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Case 521E XR Troubleshooting
The
Case 521E XR wheel loader driveline system components: Case 445TA/EGE 4-cylinder
turbocharged liquid-cooled diesel engine with a rated power of 129 hp (96 kW),
and powershift transmission with 4 forward and 3 reverse gears. The hydraulic
system has a piston pump with a rated capacity of 35.4 gal/min (134 l/min). The
Case 521E XR is equipped with a power steering system, hydraulic wet disc
brakes, and 20.5x25 tires. The wheel loader has a maximum lift height to hinge
pin of 157" (3985 mm) and boom breakout force of 20930 lbs (9495 kg). The rated
operating capacity is 6860 lbs (3112 kg), and tipping load is 13725 lbs (6225
kg).
| Engine Troubleshooting |
Engine hard to start or doesn't start
Air trapped in fuel system - Bleed air.
Fuel filter plugging - Install new filter element.
Fuel injection nozzles are faulty or clogged - Service or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Improper valve clearance - Adjust valve clearance.
Fuel injection pump is damaged - Rebuild or change fuel pump.
Engine starts and immediately shuts off
Air filter is clogged - Service or replace the air filter.
Clogged fuel filter - Change filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Fuel injection pump is not working correctly - Install a new pump or rebuild.
Engine shuts off suddenly while running
Coolant temperature is low - Warm up the engine.
Fuel filter element is dirty - Replace the filter element.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are damaged - Check and replace nozzles if required.
Fuel injection pump timing is wrong - Set the fuel pump timing correctly.
Engine stalling at idle
Incorrect low idle speed adjustment - Test and adjust.
Defective fuel injection pump - Install a new pump or rebuild.
Damaged or clogged injectors - Replace or clean fuel injectors.
Improper valve clearance - Have it adjusted.
Diesel power loss
Air cleaner is clogged - Install new air cleaner element.
Clogged or defective injection nozzles - Test injection nozzles and change if necessary.
Improper fuel injection pressure - Adjust pressure to proper level.
Valve clearance is not correct - Adjust valve clearance according to specifications.
Incorrectly set low idle speed - Adjustment required.
Dirt in the fuel lines or hoses - Clean fuel hoses and lines.
Cylinder-head gasket is broken - Replace cylinder head gasket.
Leaking or damaged piston rings - Piston rings replacement required.
Engine overheating
Lack of coolant in cooling system - Fill the cooling system and check components for leaks or other faults.
Insufficient engine oil - Add oil to the engine crankcase.
Radiator fins are dirty or radiator cap is defective - Install new cap or clean radiator.
Loose or damaged fan belt - Change the fan belt.
Engine overloaded - Reduce engine load.
Oil pressure is low
Engine oil insufficient - Add oil to the engine crankcase.
Plugged engine oil filter - Service or change engine oil filter element.
Different type of engine oil - Use proper viscosity oil.
Incorrect oil clearance in crankshaft bearing - Install new bearings.
Oil pump is damaged - Repair or replace.
Engine noises or knocks
Insufficient engine oil - Need to add engine oil.
Engine is not fully warmed up - Warm up to required temperature.
Improper fuel injection timing - Adjust fuel injection pump as required.
Low idle speed set incorrectly - Adjustment required.
Fuel injector fault - Test and replace fuel injectors if necessary.
Connecting rod failure or misalignment - Alignment procedure or replacement is required.
Pistons are scored or worn - Have pistons replaced.
| Transmission Troubleshooting |
Low transmission fluid pressure
Transmission fluid insufficient - Add fluid to the transmission housing.
Plugged transmission oil filter (if equipped) - Service or change transmission oil filter.
Defective relief valve - Change relief valve.
Transmission makes noise
Transmission oil insufficient - Fill up the transmission oil.
Transmission oil contamination - Fill up with fresh transmission oil.
Improper backlash or worn gears - Change the gears or set backlash properly.
Bearings are broken or worn - Change faulty bearings.
Worn or bent gear shift forks - Replace defective shift forks.
Shaft splines are damaged or worn - Shaft need to be changed.
Hard shifts
Worn or rusty gear shift linkage - Shift linkage need to be replaced.
Shift forks are bent or worn out - Replace the shift forks.
Defective parts in the gearshift mechanism - Replace defective parts.
Worn or improperly adjusted clutch - Adjust clutch or replace if required.
External fluid leaks
Transmission oil level is high - Correct the oil volume.
Damaged gaskets or seals - Change defective seal or gaskets.
| Hydraulics Troubleshooting |
Hydraulic system has overheating
Incorrect hydraulic pressure setting - Adjust pressure correctly.
Main relief valve failure or improper setting - Adjust or change relief valve.
Contaminated hydraulic fluid - The fluid must be changed.
Not enough hydraulic oil in the system - Fill up the hydraulic oil.
Hydraulic pump is worn - Replace or repair pump if necessary.
Lift arm can't drop or lift
Faulty lift controls - Replace or repair.
Hydraulic pump is broken - Repair or change pump if required.
Hydraulic control valve is defective - Install a new valve or repair it.
Hydraulic cylinder is faulty - Repair or replace hydraulic cylinder.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Bucket is not working
Bucket tilt controls are defective - Repair or change.
Hydraulic pump not working - Repair or install new hydraulic pump.
Hydraulic control valve failure - Repair or replace the valve.
Hydraulic bucket cylinder not working - Replace or repair cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Boom or bucket moves slowly
Defective hydraulic pump - Check the pump capacity and replace pump if required.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Insufficient hydraulic oil - Need to add oil.
Hydraulic control valve is unadjusted or worn - Adjust correctly or repair.
Low hydraulic pressure - Hydraulic pressure must be set correctly.
Jerky operation of the bucket or boom
Hydraulic system is leaking air - Bleed air from system.
Dirty hydraulic oil filter element - Clean or change the filter.
Contaminated hydraulic oil - The oil must be changed.
Cylinder tube or rod is scored - Replace failed component.
Hydraulic pump makes excessive noise
Insufficient oil level or leaking hydraulic system - Top up hydraulic oil or remedy leakage in system.
Plugged hydraulic filter - Service or replace hydraulic filter.
Plugged suction line - Suction line must be serviced.
Pump is sucking air - Bleed air from hydraulics.
Pump parts are worn out - Install new hydraulic pump or rebuild it.
| Electrical Troubleshooting |
Battery does not charge
Loose or corroded cable connections - Clean or tighten connections.
Electrical terminal connectors are defective - Replace terminal connectors.
Defective battery - Install a new battery.
Loose or worn belt - Adjust belt tension or change the belt.
Starter motor cranks slow
Battery power is low - Low battery charging, charge as required.
Battery discharges quickly - Battery needs service or replacement.
Bad battery terminals or disconnected wiring - Check cables and clean or change terminals.
Starter doesn't crank
Battery is discharged or worn - Charge or change the battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Low battery power - Battery is drained, recharge it.
Defective starter motor - Change or repair starter.
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| WHEEL LOADERS SPECIFICATIONS |
Bobcat
Caterpillar
Case
Doosan
John Deere
Kubota