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Home / Wheel Loaders / Case Wheel Loaders / Case 521E XT

Case 521E XT Troubleshooting

The Case 521E XT wheel loader is powered by Case 445TA/EGE 4-cylinder turbocharged liquid-cooled diesel engine with a rated power of 129 hp (96 kW) at 1800 rpm. The Case 521E XT is equipped with a 4-speed powershift transmission, power steering system, hydraulic wet disc brakes, and 20.5x25 standard tires. The hydraulic system has a pump with fluid flow rate of 35.4 gpm (134 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 6470 lbs (2935 kg) and tipping load of 12945 lbs (5870 kg). The max lift height is 147.4 inches (3745 mm) to hinge pin, and boom breakout force is 21650 lbs (9820 kg).

Engine Troubleshooting

Diesel engine hard to start or doesn't start
There is air in the fuel system - Bleed the system.
Fuel filter plugged - Service or replace the filter.
Burnt or clogged injection nozzle - Replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is out of adjustment - Correct valve clearance.
Fuel injection pump is broken - Install a new fuel pump or repair.

Diesel starts but immediately shuts off
Plugged air cleaner - Install new air cleaner element.
Fuel filter plugged - Replace filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Fuel injection pump is damaged - Change pump or rebuild it.

Engine shuts off suddenly during operation
Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Fuel filter element clogging - Service or replace the filter.
There is air in the fuel system - Bleed the system.
Damaged or dirty injection nozzles - Clean or replace injection nozzles.
Timing of fuel injection pump is incorrect - Check the fuel injection pump timing adjustment.

Engine stops at low idle speed
Too low idle RPM - Test and adjust.
Fuel injection pump is defective - Rebuild or change fuel pump.
Dirty or defective injectors - Change or clean fuel injectors.
Valve clearance is out of adjustment - Check and adjust as required.

Diesel power loss
Air filter is dirty - Change or service air filter element.
Fuel injection nozzles are clogged or faulty - Clean or change injection nozzles.
Fuel injection pressure is wrong - Correct the pressure settings.
Improper valve clearance - Correct valve clearance needs to be set.
Low idle speed adjustment is incorrect - Test and adjust.
Fuel lines or hoses are clogged - Clean fuel system lines and hoses.
Cylinder head gasket defective - Gasket should be replaced.
Damaged or leaking piston rings - Piston rings need to be replaced.

Engine is overheated
Insufficient coolant - Add coolant fluid and inspect the cooling system for leaks.
Not enough engine oil - Fill up the engine oil.
Damaged radiator cap or dirty radiator core - Clean radiator or replace cap.
Damaged or worn fan belt - Belt replacement is recommended.
Diesel engine is overloaded - Reduce load on the engine.

Low oil pressure
Not enough oil in the engine - Check and refill the oil.
Clogged oil filter element - Clean or replace engine oil filter element.
Incorrect oil viscosity - Use the specified type of engine oil.
Incorrect oil clearance in crankshaft bearing - Bearings need to be reinstalled.
Oil pump malfunction - Remove and inspect oil pump.

Engine knocks or noises
Engine oil insufficient - Add oil to the engine crankcase.
Engine is not preheated - Normalize the temperature by warming up the engine.
Wrong setting of fuel injection pump timing - Adjust as recommended.
Incorrectly set low idle speed - Normalize low idle speed.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Connecting rod is not aligned or worn - Replace or align connecting rod.
Worn or scored pistons - Pistons replacement required.

Transmission Troubleshooting

Insufficient transmission oil pressure
Insufficient transmission oil - Fill the transmission housing to proper oil level.
Dirty transmission fluid filter element (if equipped) - Service or change transmission fluid filter.
Relief valve is stuck - Replace relief valve as required.

Transmission noises
Insufficient transmission fluid - Checking transmission fluid level and add if necessary.
Transmission fluid is contaminated - Fill up with fresh transmission fluid.
Defective gears or improper backlash - Install new gears and adjust backlash properly.
Bearings are cracked or worn - Bearings need to be changed.
Worn or damaged gear shift forks - Shift forks need to be changed.
Shaft splines are stuck or worn out - Shaft need to be replaced.

Gear shift is hard
Stuck or worn gear shift linkage - Lubricate or replace the shift linkage.
Worn or bent shift forks - Replace defective shift forks.
Gearshift mechanism malfunction - Identify and replace failed parts.
Malfunction or incorrect clutch adjustment - Adjust correctly or replace.

Transmission fluid leaking
Transmission oil level is exceeded - Correct the oil volume.
Worn seals or gaskets - Change defective gaskets or seal.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not adjusted correctly - Adjust pressure as required.
Main relief valve improper adjustment or failure - Adjust relief valve or change if required.
Contaminated hydraulic oil - Change hydraulic oil.
Not enough hydraulic fluid in the system - Add fluid to the hydraulic system.
Worn hydraulic oil pump - Repair or change pump if required.

Boom does not raise or lower
Defective lift controls - Repair or replace.
Hydraulic pump malfunction - Install new pump or repair it.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Hydraulic cylinder failure - Change or repair lift cylinder.
Low hydraulic fluid level - Add fluid as required.

Bucket tilt does not work
Faulty bucket tilt controls - Repair or replace.
Defective hydraulic pump - Change or repair hydraulic pump if required.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Bucket cylinder failure - Repair or install a new cylinder.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.

Slow bucket or lift arm action
Hydraulic pump is faulty - Check pump performance and change it if necessary.
Oil leaks from hydraulic cylinder - Correct leakage by changing the seals.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Damaged or incorrect adjusted hydraulic control valve - Repair or set correctly.
Hydraulic pressure has dropped - Correct adjustment is required.

Bucket or boom is moving jerkily
Air trapped in hydraulic system - Air bleeding is required.
Hydraulic oil filter element clogging - Service or change the hydraulic filter.
Dirty hydraulic fluid - Hydraulic fluid change required.
Cylinder tube or rod scoring - Replace defective component.

Excessive hydraulic pump noise
Hydraulic leakage or lack of oil - Repair hydraulic leaks or add oil as required.
Dirty hydraulic filter - Replace or clean the filter.
Suction line is dirty - Need to clean the suction line.
Pump sucks air - Remove air from hydraulics.
Damaged pump parts - Rebuild or install new pump.

Electrical Troubleshooting

Battery cannot be charged
Electrical cable connections are loose or corroded - Tighten or service cable connections.
Battery terminal clamps are faulty - Change terminal clamps.
Battery bad cell - Battery change required.
Loose or defective belt - Need to adjust belt tension or replace belt.

Starter cranks slow
Low battery output voltage - Recharge the battery.
Battery drains quickly - Service charging system or replace battery.
Disconnected wires or corroded battery terminals - Connect cables correctly or replace terminals.

Starter does not work
Battery is low or faulty - Battery needs to be recharged or replaced.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery capacity - Low battery charging, charge as required.
Starter motor is defective - Starter should be changed.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders