engine is not warmed up to required temperature - Warm up the engine.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Too low idle RPM - Adjust low idling as recommended.
Defective fuel injectors - Clean or replace fuel injectors.
Connecting rod is not aligned or defective - Connecting rod needs to be replaced or aligned.
Worn or broken pistons - Pistons need to be replaced.

Transmission Troubleshooting

Low transmission fluid pressure
Low oil level - Fill the transmission housing to proper oil level.
Transmission oil filter is clogged (if fitted) - Clean or change transmission oil filter.
Relief valve failure - Replace relief valve as required.

Excessive transmission noise
Insufficient transmission oil - Check transmission oil level and add oil as required.
Transmission fluid is dirty - Change the fluid.
Defective gears or improper backlash - Adjust backlash correctly or replace the gears.
Bearings are cracked or worn - Faulty bearings should be changed.
Worn or bent gear shift forks - Change the shift forks.
Shaft splines are damaged or worn - Install a new shaft.

Difficulty shifting gears
Rusty or worn gear shift linkage - Install new shift linkage.
Worn or bent gear shift forks - Replace the shift forks.
Worn parts of the gear shifting mechanism - Change worn parts.
Clutch is out of adjustment or defective - Replace or adjust clutch.

Transmission fluid leaks
Transmission fluid level is high - Correct the fluid level.
Worn seals or gaskets - Install new components.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is incorrect - Adjust pressure as required.
Main relief valve failure or improper setting - Set up or change the relief valve.
Hydraulic oil contamination - Hydraulic oil change required.
Lack of hydraulic fluid - Check and refill the hydraulic fluid.
Hydraulic pump is worn - Repair or install new hydraulic pump.

Boom can't lift or drop
Defective lift controls - Repair or change.
Hydraulic pump not working - Repair or install new hydraulic pump.
Defective hydraulic control valve - Repair or replace the valve.
Damaged hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.

Bucket can't tilt
Bucket controls failure - Inspect and repair if necessary.
Hydraulic pump is broken - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Bucket cylinder failure - Replace or repair cylinder.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Slow bucket or lift arm action
Hydraulic pump is defective - Check pump performance and change it if necessary.
Hydraulic cylinder leaking - Install new cylinder seals.
Low hydraulic oil level - Check and refill the hydraulic oil.
Hydraulic control valve is unadjusted or worn - Repair or set correctly.
Hydraulic pressure has dropped - Adjust pressure correctly.

Bucket or boom is jerky
Air trapped in hydraulic system - Bleed air from hydraulic system.
Plugged hydraulic oil filter - Change or clean oil filter.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Cylinder tube or rod is scored - Replace defective component.

Hydraulic pump is excessively noisy
Hydraulic leakage or lack of oil - Add hydraulic oil or correct system leaks.
Hydraulic filter clogging - Change or clean oil filter.
Dirty suction line - Need to service the suction line.
Pump is sucking air - Bleed air.
Damaged pump parts - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery will not charge
Electrical wire connections are loose or corroded - Tighten or clean electrical wiring connections.
Battery terminal connectors are defective - Install new terminal connectors.
Faulty cell in battery - Replace the battery.
Loose or defective belt - Replace belt or adjust belt tension.

Starter cranks slowly
Battery voltage is low - Recharge the battery.
Battery does not hold charge - Service charging system or replace battery.
Terminals are faulty or battery cables are disconnected - Check wiring and clean or replace terminals.

Starter will not work
Battery is low or faulty - Change or recharge battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Low battery output - Charge the battery.
Damaged starter motor - Repair or install a new starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders