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Case 521E Troubleshooting
The
Case 521E wheel loader driveline system components: 274 cu.in (4.5L) Case
445TA/EGE vertical 4-cylinder turbocharged liquid-cooled diesel engine with a
rated power of 129 hp (96 kW), and 4x3 powershift transmission with torque
converter. The hydraulic system has a pump with a rated capacity of 35.4 gal/min
(134 l/min). The Case 521E is equipped with a power steering system, hydraulic
wet disc brakes, and 20.5x25 standard tires. The wheel loader has a maximum lift
height of 142.1" (3610 mm) and bucket breakout force of 18175 lbs (8245 kg). The
rated operating capacity is 7970 lbs (3615 kg), and tipping load is 15940 lbs
(7230 kg).
| Engine Troubleshooting |
Diesel hard to start or doesn't start
Air in the fuel system - Air bleeding.
Clogged fuel filter - Replace the filter element.
Burnt or clogged injection nozzle - Test injection nozzles and change if necessary.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Need to adjust valve clearance.
Fuel injection pump damage - Repair or change injection pump.
Engine starts but stops suddenly
Air cleaner is clogged - Service or replace air cleaner.
Fuel filter element clogging - Install new filter element.
Fuel injection pump is leaking - Repair any leaks.
Clogged or defective injectors - Clean fuel injectors or change it.
Fuel injection pump failure - Repair or install a new fuel pump.
Engine shuts off while running
Engine is not preheated - Warm up to required temperature.
Fuel filter plugging - Service or replace the filter.
Air in the fuel system - Air bleeding.
Defective injection nozzle - If necessary, replace with a new nozzle.
Incorrect adjustment of fuel injection pump timing - Set up as recommended.
Engine stalls when idling
Wrong adjustment of low idle speed - Adjustment required.
Damaged fuel injection pump - Rebuild or install a new injection pump.
Clogged or defective injectors - Clean fuel injectors or change it.
Excessive valve clearance - Have it adjusted.
Engine power is insufficient
Clogged air filter - Replace or clean air filter element.
Fuel injection nozzles are damaged - Check injection nozzles and replace if required.
Uneven fuel injection pressure - Adjust to proper pressure.
Excessive valve clearance - Adjust valve clearance.
Wrong adjustment of low idle speed - Adjust the low idle speed.
Fuel hoses or lines are dirty - Clean fuel lines and hoses.
Blown cylinder head gasket - Change cylinder head gasket.
Piston rings are defective or leaking - Replace the piston rings as required.
Engine overheated
Lack of engine coolant - The cooling system needs to be refilled and checked for faults.
Low engine oil level - Fill the crankcase with engine oil.
Clogged radiator fins or damaged radiator cap - Clean radiator or install new cap.
Broken or loose fan belt - Change as required.
Engine overload - Load reducing is recommended.
Oil pressure too low
Oil level is low - Fill the crankcase with oil.
Oil filter element clogged - Replace or clean engine oil filter element.
Wrong oil viscosity - Fill up with the proper oil viscosity.
Crankshaft bearing has excessive oil clearance - Change bearings.
Oil pump failure - Inspect and change as required.
Engine noise or knocking
Engine oil level is low - Checking oil level and add if necessary.
Low coolant temperature - Normalize the temperature by warming up the engine.
Incorrect adjustment of fuel injection pump timing - Set the fuel pump timing correctly.
Improperly adjusted low idle speed - Correct low idle adjustment.
Damaged or clogged injectors - Replace or clean fuel injectors.
Connecting rod misalignment or failure - Connecting rod must be aligned or replaced.
Pistons are worn or scored - Replace the pistons as required.
| Transmission Troubleshooting |
Insufficient transmission fluid pressure
Transmission oil level is low - Fill the transmission housing with oil.
Dirty transmission fluid filter (if fitted) - Clean or change transmission fluid filter.
Stuck relief valve - Replace relief valve.
Transmission makes excessive noise
Transmission oil level is low - Check and refill the transmission oil.
Transmission fluid is dirty - Transmission fluid change required.
Gears are defective or backlash is improper - Install new gears and set backlash correctly.
Worn or broken bearings - Bearings need to be changed.
Worn or bent gear shift forks - Shift forks need to be replaced.
Damaged or worn shaft splines - Install a new shaft.
Hard shifts
Corroded or worn gear shift linkage - Install a new gear shift linkage.
Worn or damaged gear shift forks - Change the shift forks.
Worn gear shifting mechanism - Repair or change worn components if necessary.
Clutch is worn or not adjusted - Adjust or install new clutch.
Transmission fluid leaking
High transmission fluid level - Drain the excess fluid.
Broken seals or gaskets - Install new gaskets or seal.
| Hydraulics Troubleshooting |
Hydraulic system overheats
Incorrect hydraulic pressure setting - Correct adjustment is required.
Misadjusted or defective main relief valve - Adjust or change relief valve.
Hydraulic fluid is dirty - The fluid must be changed.
Not enough hydraulic fluid in the system - Fill the hydraulic system with oil.
Hydraulic pump is faulty - Repair or replace pump if necessary.
Lift arm won't raise or lower
Defective lift controls - Inspect and repair if necessary.
Hydraulic pump not working - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Install a new valve or repair it.
Hydraulic cylinder is broken - Change or repair lift cylinder.
Low hydraulic oil level - Need to add oil.
Bucket does not tilt
Bucket controls failure - Repair or replace.
Hydraulic pump is broken - Install new pump or repair it.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Broken bucket cylinder - Change or repair cylinder.
Hydraulic fluid level low - Add fluid as required.
Slow bucket or lift arm operation
Defective hydraulic pump - Check pump flow and install new pump if necessary.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Defective or not adjusted hydraulic control valve - Repair or adjust properly.
Hydraulic pressure is low - Correct setting is required.
Lift arm or bucket is working jerkily
Hydraulic system is leaking air - Air bleeding is required.
Hydraulic oil filter is clogged - Change or clean oil filter.
Hydraulic oil is contaminated - The oil must be changed.
Scored cylinder tube or rod - Replace defective component.
Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Repair hydraulic leaks or add oil as required.
Clogged hydraulic filter - Clean or replace the filter.
Suction line clogging - Suction line needs to be cleaned.
Air trapped in hydraulic pump - Air bleeding is required.
Pump components are worn out - Change or rebuild pump.
| Electrical Troubleshooting |
Battery won’t charge
Corroded or loose electrical wire connections - Service or tighten cable connections.
Battery terminal clamps are defective - Terminal clamps need to be replaced.
Battery is worn - Battery replacement required.
Loose or damaged belt - Need to adjust belt tension or replace belt.
Starter turning slow
Low battery output voltage - Charge the battery.
Battery drains quickly - Service or change the battery.
Corroded battery terminals or disconnected wires - Check cable connections and change or clean terminals.
Starter will not work
Battery is low or faulty - Need to charge or replace the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery voltage is low - Recharge the battery.
Starter motor is defective - Starter should be replaced.
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| WHEEL LOADERS SPECIFICATIONS |
Bobcat
Caterpillar
Case
Doosan
John Deere
Kubota